Integrating Product Optimization And Manufacturability In Graduate Design Course

As CAD/FEA/CAM software tools are becoming increasingly user friendly and seamlessly integrated, it became feasible to use a number of them simultaneously in a senior/graduate level design course in order to provide students with opportunity to experience all aspects of product design cycle, from concept design, product optimization, to manufacturability. In the past, teaching a hands-on laboratory course on design optimization for functionality and manufacturability was virtually impossible because more powerful computer codes were very complicated and it was not practical to incorporate them in a single one semester course. However, standardization of commands and file storing formats resulted in seamless data transfer from one software package to another; thus, allowing integration of all facets of design optimization for product manufacturability in a single lab oriented design course. This paper describes the experience with metalcasting design optimization course which focuses on design of cast parts according to its functional requirements (using IronCAD), while optimizing its shape with respect to its structural integrity (using COSMOS/M and DesignSTAR), and making certain that the part can be manufactured (cast) without defects (MagmaSoft). Throughout the course students are required to make a number of design revisions in order to satisfy specified design requirements. At the end of the course, students have a chance to present and defend their design in front of the class and industry representatives.