[Coursework Description]

1) Estimate the manufacturing cost for a bearing housing following the data sheet.

Materials and dimensions of the bearing housing will depend on your student
number. The example of bearing housing drawings in default dimension is provided
in the Appendix section of this document. Solidworks part files are provided in the
Blackboard for your reference.

If your Student Number is 123456 (corresponding to ABCDEF):

Materials:
Pedestal (top/base): B is even: mild steel; B is odd: aluminium
Bearing, pin: C is even: stainless steel; C is odd: brass
Assume extra 1.5mm per machined side for raw material billets/bars.

Dimensions (see Appendix):

Length of Pedestal base = 84 + D = ................................... mm
= 104 + D = ................................... mm
Height of Pedestal base = 60 + E =
.................................... mm
Diameter of hole in bearing = 32 - F =
..................................... mm

2) The Bearing housing assembly is comprised of 4 components, plus fasteners:

1. Base of the pedestal

2. Top of the pedestal
3. Bearing (plain bearing for rapidly rotating shafts)
4. Locking Pin (interference fitting with bearing, loose fitting with pedestal)
a. Two threaded studs (fasteners)
b. Two nuts (and washers) (fasteners)

Mech. Eng. & PDE EG-386 Coursework 2017-18 Page 1

3) Use Solidworks databases for the definition of material properties (such as
material densities) and for the selection of suitable fasteners (Design library\
Solidworks toolbox). Alternatively, the following external resource would be useful for
obtaining the material properties:

- Matweb (www.matweb.com)

The Solidworks model can be used to calculate the volume removal (i.e. “Quantity” in
the costing worksheet) for each of the manufacturing process, and at the same time,
capturing the images for the manufacturing process route(s).

Alternatively, hand calculation can be applied to input the equivalent volume

removal. Also, hand sketch and/or PowerPoint drawing or equivalent would be
acceptable, in lieu of the Solidworks captured images.

[Requirements]
The student is required to submit the following two completed documents (1 and 2).

1. A completed Costing Sheet (template provided) comprised of

1.1) An individual costing worksheet with detailed description of the selected

manufacturing process route:
- Worksheet “Assembly”
- Worksheet “Pedestal Base”
- Worksheet “Pedestal Top”
- Worksheet “Bearing”
- Worksheet “Pin”
[10 points]

1.2) Use the given worksheet “Tolerance Bearing” and define tolerance fitting
required for the Bearing:
- Bearing fitting to the Pedestal Top
- Bearing fitting to the Pedestal Base
- Bearing fitting to the Pin
[3 points]

1.3) Use the given worksheet “Summary” and complete the necessary
information:
- Table detailing cost for parts and assembly
- Table and Pie-charts detailing cost of materials and manufacturing
processing (machining, set-up, assembly, etc.)
[5 points]

1.4) Use the given worksheet “Stud” and estimate the cost of making the
threaded studs in lieu of buying off-the-shelf fasteners, assuming alloy steel.
Comment on the results.
[2 points]

Mech. Eng. & PDE EG-386 Coursework 2017-18 Page 2

 2. A4 sized PDF document(s)* answering the following:

*the document(s) can be either descriptive (your own thoughts in written text,
a single page max) or reproduced technical drawings saved in PDF format via
Solidworks.

2.1) The example of bearing housing drawings in default dimension is

provided in the Appendix section of this document. Considering the BSI/ISO
standards for producing the technical drawings, how would you update and
reproduce the drawings by paying close attention to the assembly, dimension,
tolerance and surface finish?

[Assembly]
- Any other information or dimension needs to be included here?

[Dimension]
- All the part drawings correctly dimensioned?

[Tolerance and Surface finish]

- Any thoughts on general tolerance and surface finish, reflecting your raw
material and chosen manufacturing process routes?
- Any thoughts on specific tolerance and surface finish, considering the fitting
and assembly?

[10 points]

TOTAL [30 points]

[Submission]
Please submit electronically completed College of Engineering Cover Sheet,
together with the completed worksheet (Excel) and any other supplementary
documents providing answers to the Requirements in PDF format to the link for
Mechanical Engineers and Product Design/Submission of Mechanical & Product
Design Coursework”

Please be reminded of the University’s regulations for

Plagiarism/Collusion/Academic Misconduct. Penalties will apply.

Note: Late submission will receive zero marks

Mech. Eng. & PDE EG-386 Coursework 2017-18 Page 3

[Marking Scheme]
Criteria 0-10% 20-30% 40% 50% 60% 70-80% 90-100% Mark
(Poor) (Deficient) (Mediocre) (Adequate) (Competent) (Very Good) (Excellent)
1. Costing Sheet No calculation. Copy Incorrect Many omissions or Adequate Competent but some Very well presented Excellent costing
1.1) Calculation and pasted info from calculations. errors but some calculations. Some minor errors in with accurate sheet. Clear
the example. Irrelevant selection of relevant calculations aspects of the calculations. calculations. understanding on
manufacturing are correct; costing not Evidence of clear manufacturing
processes and insufficient effort in completed or not fully understanding of process and costing.
steps. Clear lack of carrying out costing investigated. manufacturing Faultless.
understanding. for all given parts. process and costing.
/5
1.1) Detailed description Missing. Some descriptions Limited efforts, some Adequate Consistent effort and Very good effort and Excellent effort; clear
of each manufacturing are given but no critical errors in descriptions. Some good descriptions. Only consistency shown and consistent
process route details (i.e. covering understanding aspects of the occasional mistakes in throughout. Very understanding on
- Base the major manufacturing process route not writing. good understanding manufacturing
- Top manufacturing processes. Missing completed or not fully on manufacturing process route shown
- Bearing processes from a major process investigated. processes. throughout. Evidence
- Pin billet/round bar to a routes. of supplementary
final machined piece reading; faultless.
with grinding and
polish if needed.
/5
1.2) Tolerance fitting Little work done, Not specified with Minimal effort in Largely adequate use Competent but some Very good Clear and consistent.
required for the pin many major errors. hole/shaft basis carrying out the and selection of minor errors in the understanding on Excellent
- Bearing fitting to tolerance fitting. tolerance fitting. appropriate tolerance selection of tolerance tolerance fitting. understanding on
Pedestal Top/Base and Inappropriate fitting. Some values. Some minor tolerance fitting in
Pin selection of tolerance inconsistencies mistakes on cosideration of
application (too tight between the values tolerance values; relevant application
or too loose fitting). indicated here and some improvements and operational
the drawing(s). possible. conditions.
/3
1.3) Summary No summary given Failed to show Minimal effort in Most of the main Clear evidence of Very good effort. Excellent summary.
a) Table detailing cost (no change from a understanding of carrying out the points or details have understanding of Professional Demonstrated with
for parts/assembly template). manufacturing summary. Limited been covered but manufacturing process standard with table and charts to
process and costing. understanding of improvements and costing. Clear accuracy. Clear explain the costing
b) Table and Pie-charts No effort shown. manufacturing possible. Adequate logical table and charts evidence that the breakdown
detailing cost of process and costing. effort shown. that connects summary summary effectively. Clear
materials and Misses some in a seamless fashion. demonstrates one's understanding of
manufacturing important details. in depth manufacturing
processes Inaccurate costs. understanding of process and costing.
manufacturing Faultless.
process and costing.
/5
1.4) Cost of making Cost estimation Limited evidence of Minimal effort in Most of the main Competent but some Very good Clear and consistent.
threaded studs missing. one's effort. Badly carrying out the work. manufacturing minor errors in the understanding on Excellent
- Costing presented. Clear Limited process and costing calculations. manufacturing understanding on
- Comment (description deficiency in understanding of have been covered Presentation and process and costing. manufacturing
on the result) understanding of manufacturing but improvements description can be Consistency shown process and costing.
manufacturing process and costing. possible. Adequate improved. throughout. Clear comparison
process and costing. Misses some effort shown. made between buy
important details. and make threaded
Inaccurate costs. studs.
/2
2. Engineering No efforts. Submitted Limited evidence of Minimal effort in Moderate effort. Competent Very good effort. Excellent
Drawings document(s) do not one's effort. Badly carrying out the work. Lagely adequate understanding. Only Clear understanding understanding.
- Assembly take the BSI/ISO presented. Clear Understanding the understanding of occasional mistake or of engineering Professionally
- Dimension standards into deficiency in BSI/ISO standards relevant dimension, ambiguity. Some drawings. Very well presented
- Tolerance and Surface account. understanding the on assembly, tolerance and inconsistencies presented. Some considering the
finish BSI/ISO standards of dimension, tolerance surface finish in view between the costing minor mistakes or BSI/ISO standards.
assembly, and/or surface finish of assembly. sheet information typos. No improvement
dimensioning, at times incorrect or Reasonable (manufacturing possible.
tolerance and unclear. presentation. process) and
surface finish. descriptions/drawings.
/10

TOTAL /30

Mech. Eng. & PDE EG-386 Coursework 2017-18 Page 4

[Appendix] Bearing Housing Drawings (in default dimensions)

[Figure A-1]

Page 5
[Figure A-2]

Page 6
[Figure A-3]

Page 7
 [Figure A-4]

End of document

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