Reference no: EM132182385
Learning Outcomes
1. Employ the principles of solidification, diffusion and solid state deformation to the relevant manufacturing process.
2. Develop a broad knowledge base of the various types of manufacturing processes (e.g. casting technology, forming and shaping processes, material removing processes and joining processes).
3. Evaluate manufacturing processes on the basis of cost, accuracy and lead time to form judgments about their applicability to given manufacturing situations, including considerations of environmental and end of life costs of products.
4. Evaluate common engineering materials on the basis of mechanical and physical properties, cost and manufacturing properties, and form judgments about their applicability to given product functional requirements.
Task and Mark distribution:
You are given a list consisting of few "classes of materials" including aluminium alloys, cast iron, magnesium alloys and composite material. You are asked to choose a material from this list for a cylinder head (for a four-cylinder petrol car) to be made later this year, or early next year. A schematic diagram (Figure 1) shows a design of a typical cylinder head. Figure 2 presents how this component is placed in relation to an internal combustion engine.
Scope:
Students are asked to prepare a case study presenting a suitable material for the cylinder head which should also include the manufacturing route of the component. In addition to the material selection students are asked to include the production process by which the component will be manufactured. Scientific reasons for the selected process(s) should be included. The areas that are needed to be covered in the report are listed in Table 1.
Section Subject Matter
1 Component Function and Operating Environment
1a Review the function (or role) of your chosen component including the context of the larger assembly to which it belongs.
1b Outline the service conditions that are caused by the component's function and the environment in which it functions which the component will be designed to withstand (e.g., types of stresses, temperatures, service atmospheres etc.).
2 Material Properties and Selection
2a Discuss and justify the material property requirements for the component by relating the material property requirements to the service conditions & requirements identified in your answer to section 1b. This should include some quantitative values of the required properties.
2b Identify the material or materials used to make the components on the physical model (ignore any small brackets, bolts and other small components attached to the component). Chemical content of the main constituents should be included. Using the identified material properties from question 2a, perform a material selection analysis (using CES software) to justify the material used on the physical model. Use relevant performance indices to aid you CES selection. Hence justify the material used on the model.
3 Component Manufacturing Route
3a Manufacturing route selection: Discuss several potential suitable manufacturing routes for your component in the selected material. Perform a CES process selection exercise relevant to your component and your selected material and in order to downselect and justify a final process route.
3b Review & explain the selected manufacturing route in detail.
4 Alternative Materials and Manufacturing Routes
4a List alternative materials that are also used to make the component you have selected. Chemical content of the main constituents should be included. For each material make reference to your CES analysis from Section 2b and compare properties (both materials & physical). Select what you believe to be the "best" alternative material and explain why it is the best alternative.
4b Describe the main differences between the component on the physical model and the same component made from your best alternative material in terms of: its structure, the manufacturing routes required to make it.
5 Should there be any differences in the required properties and hence the chosen material if a diesel engine was to be manufactured? Explain.
Other Report structure presentation, referencing & technical writing style, adherence to the requirements contained in this document.