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Whitney, Daniel E., 2.875 Mechanical Assembly and Its Role in Product Development, Fall 2004. (Massachusetts Institute of Technology: MIT OpenCourseWare), http://ocw.mit.edu (Accessed 07 Jul, 2010). License: Creative Commons BY-NC-SA
Mechanical Assembly and Its Role in Product Development
Fall 2004
Machine tool performance is improved by the precision and flexibility of modern metrology instruments. (Image courtesy of National Institute of Standards and Technology (NIST).)
Course Highlights
This course features a complete set of lecture notes.
Course Description
The course presents a systematic approach to design and assembly of mechanical assemblies, which should be of interest to engineering professionals, as well as post-baccalaureate students of mechanical, manufacturing and industrial engineering. It introduces mechanical and economic models of assemblies and assembly automation at two levels. "Assembly in the small" includes basic engineering models of part mating, and an explanation of the Remote Center Compliance. "Assembly in the large" takes a system view of assembly, including the notion of product architecture, feature-based design, and computer models of assemblies, analysis of mechanical constraint, assembly sequence analysis, tolerances, system-level design for assembly and JIT methods, and economics of assembly automation. Class exercises and homework include analyses of real assemblies, the mechanics of part mating, and a semester long project. Case studies and current research are included.
*Some translations represent previous versions of courses.
Syllabus
Textbook
Whitney, Daniel E. Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development. New York, NY: Oxford University Press, 2004. ISBN: 9780195157826.
Course Goals
While much is written about the design and manufacture of individual parts, there is surprisingly little information about how those parts go together into a product that actually does something. This course addresses the following question: What is a competently designed assembly, and how would we know one if we saw one? Specific objectives for students include:
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Understand a systematic approach to analyzing assembly problems.
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Appreciate the many ways assembly influences product development and manufacturing.
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See a complete approach that includes technology, systems engineering, and economic analysis.
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Get a feeling for what is technologically feasible.
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Practice the systematic process on a semester-long project of your own.
Prerequisites
2.008
Course Mechanics
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Class lectures and discussions
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Readings for each class session
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A project to be done in phases during the term
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Homework
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A mid-term and a final project presentation
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No quizzes or final exam
Grading
Course grading.
| ACTIVITIES |
PERCENTAGES |
| Homework |
1/3 |
| Project Report |
1/3 |
| Midterm and Final Presentations |
1/3 |
Calendar
Course schedule.
| Lec # |
Topics |
KEY DATES |
| 1 |
Introduction, Logistics, Context, History |
|
| 2 |
Assembly in the Small - Step-by-step Process - Assembly Motions and Forces |
|
| 3 |
Assembly in the Small-Rigid Part Mating Theory and RCC |
Student project descriptions due |
| 4 |
Key Characteristics |
|
| 5 |
Mathematical Models of Assemblies, Feature-based Modeling of Assemblies |
Problem set 1 due |
| 6 |
Constraint in Assembly-1 |
|
| 7 |
Constraint in Assembly-2 |
Project report 1 due |
| 8 |
Variation Buildup in Assemblies-1 |
|
| 9 |
Variation Buildup in Assemblies-2 |
Problem set 2 due |
| 10 |
Assembly Sequence Analysis, Algorithms, and Software |
|
| 11 |
The Datum Flow Chain-1 |
|
| 12 |
The Datum Flow Chain-2 |
Problem set 3 due |
| 13 |
More DFC |
|
| 14 |
Assembly in The Large - Basic Issues, Economics, Step-by-step Process |
Problem set 4 due |
| 15 |
Product Architecture, Flexibility |
|
| 16 |
Design for Assembly - Theory and Examples |
Project report 2 due |
| 17 |
AITL System Design Issues: Kinds of Assembly Lines and Equipment, Production Volume, Cycle Times |
|
| 18 |
Mid-term Presentation of Student Projects Covering First Three Reports |
Project report 3 due |
| 19 |
Assembly in The Large: Workstation Design Issues |
|
| 20 |
Assembly System Design Techniques and Simulation |
Project report 4 due |
| 21 |
Economic Analysis of Assembly Systems |
|
| 22 |
Flexible Manufacturing Systems |
Project report 5 due |
| 23 |
Outsourcing, and Supply Chain Management or Student Show and Tell |
|
| 24 |
767 Wing Case Study |
Project report 6 due |
| 25 |
Student Project Presentations |
|
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