EMAE 360 Fall 2014 Schedule

WEEK Sunday Monday Tuesday Wednesday Thursday Friday Saturday

1 (Aug) 24 Aug 25
Administrative
26 27 28 29 Team Assignment,
Project Assignment
30
2 (Sept) 31 Sept 1
LABOR DAY NO CLASSES
2 3

4 5 6
3 7 8 PROJECT PLAN REVIEW 9 10 PROJECT PLAN
REVIEW
11 12 PROJECT PLAN
REVIEW
13
4 14 15 16 17 18 19 20
5 21 22 Progress Reports 23 24 Progress Reports 25 26 27
6 (Oct) 28 29 30 Oct 1 2 3 4
7 5 6 CONCEPTUAL DESIGN
REVIEW
7 8 CONCEPTUAL DESIGN
REVIEW
9 10 CONCEPTUAL DESIGN
REVIEW
11
8 12 13 14 15 16 17 18
9 19 20 Progress Reports
MIDTERM GRADES DUE
21 22 Progress Reports 23 24 25
10 26 27
FALL BREAK NO CLASSES
28 29 30 31 Nov 1
11 (Nov) 2 3 Progress Reports 4 5 Progress Reports 6 7 8
12 9 10 11 12 13 14 15
13 16 17 Progress Reports 18 19 Progress Reports 20 21 22
14 23 24 25 26 27
THANKSGIVING
28 THANKSGIVING
BREAK NO CLASSES
29
15 (Dec) 30 Dec 1 DESIGN REVIEW 2 3 DESIGN REVIEW 4 5 DESIGN REVIEW 6
16 7 8 FINAL REPORTS DUE 9 10 FINAL REPORTS DUE 11 12 FINAL REPORTS DUE 13
17 14 15 16 17 18 19 FINAL GRADES DUE 20



EMAE 360
Team Design Assignment

The Spartan Motorcycle Company is planning to introduce a new motorcycle model for 2016. First year
sales are anticipated to be 7500 units, with volumes increasing to 12,000 in the second year and 15,000
in the third year. Your design team is responsible for the new engine design that will differentiate this
motorcycle from other competitors.

Engine Requirements:
2 or more cylinders, 4-stroke cycle
Displacement 1500 to 1800cc
Fuel injection, spark ignition
Runs on standard gasoline
Compression ratio 9:1 to 10:1
Performance Requirements:
Capable of 5000 rpm continuous service, idle at 800 rpm
Powers a six-speed transmission
Must meet all relevant specifications and standards for safety, fuel efficiency, noise and emissions

Your design should be planned to maximize fuel efficiency, minimize overall dimensions and weight, and
minimize the cost to produce. Engine reliability and durability should also be considered.
Your design file should include technical specifications, a theory of operations, a risk analysis and FMEA,
and a detailed design with a bill of materials. Each component should be described (manufacturing
process, mechanical drawing, material of construction, heat treatment if needed, cost to manufacture or
buy, etc.) Assembly and required fluids and lubricants should also be covered.

EMAE 360
Design for Manufacturing II
Fall 2014


Instructor: Sunniva R. Collins, Ph. D.
Office: 415B Glennan
Office Hours: MW 12:20 to 1:30; or by appointment
Phone: 216-368-4155 (office)
216-536-6198 (cell)
Email: sunniva.collins@case.edu

Course Description and Requirements
Catalog Description: This is the final course of a 3-course sequence focusing on "Engineering
Design and Manufacturing," and is the senior design course focused on a semester-long design
project. The course draws on a student's past and present academic and industrial experiences
and exposes them to the design and manufacture of a product or device that solves an open-ended
"real world" problem with multidimensional constraints. The students form design teams to
work on the solution to a common problem. The outcomes of the course continue to focus on the
student's ability to function on multidisciplinary teams while applying their knowledge of
mathematics, science and engineering to design a system, component, or process that meets
desired needs within realistic, multidimensional constraints, such as: economic, environmental,
social, political, ethical, health and safety, manufacturability, and sustainability. Professional
communication skills are emphasized and expected during all stages of the design process and
will include formal and informal oral presentations, periodic peer-focused design reviews, and a
development through its various evolutionary stages to completion.
Prerequisites: EMAE 160 or EMAE 172, and EMAE 260. Counts as SAGES senior Capstone
Course Objectives: On completion of this course, students should have developed:
1. An ability to apply knowledge of mathematics, science, and engineering to an engineering
design problem
2. An ability to design mechanisms and machinery to meet desired needs
3. An ability to function in multi-disciplinary teams
4. An ability to identify, formulate, and solve an engineering design problem
5. An ability to communicate effectively, orally and in writing
6. An ability to use the techniques, skills, and modern engineering tools necessary for
engineering practice
7. Experience in interacting with professionals in the field
8. Independence in approach and methodology in solving engineering problems
9. An understanding of professional and ethical responsibility
10. A recognition of the need for, and the ability to engage in life-long learning

Requirements: The class meets three times a week: MWF 4:00 to 4:50 p.m. in Bingham 103.
The class will organize into design teams. Each team formulates the details of the project,
determines the teams mode of operation, the design activities that must be performed, the
individual responsibilities, the schedule of work, and other aspects of the development of the
design. Starting from performance requirements, each team considers alternative ways of
meeting the requirements, selects methods to investigate in detail, develops a conceptual design,
and then refines it to the preliminary design level, with the help of the instructor, TA, and
mentor(s).

Teams will report weekly on the progress of their design. Most weeks follow a prescribed
schedule of activities. Class periods are devoted to presentations of design progress and
discussions of the developing designs; work by each team separately; or lectures for background
information needed to complete the project. The instructor is available to meet with each team.

Progress Reports: Oral presentations are given weekly. These may be by one or more persons in
a group at each session, but every member of the team must participate in a progress report
presentation during the semester. In addition, each team submits a one-page weekly progress
report that includes plans for the next reporting period and a timeline of tasks.

Final Report: At the end of the semester, each team makes an oral presentation (including a
summary poster) and submits a written report describing its design. The written report should be
a good engineering report of professional quality. It should be able to be understood by a
technically trained reader who is not necessarily familiar with the particular subject matter, and
also useful to a reader who is interested in continuing the design.

Grading: The grade in this course is based primarily (75% of final grade) on the written and oral
final reports. Team grades will be self-reporting: each team member will have input on the
teams performance, individually and collectively. The progress reports will also contribute (25%
of final grade) for this course.

Bibliography: The following texts are recommended as a starting point; they are on reserve for
this class at the Kelvin Smith Library:
Introduction to internal combustion engines, 4
th
ed., Richard Stone, SAE International,
Warrendale PA, 2012
Design of machinery : an introduction to the synthesis and analysis of mechanisms and
machines / Robert L. Norton
Kinematics and dynamics of machinery / Charles E. Wilson, J. Peter Sadler
Internal combustion engine fundamentals / John B. Heywood
Vehicular engine design / Kevin L. Hoag



Special Notes on Conduct
There is a no cell phone policy during class lectures. Laptops may be used to take notes. Other uses of
the laptop during class are not permitted. If there is a special circumstance requiring the use of a laptop or
cell phone during a specific class, please see the instructor in advance.

Be engaged in class:
a. Share your concerns and ideas with the entire class, not just the person sitting next to you.
b. Ask questions.
c. Be inclusive; ask others to share their opinions and insights.
d. Professionalism and civility are expected behaviors.

We support and uphold the academic integrity standards of Case Western Reserve University
(http://www.case.edu/provost/ugstudies/acintegrity.htm). Please review the document for definitions of
violations and the standard procedures for adjudication.