Machine Design & Manufacturing
Size shafts, bolted joints and bearings, model parts parametrically, read GD&T, sanity-check FEA, choose manufacturing processes, design for manufacturing, compute Cpk and prepare parts for 3D printing.
Leads to: Mechanical Engineer
Before you start
This course builds on Engineering Mechanics: Statics & Strength, Technical Drawing & CAD Basics and Materials Science Fundamentals. Take them first if you are new to the topic.
About this course
A mid-level course for future mechanical engineers who have finished Engineering Mechanics, Technical Drawing & CAD Basics and Materials Science Fundamentals. In Machine Elements you size a shaft for torque and bending, work out the preload and separation margin of a bolted joint, and select a rolling bearing from a catalogue, with short Python exercises where the code already runs and you write one key formula. In CAD and Simulation you build a parametric part in a free tool (Onshape or FreeCAD), apply datums and position tolerances, and run a simple finite element analysis that you check against a hand calculation. In Manufacturing you compare machining, casting, forming, moulding and 3D printing, improve a part for manufacturing, compute process capability (Cpk) from measured data, and prepare a part for printing. The calculations teach the mechanics and are not design methods: real machines are designed to codes, standards and manufacturer data, and designs that affect public safety are reviewed and sealed by a licensed professional engineer. Shop content is awareness level only: never operate machine tools without training and supervision. A mechanical engineering career typically needs an ABET-accredited bachelor's degree, and the FE and PE exams for public-facing design sign-off (see ncees.org); CAD certifications such as CSWA/CSWP are optional extras.
Course content
Module 1
Machine Elements
3 lessons · 2h 3mSize the parts that carry power and load: shafts and keys for torque and bending, preloaded bolted joints, and springs, gears and rolling bearings selected from a catalogue.
- 39mShafts and keysReading
Turn power and speed into torque, combine bending and torsion with von Mises, size a solid shaft and check its key.
- 46mFasteners and jointsReading
Choose a bolt preload, estimate tightening torque, and check a tension joint for bolt load and separation.
- 38mSprings, gears, and bearingsReading
Compute a spring rate and a gear ratio, then select a ball bearing from a catalogue using the L10 life equation.
Module 2
CAD and Simulation
3 lessons · 2h 31mModel parts that change the way the design should with parametric CAD, communicate tolerances with datums and position (GD&T), and run and sanity-check a simple finite element analysis.
- 59mParametric CADReading
Build a part driven by constraints and named variables so it changes the way the design should.
- 37mGD&T in practiceReading
Read datum reference frames and feature control frames, check a hole's position, and work out bonus tolerance at MMC.
- 55mIntro to FEAReading
Run a simple linear static finite element analysis and sanity-check it with a hand calculation, reactions and a mesh study.
Module 3
Manufacturing
4 lessons · 2h 45mChoose between machining, casting, forming, moulding and additive processes, design parts that are easy to make and assemble, measure process capability, and prototype with 3D printing.
- 24mManufacturing processesReading
Compare machining, casting, forming, moulding and additive processes, and use break-even analysis to choose between them.
- 45mDesign for manufacturingReading
Apply DFM and DFA rules for machining, sheet metal and moulding to make a part cheaper and easier to make without losing function.
- 45mQuality and inspectionReading
Choose suitable gauges, read control charts, and compute Cp, Cpk and Ppk for a machined feature.
- 51mPrototyping and 3D printingReading
Pick the right kind of prototype and prepare a CAD part for 3D printing: units, orientation, supports, fits and slicer checks.