Joseph Klosowski Reflection

Let’s start out by saying Design and Manufacturing (ME250) was the best class I have taken at the University of Michigan. From what I hear from upper class men and staff it will be the greatest class I take as an undergrad.  What makes this class so great is that you get to actually use what they teach you in class.   Honestly if it wasn't for the machine shop incorporation I wouldn't have been so passionate about this course. In other classes its repetitive non sense that you will not retain when the next semester rolls around. This information that I got from this class will help me succeed as a mechanical engineer. I understand that this class covers the basics of design and manufacturing, but it’s the basics that other university’s struggle to instill in their students. The facility that taught this class was amazing. The lectures weren't your average dry seminar that you see a lot of in engineering; it was interesting and useful material. The material was extremely fascinating to me because I have a manufacturing upbringing. Most my family works/worked with the automotive industry and this class had my full attention as a gearhead like myself. I would recommend this class to anybody that shares the same ideas.

The idea of working in team is one that I enjoy.  Teamwork is a valuable trait in the industry, one that many recruiters look for in an individual. Our team had a rough start but came together to work like a fine oiled ball collecting machine. The team chemistry was there from the beginning just the clash of ideas gave us a late start on the project. I believe we used our time wisely due to the fact that we all were taking 12-13 more credit hours.  Some team members spent a lot of time in the shop manufacturing  parts whereas others where behind the scenes making new designs for more parts to be made and making sure we turned assignments in on time. Overall I think the team we had was the team to beat. With the help of the staff and our great GSI Connor our machine was the one that should have won. That sounds conceited but I truly believe we were more deserving of the 1^st place title.  However of the placement of our team at the competition this was a great learning experience and would love to do it again.

To improve this course I would suggest that the time we were allowed in the shop to be increased.  Start working on the manufacturing processes earlier in the semester.  Keep the extended hour as well, because some of us had classes that limited us from attending the machine shop in the beginning. Other than that the class was great. I have no complaints about the guidelines or the setup of the class. The staffs that teach this class are a great fit for the material and bring a lot of experience to the table. I enjoyed all the guest speakers and learned a lot of useful ways to looks at a problem.  As my performance in this class the only thing I could have improved on was my exam grade. I tested above the average but still could of done a little better. I don’t know what else to say besides great class and glad I was able to experience it with a great group of people and Robin. Only kidding Robin was alright.

Michael Kamen Reflection

                ME 250 is the best class I have taken so far at the University of Michigan.  It was actually fun, informative, and we learned actual skills to use in the field of engineering.  I really enjoyed being around so many engineers and learning from actual experiences.  I feel like I have gained more from this one class that I did in college so far.  During an internship over the summer, I realized that most of the time engineers don’t use fancy, complicated equations or crazy differential equations.  Instead you use common sense and the design process to make wise choices.

                In the design and manufacturing part of this class, I strengthened my knowledge in many fields.  I learned a new CAD software to some extent, which could be a good resource in the future of my career.  Also, I learned a little more formally about drawings, manufacturing plans, etc, instead of just learning as I make mistakes in the field.  The coolest thing about this class was the fact that we actually were able to build something physically.   Instead of just designing and having someone else construct it, we had to build our machine with our own two hands.  Using the mill and the lathe in the shop, along with all of the other tools, actually gives you a sense of what can actually be made in the real world.  Instead of designing an impossible part or tool without knowing how it will be made, we can know some processes that can make it therefore making the entire process easier on everyone involved. 

                This class also taught a lot about leadership, teamwork, and deadlines.  In the beginning, our team had a few issues getting along because of differences in opinion, but at the end we came together to complete the task at hand.  I don’t feel like there was one true definite leader in our group. We all were leaders at one point or another even though we had to pick one specific one at the beginning.  I truly believe that this is what sets the University of Michigan apart from other universities.  Everyone here is a leader and has been a leader throughout their lives.  I also learned that if you want to get something done, you need to set a deadline earlier than the actual deadline to allow for troubleshooting and adjustments.  I noticed a lot of groups just finishing up on the last day with no real time to test the capabilities of their machine.  This is where I think our group excelled.  We completed the chassis and drive-train almost 2 weeks ahead of time so we could test.  Sure enough, the hex axles that were provided in the double gearbox were not hard enough to handle the force of the set screws that kept our axles from spinning.  With a little redneck ingenuity, we were able to cut down Allen wrenches to replace the axles.  Without this, we would not have come close to getting 3rd place (even though we should have won).

                This course could be improved by changing the task for the class.  Instead of having Balltower every semester, the students should get to design the course, and choose what type of machine they want to.  It just seemed like we did the same exact thing as the class last semester and there wasn’t a whole lot of room to be creative or have an advantage in the competition.  Everyone knew every strategy and how to build a successful machine for each strategy.  Also, I feel like the motors we were provided were a major reason why a lot of teams' designs failed.  The shafts were too soft and the gears were not very strong.  I understand this is an introductory course so I wasn’t too concerned about the quality of the motors.  It was cool however to understand the mechanics behind an electric motor/gearbox.

                I could have improved in this class by practicing more with the solidworks program, for that is a useful skill.  Also, I could have improved on our planning of the building of the machine.  At the end we had to do a lot of shimming and fitting so everything would fit together properly.  With better tolerance and diligence with the design, I could have made a machine that fit together perfectly.  This is something I will definitely remember in the future. 

                I really had a fun time in this class and mostly with my group members.  I feel like we all learned numerous new skills in manufacturing and we all made new friends. Thanks Beverly, Robin and Joe for the great experience.

Beverly's Individual Reflection

Design and Manufacturing I (ME250) was my first mechanical engineering class here at the University of Michigan, and I found the class to be a good experience overall. I enjoyed working on a more hands-on project rather than in a more academically focused environment. I had no previous knowledge about machining metal or about mechanical components, so it was good to get a general overview on this topic. I feel a lot more prepared to take my future mechanical engineering course after taking this class.

For the design and manufacturing part of the class, I learned a lot about how to use the machines. I had never touched a lathe or a mill, and it was difficult at first to become acquainted with the machines. But now I feel more confident in machining parts and working in the ME shop. As for the design component of the class, my Engineering 100 (Photovoltaics & Solar Cells) used similar approach in teaching the design process, so I was familiar with this when we talked about it in class. The design portion was my favorite part of the class. I wish that we could have gone more in depth with this topic, but I do understand that there is a lot to cover in the class. I am glad that I learned how to make a Pugh Chart because I actually ended up making one for a BLUElab Design Review later this semester.

In terms of teamwork and time management, the most difficult problem I think our team dealt with was getting enough time on the mill and lathe in the machine shop. It was frustrating that we could not work when we needed to. I had no idea when the machines were available and I could not sign up for the times myself, so Robin, our designated team leader, had to do this for our team. Eventually, everything worked out so that we had our machine done early, but we ended up using less precise tools such as the band saw and the drill press to get everything finished. I also found that it was sometimes difficult to work as team due to differences in our individual schedules. This was to be expected though, and we managed to work around our schedules.

Although making the machines to play the Ball Tower Game was fun, I wish that there were a more practical application for our designs. For instance, our machine was specifically designed for the Ball Tower Game, which is only ever played in ME250 at the U of M, and had very little practical applications outside of the game. That said, I think that the Ball Tower Game was a good way to have an even playing field for each team since there was a clear set of rules for the game. This definitely allowed us to put an equal focus on design and machining in the time allotted for the class.

I think that the course could be improved by making the lectures more interactive. Especially because the lecture is in the early morning, I have a hard time focusing on things like 10 different slides on 15 different types of ball bearings. Information like this was very unfiltered, and I felt like there was just a lot of information being thrown at me. I really wanted to see the main message (in this example, the main types of bearings, what they do, and some common applications) instead of a lot of specific information. The lecture slides could definitely be more clear, concise, and direct. I think this would greatly help students understand the manufacturing and building process better and would improve students’ performances on the exam and the competition.

I could have improved my performance in this course by practicing using the tools and machines in the shop more. Unfortunately, this semester was a busy one for me, so this was not really an option. My group members had more experience building projects and using machinery than me, so often I worked much slower and less efficiently than them. At the end of the class though, I still feel like I learned a lot about CAD and manufacturing since I essentially had no previous skills or knowledge.

Finally, I would like to say that I had a pretty good experience in ME250. Team Holy Moly is awesome, and Connor Moelmann is one of the better GSIs I’ve had at the U of M. I’m glad that we were able to work everything out for this class, and I look forward to taking ME350 in the future.

Bill of Materials/Parts List

Bill of Materials/Parts
#	Description	Use	Dimension	Supplier	Part#	Other details
1	¼” Aluminum plate	Base Plate	8.5”x8” cut from a 18”x 12” piece	Alro Steel	Quote	Price=$15.84
2	(2) ¼” Aluminum plate	Long Sides	9”x 3”	Kit	Quote
3	(2)¼” Aluminum plate	Short sides	8”x 3”	Kit	Quote
4	(8)¼” Aluminum Angle Stock	Brackets for Assembly	1”x1”x1”	Kit	Quote
5	(4)Flanged SS bearings	Axle bearings	¼”x ½”x 1/8”	Kit+2 From Mcmaster	57155K304	Additional $11.24
6	(20) Countersink Flathead screws	Fasteners	10-24 x ½”	Found in  Bob’s shop	Quote
7	(2)  Threaded Aluminum disc	Casters	½”x1”	Found in Bob’s shop	Quote
8	Tamiya 70168 Double Gearbox	Drive Motor	2 ¾”x 2 ¼”x ¾”	Kit	114	344:1 gear ratio
9	(2)Rubber  tread wheels	Wheels	2 ½” x 1”x ¼” shaft	uVolt	ROB201	Price=$3.50 each
10	(2) Steel shaft	Axle	¼”x 2 7/8”	Kit	8893K36
11	Aluminum square stock	Tower pusher	½”x 3”	Kit	Quote
12	¼”Aluminum plate	Tower pusher	2”x3”	Kit	Quote
13	(2)¼” Aluminum Angle Stock	Bearing Holder	1”x1”x1”	Kit	Quote	Pressed in bearings
14	(4) Electrical connector, Male	Hook to battery Supply		Crib	7060K81
15	Wire	Run power to motor	24”	Crib
16	(4) Steel rod	Dowels to connect long sides to base plate	1/8”	Found in Bob’s shop	Quote	Lower amount of brackets
17	(2)  1/16” Aluminum plate	Guide the tower pusher	1/16” x 6”x2”	Kit	Quote
18	1/16” Aluminum plate	Collect balls in front	3”x 23”	Kit	Quote
19	(3)Grey PVC block	Motor and bearing spacer	.4” x3”	Found in Bob’s shop	Quote
20	(6) Stainless Steel Socket Head Screws	Hold motor and bearings in place on chassis	8-32 screw	Hardware store	G4671	$0.40 each
21	Loctite	Hold set screws in place	Red	Hardware store		$7.89
22	(8)Set screws	Hold axels in desired location	6-32 screw	Hardware store	K7845	$0.20 each
23	(2)Allen wrench	To replace factory axels	7/64”	Hardware Store		$0.69 each