Design and Development in Automotive and Mechanical Engineering (M. Eng.)

Numerical Methods in CAD

Module Numerical Methods in CAD

Courses

a) CAE Methods and Algorithms 2 ECTS
b) Numerical Mathematics 2 ECTS

Contents

• Advanced topics of matrix calculus
• Analysis of functions of several variables (especially optimisation)
• Iterative methods for solving linear equation systems
• Power series, Taylor series, Fourier series
• Nonlinear equations and nonlinear equation systems
• Numerical methods for initial value problems of ordinary differential equations

Examination Forms and Prerequisites for Awarding ECTS Points
Written examination (90 mins); graded

Design and Development 1

Module Design and Development 1

Courses

a) Design Methodology Case Study 2 ECTS
b) Ecologic and Economic Design 2 ECTS
c) Reliability 2 ECTS

Contents
a) Design Methodology Case Study: Design constraints, QCD requirements, design and development Team, breakdown structures, functional decomposition of technical systems, product design specification, V – Cycle, tender and project cost management, change and configuration management, safety management and engineering
b) Ecologic and Economic Design: Resources, future resource availability, negative effects of industrial processes and products on humans and the environment, environmental burden of disease in Europe, EU directives on environmental protection (design engineering view), ECO‐design methods including Luttrop's "Golden Rules and additions", ecological design and economic design ‐ no area of conflict!
c) Reliability: Definition, significance and overview of reliability, techniques in the product development and in the product life cycle; statistics, probability theory, life time distribution, reliability of systems;

Examination Forms and Prerequisites for Awarding ECTS Points

• Design Methodology Case Study: Certificate
• Ecologic and Economic Design: Written exam 90 minutes (closed)
• Reliability: Written exam 60 minutes (open)

Dynamics

Module Dynamics DDM

Courses

a) Multi Body Systems 2 ECTS
b) Simulation of Multi Body Systems 2 ECTS

Contents

Contents
a) Multi Body Systems:
Description of finite rotations, rotation matrix, speed and acceleration, forces and constraints, equations of motion, state‐space equations, numerical solutions, user defined force elements.
b) Simulation of Multi Body Systems:
Introduction to Matlab Symbolic toolbox and Simcape. Modelling and Simulation of different examples with SimMechanics, e.g.: mechanical conveyor, hydraulic excavator, Modelling and calibration of subsystems of “Esslingen Driving Simulator” and system integration in group work.

Examination Forms and Prerequisites for Awarding ECTS Points
Multi Body Systems: Written exam, 90 minutes, graded
Simulation of Multi Body Systems: Group projects with presentations, not graded

Integrity of Structures

Integrity of Structures

Courses

a) Integrity of Structures 4 ECTS

b) Failure Analysis 2 ECTS

Contents

a) Integrity of Structures: Advanced concepts for the life‐time assessment under variable amplitude loading: Nominal stress concept for cyclic loading, structural stress concept for cyclic loading, local stress concept for cyclic loading, local strain concept for cyclic loading, fracture mechanics concept Application of numerical tools for the life time prediction Selected topics / ongoing research topics: e.g. very high cycle fatigue (VHCF); fatigue behaviour of composite materials; Influence of edge conditions on fatigue behaviour, multiaxial fatigue... Laboratory exercises: Non‐destructive testing, experimental determination of material and component flow curve, Neuber`s Law, Masing behaviour, local stress‐strain loops, test drives with strain gauges, collecting data for load time history, numerical life time assessment

b) Failure Analysis: Historical failures, typical failures at car structures, reason for failures, concepts for component optimization, definition and classification of failures, methods of failure analysis, characteristics of failures under static and cyclic mechanical, thermal and chemical loading, practical case studies and exercises

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 120 minutes, graded

Lab reports and lab tests

Vibration and Acoustics 1

Module Vibration and Acoustics 1

Courses:

a) Vibration and Acoustics Measurement 2 ECTS

b) Vibration and Acoustics Measurement 2 ECTS

Contents
a) Vibration and Acoustics Measurement: Vibration measurement by mechanical means, optical and laser basics, vibration measurement by interferometric and holographic means, acoustic noise measurement, analysis of dynamic signals.
b) Laboratory Vibration and Acoustics Measurement: Introduction and handling of measurement equipment, FRF measurement on an automotive component, order tracking measurement on a car, Speckle interferometry, laser vibrometry.

Examination Forms and Prerequisites for Awarding ECTS Points
Written exam, 90 minutes, graded
Lab reports and tests, not graded

Advanced Strength of Materials

Module Advanced Strength of Materials

Courses

a) Lightweight Design 4 ECTS
b) Advanced Finite Element Method 2 ECTS

Contents
a) Lightweight Design: Principles and objectives of lightweight design; One‐dimensional members (Bars and Beams); Plates and shells; Stability problems; Selected examples of lightweight design
b) Advanced Finite Element Method: Theoretical background of FEM, fundamental equations, numerical accuracy and convergence, applications and influence of boundary conditions, nonlinearity (material); lab exercises

Examination Forms and Prerequisites for Awarding ECTS Points
Advanced Strength of Materials: Written exam, 120 minutes, graded
Advanced Finite Element Method: Individual semester project, not graded

Advanced Materials Technology

Module Advanced Materials Technology

Courses

a) Advanced Engineering Materials 2 ECTS
b) Surface Technology 2 ECTS
c) Composite Materials 2 ECTS

Contents

a) Advanced Engineering Materials:

Car Body Technology: Car Body Parts, Deep Drawing, Cutting, Hemming, Extruding, Integrated Approach

Sheet Materials: Strengthening, Production of Sheet Materials, Properties

High Strength Steel Sheets: Phases, Mild Steels, IF‐Steels, BH‐Steels, Micro Alloyed Steels, Multiphase Steels, Press Hardening Steels, Recent Developments

Aluminium Sheets: Wrought Alloys, Strengthening Mechanism, Naturally Hard Alloys (5xxx), Precipitation Hardenable Alloys (6xxx), Superplasticity, Aluminium/Steel‐Mix Bodywork

Tailored Components: Tailored Blanks, Partial Press Hardening, Multilayer Sheets, Fusion Sheets

Plastic Behaviour: Characteristic Values, Anisotropy, Yield Locus, Plastic Behaviour, Forming Limits, Wrinkle Formation

Method Planning: Material Flow, Process Chains, Derivation of Method from Component Geometry, Drawing Method

b) Surface Technology: Basics in corrosion, thermal coating, CVD, PVD, electrochemical deposition, corrosion protection of stainless steel and light metals, leak, sealing, dip coating, design of the corrosion protection for all the components of passenger cars, testing methods

c) Composites materials: Understanding polymers, molecule structure, modelfree reaction kinetics, classification, thermal and mechanical properties, reinforced polymers, fibre materials, laminate properties, testing composite materials, designing with polymers and reinforced materials.

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 120 minutes, graded

Project Work DDM

Module Project Work

Courses

a) Project Work 7 ECTS

b) Project Work ‐ Presentation 1 ECTS

Contents
a) Project Work: Application of project management, constitution of hierarchy (project‐manager, teams members), constitution of project structure (time schedule, work packages), realisation of given tasks, documentation and evaluation of results
b) Project Work – Presentation: Presentation of results within a seminar, project feedback

Examination Forms and Prerequisites for Awarding ECTS Points
a) Group report
b) Presentation in a group (20 min.) + discussion (10 min.)

Design and Development 2

Module Design and Development 2 DDM

Courses

a) Advanced CAD 2 ECTS

b) Design of Experiments 2 ECTS

Contents
a) Advanced CAD: General introduction in the latest Revision CREO from PTC with practices; Learning of special advanced features of a CAD system; Learning of special advanced modules of a CAD system, like sheet metal, surface, mechanism,cabling and piping. Several programing tools and possibilities; Criteria for choosing a CAD System; Subassembly and skeleton technology; CAD and Internet; Data exchange, direct and indirect data exchange; Many practice by using the CAD‐System by working out examples; Theoretical background of CAD‐System modules.

b) Design of Experiments: General introduction into DOE, differences to experience‐based test planning, execution and results of a DOE; Attempts plan: selection parameters to be investigated and result sizes, establishing the testing area; Test plan designs: Overview DOE designs (factorial, response surface, mixture, optimal designs), selection of designs; Creating designs with a DOE software tool; Specific variables in the DOE: randomization, blocks replication, resolution / confounding; Evaluation of experimental design results: effects and effect size, interactions, statistical tests in the DOE, review the validity; Optimization calculation, prediction and confirmation tests: graphical representation of the effects of parameters, numerical optimization, predict outcomes, evaluation of test results; Application of the DOE to some practical examples as well to a final exercise with all the main points mentioned

Examination Forms and Prerequisites for Awarding ECTS Points
Advanced CAD: Several attestations, graded
Design of Experiments: Written exam 60 min, graded

Design for Manufacturing

Module Design for Manufacturing DDM

Courses

a) Production‐oriented Product Design 6 ECTS
b) Product Life Cycle Management 2 ECTS

Contents
a) Production‐oriented Product Design:
Part 1: Root cause investigation: root cause investigation on failing products with the aim to identify failures in production oriented product design, 4 to 6 cases, ambivalent data situation, insufficient information, without obviously correct answers and a ticking clock, which requires fast actions, inter‐cultural investigation teams.
Part 2: Basics (process, weldability of materials and design) for relevant joining technologies (e.g. laser beam welding, resistance welding, friction welding, ultrasonic welding, mechanical joining, adhesive bonding), methods of quality assurancein production, health and safety instruction, industrial applications, practical laboratory
Part 3: Textile techniques, composite design, production of preforms, thermoplastic and thermoset processes, organic sheet
moulding, taping, resin transfer moulding, reactive injection moulding, polymer press processes, repairing of composite
materials, joining of polymer materials
b) Product Life Cycle Management: Understanding the method LCA Life Cycle Assessment, trends in industry and society,
training and application LCA software GaBi; executing an LCA in teams; Analysing industrial LCAs

Examination Forms and Prerequisites for Awarding ECTS Points
Written exam, 120 minutes, graded
Product Life Cycle Management: Individual semester project

Vibration and Acoustics 2

Vibration and Acoustics 2

Courses

a) Vibrations 2 ECTS
b) NVH in Automotive Systems 1 ECTS
c) Computer‐Aided Vibration Analysis 1 ECTS

Contents

Contents
c) Vibrations: Introduction to the basic theory of vibrations; practical application to typical structural noise and shake problems; principles of Fourier analysis and order tracking; multiple degree of freedom systems.
d) NVH In Automotive Systems: Definition of NVH; acoustic and vibration problems in vehicle systems.
e) Computer‐Aided Vibration Analysis: Simulation of practical vibration problems (CAT).

Examination Forms and Prerequisites for Awarding ECTS Points
Written exam, 90 minutes, graded
Laboratory reports and tests, not graded

Master Thesis and Soft Skills

Master Thesis and Soft Skills DDM

Courses

a) Soft Skills 3 ECTS
b) Master Thesis 24 ECTS
c) Defence 3 ECTS

Contents
a) Soft Skills: Communication: Sender/receiver model, levels of communication, perception and interpretation, NLP Presentation: Generation of presentations, advanced presentation techniques
Teambuilding: Individual types according to MBTI, Team Set‐Up
Management and Leadership: Aims, Missions, Visions, Values, Corporate Governance, Motivation, Leadership Competence
b) Master Thesis: Constitution of project structure (time schedule, work packages), realisation of given task with scientific methods and within a given timeframe, documentation and evaluation of results
c) Defence: Presentation and defence of results

Examination Forms and Prerequisites for Awarding ECTS Points
a) Group work with test, oral presentation 30 minutes
b) Thesis report
c) Presentation and oral examination , 30 minutes