-- PIFCO INSTRUCTION MANUAL/n ENG3017 Mechanical Design 3 2023-24 Assignment 2 - Reverse-Engineering: Functional Analysis, Design for Manufacture, and Environmental Impacts (20% of total module assessment) In this assignment you are asked to undertake the reverse-engineering of a consumer durable (or similar product) in order to consider its overall design and that of its individual components. Central to the activities you undertake will be the analysis of its design for manufacture and assembly, the construction of a function hierarchy (Functional Analysis), and a lifecycle analysis. There is a selection of very cheap toasters, irons and hand-mixers available, and the disassembly is done in groups of four or so, (in order to economise on the number of products destroyed!). However, if you are able to find some other defunct product to use in this exercise, you are welcome to use that, (subject to checking suitability with me). Additionally, if you provide your own product, you can select your own disassembly group size and members. As you conduct the reverse-engineering exercise, you should review the operation of the product, and thus consider how each of the components contribute functionally to the operation of the product. Use this to construct a functional hierarchy. Construction of the functional hierarchy will be conducted as group exercise in class, in the tutorial sessions of 25th Jan, and 1st Feb. There is no formal assessment of this, but if absent, you may be required to submit a single page function hierarchy for your product, (not a report), to demonstrate you have engaged with this content. (Failure to engage may result in a reduction of one grade point on this assignment.) Health and safety is paramount in doing this exercise. It is important that the product you use for this disassembly is disposed of after this exercise. If the product you plan to disassemble uses mains electricity, it is a condition of using it for this exercise that, before commencement of the disassembly, you cut the electrical lead as close to the product as possible to prevent subsequent use. For the individual assessment, you should then select two components from the product and produce a brief report on each, discussing the design choices they embody. You should also use the software, OpenLCA, (to which you will be introduced), to estimate the environmental impacts of your two components. Ensure that the components you choose represent different manufacturing processes, and thus different DfM issues, and potentially different environmental impact issues. (For example, do not select two injection moulded components; for maximum marks you need to show an understanding of a wide range of DfM considerations, and even if of very different in function, two components of similar manufacture will tend to embody the same points.) If you are sharing a product, ensure that you chose different components to discuss than those of your colleagues. Probable reasons for the choice of material and choice of manufacturing process should be briefly explained, but far and away more important is that you should highlight features of the component which have been designed to aid manufacture or assembly, (or perhaps compromises in this regard to satisfy other product characteristics). Nota Bene: The DfM/LCA submission should solely focus on those aspects of the components. You should not include a discussion of how you disassembled the product; it is not of interest here. Moreover, whilst you are expected to identify the manufacturing processes used, and the reasons for their selection, you may assume that the reader is familiar with the processes. Generic explanations of the processes are NOT required, and will not gain any marks. Deliverables Design for Manufacture (Individual Submission) - 20% of total course assessment A report on two components. In effect this should be in the form of two mini-reports. (i.e., There is no requirement for a general introduction or overall conclusion.) Word count For guidance, 800 - 1200 words should be sufficient (2 components x 400 - 600 words per component/sub-assembly). You should not worry if you are slightly over or slightly short of this target, but long-rambling irrelevance and omission of relevant points are sins of equal measure. Hand-In Thursday 15th February 2023, before 12.00 noon (i.e. before the tutorial)

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