METE 401 MATERIALS ENGINEERING DESIGN I

 

 

TEXTBOOKS :

1. Ashby , Materials Selection in Mechanical Design , Elsevier , 3rd Ed., 2005

2. Fleddermann , Engineering Ethics, Prentice Hall, 2nd Ed., 2004

 

REFERENCE BOOKS :

1. Dieter , Engineering Design: A Materials and Processing Approach, McGraw Hill, 3rd Ed., 2000

2. Farag , Materials Selection for Engineering Design , Prentice Hall, 1997

3. Crane and Charles , Selection and Use of Engineering Materials , Butterworth , 2nd Ed., 1989

 

 

COURSE CONTENT :

 

1. INTRODUCTION TO ENGINEERING DESIGN      (Ashby – Ch.1, 2 )      (1 week)

·         Types of Engineering Design and the Role of Materials

·         Steps of Product Design: Conceptual Design, Embodiment Design, Detailed Design

·         Introduction to Design Tools: Modeling, Simulation, Optimization, CAD-CAM

 

2. DESIGNING AGAINST FAILURE      (Dieter – Ch.8)  (Farag – Ch.4, 6)      (3 weeks)

·         Factor of Safety in Design

·         Designing for Tensile, Compressive, Bending and Buckling Loads

·         Designing for Brittle Fracture and Low Temperature Resistance

·         Designing against Fatigue Failure

·         Designing for Creep and High Temperature Resistance

·         Designing for Oxidation, Corrosion and Wear Resistance

 

3. MATERIALS SELECTION IN DESIGN      (Ashby – Ch.3, 4, 5, 6, 9, 10)      (3 weeks)

·         The Classes and Properties of Engineering Materials

·         Methods of Materials Selection

·         Ashby Charts and the Method of Weight-Factors

·         Derivation of Material Indices

·         Use of Materials Selection Charts

·         Use of Computerized Materials Databases

·         Differences in Designing with Polymers, Composites and Ceramics

 

4. PROCESS SELECTION IN DESIGN      (Ashby – Ch.7, 8)  (Dieter – Ch.9)  (Farag – Ch.7)      (3 weeks)

·         Classification of Manufacturing Processes and their Role in Design

·         Use of Process Selection Charts and Computerized Databases

·         Designing for Castings, Forging, Deformation Processes, Powder Methods

·         Designing for Machining, Welding, Joining and Finishing Processes, Assembly

·         Designing for Residual Stresses and Heat Treatment

·         Designing for Polymer, Composite and Ceramic Processing Methods

 

5. ECONOMIC, INDUSTRIAL, AND ENVIRONMENTAL ISSUES IN DESIGN      (Ashby – Ch. 15, 16, 17, 18)  (Dieter – Ch.13)      (1 week)

·         Cost Analysis, Cost Estimates, Manufacturing Costs

·         Materials and Industrial Design, Materials and the Environment, Eco-design

 

6. ENGINEERING ETHICS      (Fleddermann –Ch.1, 2, 3, 4, 5, 6, 7, 8)      (3 weeks)

·         Professionalism, Laws, Contracts, Copyrights, Liability

·         Codes of Ethics, Ethical Theories, Solving Ethical Conflicts

·         Cases, Discussions

 

 

ENGINEERING ETHICS DISCUSSIONS:

Each team will present an engineering ethics topic with case studies followed by team discussions

 

 

DESIGN PROJECT:

Teams will submit 3 reports on a “Materials and Process Selection” project for a given design topic

 

 

REPORT CONTENTS:

 

1.  PRELIMINARY REPORT      (R1)

 

·      Engineering Drawings, Working Principles, Materials and Processes Used Today

·      Free Body Diagram and Loading (Short–Long term, Static-Dynamic, Axial-Non-axial, Pressure)

·      Stresses Developed (Tensile, Compressive, Shear, Centrifugal, Bending, Torsion, Hoop, Thermal)

·      Operating Environments (Temperature Range, Relative Humidity-fresh water, Marine Environment-sea water, Acids, Alkalis, Organic Solvents, Ultraviolet Light, Friction-wear)

·      Design Stress (Maximum or Predominant Stress), Design Environment (Critical ones)

 

2.  MATERIALS SELECTION REPORT      (R2)

 

·      Material Indices for Primary Constraints (Tmax-service , r , Cm , sY , E , KIC  )

·      Material Indices for Environmental Constraints (Resistance to Fresh Water, Sea Water, Wear, Oxidation at 500°C, Flammability, Acids, Alkalis, Organic Solvents, Ultraviolet Light)

·      Derivation of Material Indices for Mechanical Constraints (Strength, Stiffness, Toughness, Resilience)

·      Conceptual Design Stage: Materials Selection Charts (Level-1 data), List of Candidate Material Classes

·      Embodiment Design Stage: Materials Selection Charts (Level-2 data), Table of Candidate Specific Materials

·      Detailed Design Stage: Best Material(s), Precise (Level-3) data, Details

 

3.  PROCESS SELECTION REPORT      (R3)

 

·      Process Indices for Class Attributes: Material Class (Metal, Polymer, Ceramic), Process Class (Discrete-Continuous, Primary, Secondary, Tertiary), Shape Class (Prismatic, Sheet, 3D)

·      Process Indices for Physical Attributes (Mass Range, Tolerance, Minimum Thickness, Maximum Dimension, Roughness, Aspect Ratio, Adjacent Section Ratio, Hole Diameter, Minimum Corner Radius)

·      Conceptual Design Stage: Process Selection Charts (Level-1 data), List of Candidate Process Classes

·      Embodiment Design Stage: Process Selection Charts (Level-2 data), Table of Candidate Specific Processes

·      Detailed Design Stage: Details of Best Primary, Secondary and Tertiary Processes, Process Cost Analysis

 

 

GRADING :

 

·         Class Attendance                         (xx%)     (50% attendance is compulsory)

·         Final Exam                                   (50%)

·         R1-Preliminary Report                 (10%)

·         R2-Materials Selection Report     (13%)

·         R3-Process Selection Report       (12%)

·         Ethics Team Discussions              (15%)     ( 100% attendance is compulsory)