MANUFACTURE AND MATERIALS 3

SHE Level 3
SCQF Credit Points 20.00
ECTS Credit Points 10.00
Module Code M3H724815
Module Leader Anjali DeSilva
School School of Computing, Engineering and Built Environment
Subject Mechanical Engineering
Trimester
  • B (January start)

Pre-Requisite Knowledge

Manufacture & Materials 2 (SD2)

Summary of Content

The aim of this module is to provide an understanding of: -359? the structure, attributes and behaviour of ceramics , composites and polymers under mechanical loading; how to design and manufacture components with these materials; ? the failure mechanisms of materials under static and dynamic loading conditions; ? machine tools, jig and fixture design; ? the principles of engineering metrology. ? quality control and management technology. The percentage of Work Based Learning for this module, as represented by the Independent Learning "Activity Type", is 55%. The percentage of Work Based Assessment for this module is 20%, which is represented by Coursework 2.

Syllabus

Machine Tools: Machinability, comparison of cutting tool materials, relationship between cutting parameters, tool life and power requirements. Machine tool design, need for stiffness and damping, chatter and limiting width of cut; need for swarf clearance, effective safeguarding, loading/unloading of work; special requirements of power presses. Jig and Fixture Design: Kinematics of component location, Component clamping principles, location/guidance of cutting tools, Construction of jigs and fixtures and the use of standard and purchased parts, Preparation of designs for drilling, milling and assembly fixtures. Metrology: Evolution of length standards. Limits and fits; clearance, interference and transition fits, preferred sizes, BS4500 ISO system of limits and fits. Geometric tolerancing; specification of procedures to inspect dimensional and geometric features for compliance to specified tolerance. Surface texture; specification and assessment of surface texture, BS 1134. Ceramics: Structure - crystalline, silicates and glass, glass ceramics; Mechanical properties- deformation and dislocation movement in ceramics, defect sensitivity, failure prediction - Weibull analysis; Thermal, electrical and magnetic properties of ceramics; Manufacture - powder methods, control of porosity and defect size, reaction bonding; Applications - aerospace, automobile, tooling; medical, electronic. Composites: Definitions; Types of reinforcement and matrix; Function of matrix material; Modelling elastic behaviour of composites; Degree of anisotropy; Strength and stress transfer; Failure modes; Types of composites (polymer, ceramic and metal matrix), their manufacture and applications. Polymers: Thermoplastic, Thermoset & Elastomers; Bonding & Structure, Properties; Mechanical behaviour; Crystallisation, melting and glass transition phenomena; Processing and Applications Failure in Materials (ADS): Fracture - Ductile and brittle fracture; Basic principles of fracture mechanics; Griffith's theory; Fracture toughness; Impact testing; Ductile-to-brittle transition; Fatigue - Cyclic stresses, S-N curves, Crack initiation and propagation, Factors that affect fatigue life; Creep - Generalised creep behaviour; Stress and temperature effects. Quality Management: Quality Management philosophies: Deming, Juran, Crosby, Feigenbaum, Ishikawa; Total quality management (TQM), Criteria for successful implementation, role of industrial relations. Statistical methods in quality assurance : Review and revision of statistical theory; control charts for variables, calculation of control limits, construction and interpretation of range and average charts, comparison of BS2564 and ASTM. Control charts for attributes, construction and interpretation of number defective and fraction defective control charts. Process capability: Concepts, calculation of capability indices C p , C pu , C pl and C pk ; The Six Sigma concept

Learning Outcomes

On completion of this module the student should be able to:Specify appropriate dimensional and geometric tolerances; surface texture; for mechanical components and procedures to check compliance with tolerance.Explain the principles underlying machine tool design.Explain how the bonding & structure of ceramics, polymers, and composites affect their properties and processing.Assess the impact of material behaviour under a range of static and dynamic loading conditions and the possible failure modes.Apply appropriate rules when designing components with ceramic, polymer or composite materials and select engineering ceramics / composites/polymers for particular applications with due regard to their properties and processing.Evaluate quality management philosophiesConduct process capability studiesConstruct and evaluate control charts for variables and attributes.

Teaching / Learning Strategy

Lectures,Flipped Tutorial & Seminars, Practical Experiments, Work Based Case Studies, Videos. The students will be encouraged to reflect upon the theoretical learning within the work place and the application of newly learned concepts to the work environment. Work Based Education aims to maximise the direct and digitally mediated contact time with students by practicing teaching and learning strategies that use authentic work based scenarios and encourage action learning, enquiry based learning, problem based learning and peer learning. All these approaches aim to directly involve the students in the process of learning and to encourage sharing of learning between students. The module team will determine the level and accuracy of knowledge acquisition at key points in the delivery, inputting when necessary either directly or with the support of external experts who will add to the authenticity, the credibility and application of the education and learning to the workplace.

Indicative Reading

Recommended: "Materials Science and Engineering", William D Callister and David G Rethwisch, John Wiley and Sons, 2011, 8th ed. ISBN:978-0-470-50586-1 "Composite Materials: Engineering and Science", F L Matthews, R D Rawlings, Chapman & Hall, 1994. "Jig and Fixture Design Manual", E Henrikson, Industrial Press, 1973. "Materials Selection in Mechanical Design", M J Ashby, 4 th Edition, Butterworth- Heinmann, 2011, ISBN978-1-85617-663-7 "Statistical Process Control", John S Oakland, Butterworth Heinemann, 2003, 5th edition, ISBN 0 7506 5766 9 "Managing Quality", B G Dale, T Van der Wiele and J Van Iwaarden, Blackwell, 2007, 5th edition, ISBN 978 1 4051 4279 3 "Introduction to Statistical Quality Control", Douglas C Montgomery, John Wiley and Sons, 2005, 5th edition, ISBN 0 471 65631 3 Journals, Periodicals eg. Institution of Materials, I MechE, ASME and SME.

Transferrable Skills

Further enhancement of report writing skills.

Module Structure

Activity Total Hours
Independent Learning (FT) 110.00
Tutorials (FT) 12.00
Assessment (FT) 18.00
Lectures (FT) 36.00
Practicals (FT) 24.00

Assessment Methods

Component Duration Weighting Threshold Description
Coursework 2 n/a 20.00 35% Major: Technical analysis/report (Week 13-20)
Coursework 1 n/a 10.00 35% Minor: CAM Exercise (Week 11-14)
Exam (Exams Office) 3.00 70.00 35% WRITTEN EXAMINATION