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Introduction to EngineeringDesignFinal ExaminationParts A, B & CANSWER KEYSpring 2009PRACTICE EXAMFor Teacher Use ONLYProject Lead The Way Copyright 2006 - Page 1 of 21

Part A – Multiple Choice BCCCDABDCBADCBDABCCBADADACDACADCBAIED Assessment ConceptsUnit 1.1 History of DesignUnit 2.1 Design ProcessUnit 2.1 Design ProcessUnit 2.1 Design ProcessUnit 2.2 Principles & Elements of DesignUnit 2.2 Principles & Elements of DesignUnit 3.1 Portfolio DevelopmentUnit 3.1 Portfolio DevelopmentUnit 4.1 Sketching & Visualization TechniquesUnit 4.2 Pictorial SketchesUnit 4.2 Pictorial SketchesUnit 5.2 Geometric Relationships - ConstraintsUnit 5.1 Geometric Relationships - Forms and ShapesUnit 5.1 Geometric Relationships - Forms and ShapesUnit 6.4 Modeling - MathematicalUnit 6.5 Modeling - ComputerUnit 6.1 Modeling - ConceptualUnit 6.5 Modeling - ComputerUnit 6.5 Modeling - ComputerUnit 6.1 Modeling - ConceptualUnit 6.3 Modeling - PhysicalUnit 6.5 Modeling - ComputerUnit 7.4 Assembly Modeling – Sub-AssembliesUnit 7.4 Assembly Modeling – Assembly ConstraintsUnit 7.5 Assembly Modeling – Driving ConstraintsUnit 8.1 Model Analysis & Verification – Mass PropertiesUnit 8.1 Model Analysis & Verification – Mass PropertiesUnit 8.1 Model Analysis & Verification – Mass PropertiesUnit 9.1 Model Documentation – Working DrawingsUnit 9.1 Model Documentation – Working DrawingsUnit 7.1 Assembly Modeling – Adding ComponentsUnit 9.1 Model Documentation – Working DrawingsUnit 9.1 Model Documentation – Working DrawingsUnit 9.1 Model Documentation – Working DrawingsUnit 9.3 Model Documentation - AnnotationUnit 10.2 Presentations - AidsUnit 10.2 Presentations - AidsUnit 11.6 Production - Manpower and Facility RequirementsUnit 11.4 Production – Material Procurement, Handling & Cost AnalysisUnit 12.1 Marketing – Product Cost AnalysisAnswer Breakdown: A-10; B-10; C-11; D-9Project Lead The Way Copyright 2006 - Page 2 of 21

Part A Scoring Conversion ChartRaw ScoreConversionRaw ScoreConversionRaw ScoreConversionRaw 109865431Part B – High School Performance Exam50 POINTS1. Match the picture of each line type below with its corresponding name byplacing the letter of the correct name in the numbered space provided.[6 POINTS - 1 point each]Section 4.1: Line typesAnswer BankA. Dimension LineB. Hidden LineC. Center LineD. ConstructionLineE. Object LineF. Section LineG. Extension LineH. Leader Line1.1 C1.4 A1.2 E1.5 H1.3 B1.6 GProject Lead The Way Copyright 2006 - Page 3 of 21

2. Match the correct term from the answer bank to the definition.Place the letter of the mass property in the space provided.[4 POINTS – 1 point each]Section 8.1: Analysis2.1 B is the amount of threedimensional space an object takes up.Answer BankA. Centroid (Center of Gravity)B. VolumeC. Principal AxesD. Mass2.2 E is the extent of a 2dimensional surface enclosed within aboundary.E. Surface AreaF. Moments of Inertia2.3 A is a 3D point defining thegeometric center of a solid.2.4 D is the amount of matter in an object or the quantity of the inertia of theobject3. Using the dimension parameters shown on the drawing below, write theequation for dimension d0 so that the thickness of the part is uniformthroughout its length.[4 POINTS]Parametrics3. Ans: d0 d2 – d1Project Lead The Way Copyright 2006 - Page 4 of 21

4. List the 6 Degrees of Freedom (DOF) for the coordinate axis shown below.Y[6 POINTS – 1 point each]4.1 Linear Translation along the x-axis.4.2 Linear Translation along the y-axis.4.3 Linear Translation along the z-axis.4.4 Rotation about the x-axis.XZ4.5 Rotation about the y-axis.4.6 Rotation about the z-axis.5. Directions: List the assembly constraints needed to properly constrain theassemblies below. Assume that Part B in each problem below is the grounded part. [6points- 2 points each]5.1A – PlateB – BlockConstraint(s): Apply a Mate constraint between the back face of the Plate (Part A)and the corresponding front face of the Block (Part B). Apply a Flushconstraint with an offset between the end of the Plate (Part A) and thecorresponding end of the Block (Part B). Apply a Flush constraint with anoffset between the top edge of the Plate (Part A) and the corresponding topedge of the Block (Part B).Project Lead The Way Copyright 2006 - Page 5 of 21

5.2A – Coffee CupB – BaseConstraint(s): Apply an Insert constraint between the bottom circular face of theCoffee Cup (Part A) and the corresponding circular face of the Base (PartB). Apply an Angle constraint with between the workplane through theCoffee Cup (Part A) and the side of the Base (Part B).5.3A – PinB – BlockBAConstraint(s): Apply an Insert constraint between circular face of the Pin (Part A) andthe corresponding hole face of the Block (Part B).Project Lead The Way Copyright 2006 - Page 6 of 21

6. Many successful designs incorporate the arrangement of individual elementscalled Design Principles. Look at the following examples and match thegraphic with the appropriate design principles from the Answer Bank.Answers may be used only once.[4 POINTS – 1 point each]-Answer BankOppositionSubordinationTransitionRadial Balance-RhythmEmphasisProportionUnity6.1 Radial Balance6.2 Rhythm6.3 Opposition6.4 ProportionProject Lead The Way Copyright 2006 - Page 7 of 21

7. Whether sketching or creating mechanical parts with a 3-D solid modelingsoftware, two common methods of creating parts are: additive (join) and/orsubtractive (cut). Use the illustration of the Finished Model below to answerquestions 7.1 – 7.4.[4 POINTS]Finished ModelAdditive Problem:Describe the two steps used to create theFinished Model using an additive part creationprocess. Use the two sketches to the right inyour description.(2 points)7.1 Step 1: Draw sketch A and extrude it the appropriate depth.7.2 Step 2: Draw sketch D on top surface C and join extrude it the appropriateheight.Subtractive Problem:Describe how you would use the two sketches below to transformblock ABD into the Finished Model using the subtractivemethod. (2-points)Block ABD21Finished Model7.3 Step 3: Draw sketch 1 on surface A of Block ABD and cut extrude it through thepart.7.4 Step 4: Draw sketch 2 on top of surface D of Block ABD and cut extrude it downthe appropriate distance to create cube D on the Finished Model.Project Lead The Way Copyright 2006 - Page 8 of 21

8. Sketch and dimension the three orthographic projections (front, top & rightside views) of the isometric part shown at right. Grid Scale: 1 square ¼-inch[10 POINTS] [Scoring Rubric is on the next page.]Project Lead The Way Copyright 2006 - Page 9 of 21

Orthographic Drawing with Auxiliary View [7-Points]Point ValueAwarded ÎSkill or conceptassessed ÐOrthographicAlignmentPoint ValueAwarded Î32All features of thefront, top andright-side viewsare alignedorthographically.Most features ofthe front, top andright-side views arealignedorthographically –some minormisalignment offeatures betweenviews.432Two views arecomplete andcorrect - One viewhas a smallamount of missingor incorrectly sizedfeatures.Two or moreviews havemissing orincorrectlysized features(OR) two viewsare completeand correct butthe third view ismissing.Front, top andright-side viewsare complete andare the correctshape and en 2 ormore views.Drawing viewsare ent (3)1Total DrawingFeatures (4)Significant errorsor missing featuresin all drawingviews.Dimensions [3-Points]Point ValueAwarded ÎSkill or concept tobe assessed ÐDimensioning3All dimensions andannotations arepresent and havecorrect placement.2More than half ofthe dimensions andannotations arepresent and havecorrect placement.10Fewer than halfof the dimensionsand annotationsare present andhave dTotal Score for Orthographic Drawing with Auxiliary (out of 10points):Project Lead The Way Copyright 2006 - Page 10 of 21

9. Use the drawing below to answer the following questions.Print Reading[6 POINTS – 1 point each]9.1 What is the fillet radius? R.259.2 What is the depth of the counter bore? .259.3 What is the angular measurement between the counter boredholes? 60 degrees9.4 What is the overall size of the keyway? 1/4 x 1/89.5 What is the distance from the center of the part to the center ofthe counter bored holes? 2.259.6 What is the overall thickness of the part? 1.50Project Lead The Way Copyright 2006 - Page 11 of 21

Part C – College Credit Performance Exam1. Identify the three line types indicated on the orthographic drawing below andexplain why each is used?[6-POINTS: 1 point for each line type, 1 point for each explanation of use]1.1Line type: Cutting Plane LinePurpose: A cutting plane line is used to show where a part has been cut in theadjacent section view and in which direction the section should be viewed.1.2Line type: Hatch Marks or Section LinesPurpose: Hatch Marks or Section Lines are used to show where material has beensliced by the cutting plane in a section view.1.3Line type: Hidden LinesPurpose: Hidden Lines are used to show edges that are not visible as object lines inan orthographic view.Project Lead The Way Copyright 2006 - Page 12 of 21

2. Calculate the surface area for the part below and determine the amount ofstain the manufacturer would have to buy in order to cover 80 wood blocks;assuming each quart would cover 160 square inches. Show your work below.What is the surface area of the part? 9.5 in2How many quarts of stain should be ordered for 80 blocks? 5 quarts[4-POINTS: 2 points for surface area, 2 points for amount of stain]Wood BlankSurface Area Calculations:Surface area of front and back: [2.25(.5) .75(.5)] *2 3 in2Surface area of top and bottom: (2.25 x 1) *2 4.5 in2Surface area of left and right sides: (1 x .5) *4 2 in2Surface Area of Block: 3 4.5 2 9.5 in2Quantity of Stain Calculations:Total Surface Area Surface Area of Block x Number of BlocksTotal Surface Area 9.5 in2 x 80Total Surface Area 760 in2Quarts of Stain Total Surface Area Area Covered in 1 QuartQuarts of Stain 760 in2 160 in2 4.75Quarts of Stain rounded to the nearest quart 5 quartsProject Lead The Way Copyright 2006 - Page 13 of 21

3. Using the dimension parameters shown on the drawing below, write theequation for d2 so that Hole B is always centered between the left edge of theblock and the left edge of Hole A.[5-POINTS]Equation: d2 (d1-d0/2)/24. List the assembly constraints needed to properly constrain the parts in thethree assemblies shown below. List the Degrees of Freedom (DOF), if any, thatremain on Part A based on the constraints applied. Assume that Part B in eachproblem below is the grounded part.[9-POINTS – 2 points for listing constraints, 1 point for identifying degrees of freedom]BBAA4.1Assembly Constraints: Apply an Insert constraint between the underside of the hexhead of the pin (Part A) and bottom of the hex hole in the block (Part B). Apply a FaceMate between one side of the hex head (Part A) and a corresponding side of the hexhole (Part B).List the Degrees of Freedom that remain on Part A (be specific).There are no degrees of freedom. The parts are fully constrained.Project Lead The Way Copyright 2006 - Page 14 of 21

HINGE ASSEMBLYNote: The user wants to drive one of the constraints to show the articulation of thehinge.4.2Assembly Constraints: Apply an Insert constraint between the face and center axisof the cylindrical barrel on hinge A with the face and center axis of the cylindrical barrelon hinge B. Apply an Angle Constraint between the flat face or edge of hinge A withthe opposing flat face or edge of hinge B. (for creating the drive constraint)List the Degrees of Freedom that remain on Part A (be specific).There are no degrees of freedom. The parts are fully constrained.AABBBall Joint and Socket4.3Assembly Constraints:Apply a Tangent constraint between the spherical ball of theball joint and the spherical cavity of the socket. Apply an Angle constraint between thecenter axis of the ball joint stem (Part A) and the top flat surface of the socket (PartB).List the Degrees of Freedom that remain on Part A (be specific):Rotation about the vertical (Y) axis.Project Lead The Way Copyright 2006 - Page 15 of 21

5. Part Model Creation[5-POINTS – 1 point each]The process of developing a 3D CAD solid model of a hammer head has beendivided into four phases. Each phase lists specific steps in the model’s creation.Study the graphics below and the steps that are given for each phase. Thencomplete the process by writing the missing steps on the lines provided. In eachcase, you must identify the specific CAD function(s) being used, along with the name ofthe model feature (as labeled below) that you are referencing.Hammer EndsFinished Hammer HeadEyeCenter BlockHammer NeckPhase 1: Creating the Center BlockCenter BlockStep 5.1: Draw and dimension a sketch of the Center Block feature.Step 5.2: Extrude the sketch of the Center Block to the appropriate dimension.Project Lead The Way Copyright 2006 - Page 16 of 21

Phase 2: Creating two Hammer EndsHammer EndsStep 5.3: Offset a vertical work plane halfway through the width of the Center Block.Step 5.4: Create a sketch plane on the work plane.Step 5.5: Draw and dimension half of the profile of the two Hammer Ends andconstrain them to the geometry of the Center Block.Step 5.6: Use the Revolve tool and perform a Full Revolve on the sketches of theHammer Ends.Phase 3: Creating the Hammer NeckHammer NeckStep 5.7: Step 5.7: Offset a horizontal work plane from the bottom of the Center Blockto a distance that is equal to the height of the hammer neck.Step 5.8: Create a new sketch plane on the horizontal work plane.Step 5.9: Draw and dimension a rectangle on the sketch plane and constrain it to thebottom of the Center Block.Step 5.10: Loft the bottom of the Center Block to the Sketch of a rectangle.Project Lead The Way Copyright 2006 - Page 17 of 21

Phase 4: Creating the Eye and Rounded Edges on the Hammer HeadEyeRound EdgesStep 5.11: Create a new sketch plane on the top of the Center Block.Step 5.12: Draw a sketch of a rectangle with corner fillets and constrain it to theHammer Head.Step 5.13: Use the cut feature of the extrude command to remove the hammer eyethrough all of the part.Step 5.14: Use the Fillet tool to create the r rounded edges on theCenter Block.Project Lead The Way Copyright 2006 - Page 18 of 21

6. Use the Answer Bank to fill in the missing steps of the design process byplacing the letter that corresponds to the missing step in the blank spaceprovided. [6 Points – 1 point each]Phase 1:Problem IdentificationDescription:Identify areas of need or want through market research. Compose aformalized design brief stating the problem that needs to be solved.Identify all constraints that affect the design and classify theconstraints within the various resources available.Phase 2:CDescription:Brainstorming occurs and ideas are collected and/or recorded, oftenin graph form. Research is completed. Thumbnail sketches of ideasare drawn.Phase 3:Refinement of Preliminary IdeasDescription:Phase 4:FDesign AnalysisDescription:DPhase 5:ADescription:Detailed documentation of final design is created. Prototyping isdone. Testing and analysis completed.Phase 6:EDescription:BPhase 7:PresentationDescription:Several forms of reporting may be used to adequately express thedesign solution to any and all parties involved.ANSWER BANK:A. Development and ImplementationB.Reassess the design specifications. Implement any modifications that might be necessary. Updatedrawings.C.ConceptualizationD.Compare alternatives and specifications. Create a decision-making matrix to compare the attributesof the various design solutions and analyze trade-offs. Generate alternative solutions that bettersatisfy the design criteria. Narrow the available solutions and select a final design.E.OptimizationF.Workable solutions are identified. Detailed/annotated sketches are developed. Analysis of possiblesolutions assembled.Project Lead The Way Copyright 2006 - Page 19 of 21

7. ORTHOGRAPHIC DRAWING: [10 points]Sketch a front view, full section of the mounting bracket and dimension the part.Drawing: 7 PointsDimensions: 3 PointsSee scoring rubric on next pageProject Lead The Way Copyright 2006 - Page 20 of 21

Section Drawing [7-Points]Point ValueAwarded ÎSkill or conceptassessed Ð321Most features ofthe section vieware alignedcorrectly, someminormisalignment offeatures betweenviews.SectionAlignmentAll features of thefront section vieware alignedcorrectly.Point ValueAwarded Î43The full sectionfront view iscomplete and isthe correct shapeand size. Hatch iscorrectly sizedand placed.The full sectionfront view is mostlycomplete – someminor features aremissing – Hatch iscorrectly placed.Incorrect hatchscale or ween thetop view andthe sectionview.TotalOrthographicAlignment (3)Views are notaligned.21Front sectionview isincorrectlysized and hasincorrect ormissing hatchpattern andplacement.Significant errorsor missing featuresin the front sectionview. Hatchpattern andplacement isincorrect ormissing.Total DrawingFeatures (4)Dimensions [3-Points]Point ValueAwarded ÎSkill or concept tobe assessed ÐDimensioning3All dimensions andannotations arepresent and havecorrect placement.2More than half ofthe dimensions andannotations arepresent and havecorrect placement.1Fewer than halfof the dimensionsand annotationsare present andhave edTotal Score for Section Drawing (out of 10 points):8. Print Reading[5 POINTS - 1 point each]Use the drawing of the pivot arm to answer the following questions.8.1 What is size of dimension A? 18.2 What is the thickness of the part at B? .508.3 What is the overall length of the part? 6.13 .50 .62 ANS 7.258.4 What is the width of the keyway? .138.5 From what material is the part made? Aluminum 6061Project Lead The Way Copyright 2006 - Page 21 of 21

14 D Unit 5.1 Geometric Relationships - Forms and Shapes 15 C Unit 6.4 Modeling - Mathematical 16 B Unit 6.5 Modeling - Computer 17 A Unit 6.1 Modeling - Conceptual 18 D Unit 6.5 Modeling - Computer 19 C Unit 6.5 Modeling - Computer 20 B Unit 6.1 Modeling - Conceptual 21 D Unit 6.3 Modeling - Physical 22 A Unit 6.5 Modeling - Computer

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