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Module details for 2022/23.

15 credits

FHEQ Level 4

Module Outline

The main objective of this module is to inform students about the importance of the relationships between product design, material properties and manufacturing processes for the production of products that satisfy customer quality and functionality requirements. The necessary supporting IT infrastructure is also introduced. The student will acquire knowledge to enable them to make economically viable selections of materials and manufacturing processes. The module also considers how to minimise environmental impact.

At the end of the module the student should be able to specify materials and manufacturing processes that would permit economic manufacturing processes related to production volumes, which are a major consideration when investing in tooling.

In detail the module informs students how material properties arise from the atomic and crystalline nature of: metals, ceramics, polymers and composites. It also explains how material properties can be enhanced via the manufacturing methods employed.

The failure mode of materials is considered in the context of product functionality, factors of safety and manufacturing processes.

Throughout the course the materials and methods of production of a wide range of products are considered. The module is supported by laboratory work, workshops and demonstrations.

Module Topics
Introduction to Materials and Material Science: Principal characteristics and applications of plastics, metals, composites, ceramics, and natural materials. Historical and recent developments in material science with respect to design and engineering applications.

Introduction to Atomic and Macroscopic Level Properties of Materials: key chemical, electrical, mechanical, thermal, environmental, and manufacturing properties of materials. How material properties arise from atomic level interactions; atomic bonding, the basic force/separation curve and the development of the stress/strain relationship.

Introduction to Behaviour of Materials under Load: introduction to forces and basic types of loading cases. Stress and strain curves. Mechanics of materials under axial tensile and compressive forces. Stress concentrations. Introduction to design stresses and factors of safety.

Selection of Materials: basic methods of material selection, use of software in material selection.
Engineering Failures: Typical failure mechanisms of materials such as fatigue, creep, crack growth, and corrosion. Case studies of engineering failures with respect to material selection and design.

Introduction to Manufacturing processes: Casting, moulding, forming, machining, joining, rapid manufacturing and 3D printing. Correct machine shop working practice and related health and safety considerations. Practical lathe or milling exercise to understand feeds and speeds, operation, parting off, surface finish, tool selection, and cutting fluids/coolants. Engineering tolerances. Cost of manufacture and materials, and related design considerations.

AHEP4 Learning Outcomes
C1, C2, C3, C4, C5, C10, C11, C14, C15, M1, M2, M3, M4, M5, M7, M12, M13, M16, M17

Library

Material science; selection of materials. Jones, S.W.
Selection and use of engineering materials, Charles, J.A., Crane, F.A.A., Furness, J.A.G.
Materials science and engineering; an introduction, Callister, W.D.
Materials selection in mechanical design, Ashby, M.F.
Engineering mechanic, Statics, Bedford, A, Fowler, W., any edition
Engineering mechanics , Vol. 1, Statics, Meriam, J. L, Kraige, L.G., Wiley, any edition
Statics and Mechanics of materials, Hibbeler, R.C., SI, ed. Pearson
Mechanics for engineers, Statics, Beer, F. P., Johnston, E. R., any edition
Mechanics of Materials, Beer, F.P., and Johnson, E.R.,
Mechanics of Materials, Gere, J.M. and Timoshenko, S.P.,

Module learning outcomes

Demonstrate understanding of the underlying principles and concepts of the relation between material properties and design.

Demonstrate the evaluation of material behaviour for different loading cases.

Apply the principles of selection of materials, and analyse the failure modes of materials.

Have knowledge and experience of the basic principles of manufacturing processes.

View timetable

Timing

Submission deadlines may vary for different types of assignment/groups of students.

Weighting

Coursework components (if listed) total 100% of the overall coursework weighting value.

How to read the week pattern

The numbers indicate the weeks of the term and how many events take place each week.

Prof Chris Chatwin

Assess convenor
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