BDA 31203 Project 2nd Semester 2014/2015

DEPARTMENT of MATERIAL & ENGINEERING DESIGN

FACULTY of MECHANICAL & MANUFACTURING ENGINEERING
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
BDA 31203 MECHANICAL COMPONENT DESIGN (MCD)

Instructions: This is a group based design project. Students caught for plagiarism
will be given ZERO (0) for the project.
MCD Project

Design project is one of the important aspects in this course where it brings 40% of marks.
This design project is target to meet the requirements of the University which offer high quality
learning through student-centered learning by implementation of a PO-PBL (Project Oriented Problem Based Learning) activity.

At the end of this project, students will be able to improve their technical report writing skills
with the ability to:
- justify a design project in a formal report.
- perform and present design calculations in a neat and organized manner.
- present the outcomes of the design in the form of engineering drawings.

The project will be carried out in groups where each group has 3 to 5 members. Theme of the
project is Designing a Gearbox / Transmission System. In this project, students have to
design a suitable gearbox / transmission system which applied whether at an escalator system,
motorised trolley or trommel machine that satisfied with power / torque requirement at the
machine and power / torque provide from the motor. Students also must analyze all mechanical
components inside the gearbox / transmission system such as shaft, bearing and gears in term of
their strength, static and fatigue safety, reliability, dynamic motion, life estimation and others
like what have been learned in the theory to predict or simulate the real physical system and
product behaviour. Then students also need to come out with engineering drawing of their
design (assembly drawing ; exploded drawing + BOM ; detail parts drawing) by using suitable
CAD Software.

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BDA 31203 Project 2nd Semester 2014/2015

The project will be evaluated as follows:

Final Project Report

(35 marks)

Soft Skill (Life Long Learning)

( 5 marks)

TOTAL

(40 marks)

Example of gearbox

Example of Escalator system

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BDA 31203 Project 2nd Semester 2014/2015

Example of motorised trolley

Example of Trommel Machine at gold mining industry

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BDA 31203 Project 2nd Semester 2014/2015

DRAF of PROJECT REPORT ASSESSMENT

(BDA 31203)
NO
1.0

2.0

CONTENTS
INTRODUCTION
1.1 Group Description
1.2 Product / Project Background
1.3 Objective & Design Scope
1.4 Milestone / Planning Chart

DESIGN & ANALYSIS

2.1 Concept Development (Sketching)
2.2 Engineering Analysis
Fundamental Analysis (Create Situation with basic analysis,
Power Required, Motor selection, Gear Ratio needed)
Gear Fundamental Analysis (module, No. of teeth, Pitch
Diameter, Torque, rpm, Acting load, contact ratio)
Gear Failure Analysis (AGMA Bending Failure, AGMA Pitting
Failure, Bending and wear factors of safety are minimized, Gear
face width and Qv are reasonable. Material selection is discussed.
Shaft center-distance constraints met. Especially well done
drawings.)
Shaft Analysis (Shaft material selection discussed, min diameter
required, stress concentration are included, Fatigue and yield
factors of safety are met., tolerances and fitting. Especially well
done drawings.)
Bearing Analysis (Bearing forces correctly resolved. Bearing
sizes are consistent with other calculations. Correct procedures
used.)
Housing Analysis (Housing is designed so that all components
can fit and be assembled. Sound engineering effort made to
reduce overall weight. Innovative design (clear and reasonable).
Especially well done drawings.)
2.3 Detail design (engineering drawing)
- Assembly drawing
- Explode Drawing with BOM
- Component detail drawing

MARKS

10 %

5%
10 %
10 %
15 %

15 %

5%

5%

10 %

3.0

CONCLUSION & RECOMMENDATION

10 %

4.0

REFERENCES

5%
TOTAL

100 %

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1.4 PROJECT DESIGN PLANNING CHART

No.

Activities

Sub-topic

W6

W7

W8

W9

W10

W11

W12

W13

W14

29-Mar
~

5-Apr
~

19-Apr
~

26-Apr
~

3-May
~

10-May
~

17-May
~

24-May
~

31-May
~

4-Apr

11-Apr

25-Apr

2-May

9-May

16-May

23-May

30-May

4-Jun

Select Team Members

Form Group

Group Organization / Post

Group Name
Group Logo
Project Title Selection
2

Introduction

Design & Analysis

1.0

Group Description

1.1

Product / Project Background

1.3

Objective & Design Scope

1.4

Milestone & Planning Chart

2.1

Concept Development

2.2

Engineering Analysis
Fundamental Analysis
Gear Fundamental Analysis
Gear Failure Analysis
Shaft Analysis
Bearing Analysis
Housing Analysis

2.3

Detail Design (Eng. Drawing)

Asembly Drawing
Explode Drawing with BOM
Component Detail Drawing

Conclusion & Recommendation

Report Writing

Submit Report & Final Presentation

Marks

Planning
Actual

Done

FACULTY OF MECHANICAL & MANUFACTURING ENGINEERING

UNIVERSITI TUN HUSSEIN ONN MALAYSIA
BDA 31203 - DESIGN PROJECT REPORT (Evaluation Criteria,

[5] - Very Good,

No.
1

[4] - Good,

GROUP NAME :[3] - Intermediate, [2] - Weak,

[1] - Very Weak )

Evaluate Item
Introduction (10%)
1.1 Group Description

Marks
(W = 0.4)

5 4 3 2 1

1.2 Product / Project Background

(W = 0.6)

5 4 3 2 1

1.3 Objective & Design Scope

(W = 0.4)

5 4 3 2 1

1.4 Milestone / Planning Chart

(W = 0.6)

5 4 3 2 1
TOTAL (10%)

Design and Analysis (75%)

2.1 Concept Development [Sketching] (5%)

Addresses the entire system (global picture)

Shows how each component fits together

Labels components to identify key features and provides description

Shows approximate dimensions

(W
(W =
= 0.2)
0.2)
(W =
= 0.2)
0.2)
(W

Provides realistic visualization (3D sketching + shading)

(W = 0.2)

(W
(W =
= 0.2)
0.2)
(W =
= 0.2)
0.2)
(W

5
5
5
5
5

4
4
4
4
4

3
3
3
3
3

2
2
2
2
2

1
1
1
1
1

2.2 Engineering Analysis

Fundamental Analysis (10%)

Power required are determine with proper justification and calculation

(W = 0.8)

Motor is been selected properly with proof and reasonable power

(W = 0.6)

Gear ratio is determine accordingly

(W = 0.6)

5 4 3 2 1
5 4 3 2 1
5 4 3 2 1

Gear Fundamental Analysis (10%)

Number of gear teeth are determine properly

(W = 0.4)

Diameter, torque and RPM are calculate properly

(W = 0.6)

Module selection are reasonable

(W = 0.2)

Contact ratio analysis are also included

(W = 0.4)

Acting load at each gear are been calculated correctly

(W = 0.4)

5
5
5
5
5

4
4
4
4
4

3
3
3
3
3

2
2
2
2
2

1
1
1
1
1

5
5
5
5
5
5

4
4
4
4
4
4

3
3
3
3
3
3

2
2
2
2
2
2

1
1
1
1
1
1

5
5
5
5
5
5
5

4
4
4
4
4
4
4

3
3
3
3
3
3
3

2
2
2
2
2
2
2

1
1
1
1
1
1
1

Gear Failure Analysis (15%)

Material selection has been discuss properly

(W = 0.4)

Determination of face width and Qv are reasonable

(W = 0.2)

Correct prosedure used to calculate AGMA bending and pitting stress

(W = 1.0)

Describe with details

(W = 0.5)

Used proper justification and assumption

(W = 0.5)

Bending and pitting safety factor are in acceptable range

(W = 0.4)

Shaft Analysis (15%)

Correct resolve forces at the shaft free body diagram

(W = 0.6)

Calculate bending load with proper bending moment diagram

(W = 0.6)

Shaft material selection is also been discussed

(W = 0.2)

Include with proper stress concentration factor analysis

(W = 0.4)

Calculated minimum diameter required at each gear

(W = 0.4)

Fatigue and yield factors of safety are met

(W = 0.4)

Included with tolerances and fitting analysis at each shaft

(W = 0.4)

Bearing Analysis (5%)

Bearing forces have been correct resolved

(W = 0.4)

Correct prosedures used to determine bearing load rating

(W = 0.4)

Suitable bearing size have been selected

(W = 0.2)

5 4 3 2 1
5 4 3 2 1
5 4 3 2 1

Housing Analysis (5%)

All component are fit well and assemble properly

(W = 0.2)

Fitting analysis are also included at bearing support

(W = 0.3)

Engineering effort to reduce overall weight

(W = 0.2)

Innovative design (clear and reasonable)

(W = 0.3)

5
5
5
5

4
4
4
4

3
3
3
3

2
2
2
2

1
1
1
1

(Evaluation Criteria,

[5] - Very Good,

No.

[4] - Good,

[3] - Intermediate, [2] - Weak,

[1] - Very Weak )

Evaluate Item

Marks

2.3 Detail Design - Project Drawing (10%)

Show assemble component in 3D drawing with adequate clarity

(W = 0.3)

Use exploded views with BOM to show assemble of parts

(W = 0.3)

Provide adequate dimensioning and tolerances to build part properly

(W = 0.4)

Adheres to ANSI standard

(W = 0.4)

Arrange the drawing in systematic approach

(W = 0.3)

Fill all the information required in the drawing title block

(W = 0.3)

5
5
5
5
5
5

4
4
4
4
4
4

3
3
3
3
3
3

2
2
2
2
2
2

1
1
1
1
1
1

TOTAL (75%)
3

Conclusion and Recommendation (10%)

Conclude on Project Understanding, results and Achievement

(W = 1.0)

5 4 3 2 1

Recommendation

(W = 1.0)

5 4 3 2 1
TOTAL (10%)

References (5%)

Use proper format

(W = 0.5)

Well presented and organized

(W = 0.5)

5 4 3 2 1
5 4 3 2 1
TOTAL (5%)

Bonus
Report Appearance

Follow the format / Have table of contents

(W = 0.5)

Contents are organize well & report is binding properly

(W = 0.5)

5 4 3 2 1
5 4 3 2 1
TOTAL (5%)

OVERALL MARKS (100%)

Criteria

Method use to find

information

Uses a limited number of

different technologies, locates
basic resource and ineffective
use of skimming and scanning
given information
appropriately with assistance

Usually use a variety of

technologies, obtains relevant
information but less effective
use of skimming and scanning

Consistently and accurately

uses a variety of technologies
to access and obtain relevant
wide-ranging information
quickly using skimming and
scanning

Organizing, Evaluating
and Integrating
Information

Uses given information

appropriately with assistance

Adds given information

appropriately to own
information

Integrates given information

with own information

Self-esteem

Limited skills of listening,

sharing/connecting ideas,
communication technique, selffocus and uses a variety of
productivity tools.

Requires skills of listening,

sharing/connecting ideas,
communication technique, selffocus and uses a variety of
productivity tools.

Consistently uses skills of

listening, sharing/connecting
ideas, communication
technique, self-focus and uses
a variety of productivity tools.

Motivation

Sets priorities to achieve goals

and directs own learning only
with assistance and rarely
begins without prompting

Usually sets priorities to

achieve goals, directs own
learning with minimal
prompting and begins work
without prompting

Consistently sets priorities to

achieve goals, directs own
learning with minimal
prompting and begins work
without prompting

Independent

Ability to Seek and Manage / Access Relevant

Information From Various Sources
Ability to accept New Ideas and Capable for Self-Directed or
Autonomous Learning

Continous Learning and Information Management

SOFT SKILL ASSESSMENT WITH CUMMULATIVE RUBIC

2

Use of time and uses outside

sources for learning are
moderately effective, and
occasionally needs
encouragement to do work.

use of class time is

effective,find and use some
outside resources effectively
and requires no encouragement
to do work.

Use of class time in highly

effective, incorporates a
variety of resources in a highly
effective manner and works in
a self-directed manner and
encorages others.