Units

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Sample subject outline - Semester 2 2013

Note: Subject outlines often change before the semester begins. Below is a sample outline.

Rationale

This unit builds on the formative body of knowledge you have acquired in ENB231 on the role of materials in terms of the design processes and material selection to entail the manufacturing of different types of materials for various applications. ENB331 helps you take a closer look at the material removal mechanisms, mechanics of metal cutting and failure of materials which are important to graduate engineers in making numerous shopfloor decisions.

Aims

The aim of this unit is to introduce you to the fundamentals of material removal processes, mechanics of metal cutting, failure of materials, the properties and manufacturing techniques used for advanced materials such as ceramics & plastics, and the emerging trends of advanced manufacturing processes.

Objectives

On completion of this unit, you should be able to:
1.Describe the physics of the mechanics of metal cutting involved in material removal.
2.Describe different material removal processes and relate the relative advantages and disadvantages in process selection based on material properties.
3.Explain the different failure mechanisms of materials during manufacture and in-service.
4.Interpret and analyse data/information related to failure of materials in-service and during different material manufacturing processes.

Content

This unit will entail the instruction in the following topical areas:
1. Fundamentals of metal cutting - Deformation mechanisms involving tool-work piece interactions and material properties related to tool material selection.
2. Material Removal Processes: Introduction to material removal processes - cutting, turning, drilling, lathe operations, grinding and abrading and the methods of processing of ferrous, non-ferrous and intermetallic alloys.
3. Fracture, fatigue and failure of materials in relation to manufacturability, service and maintenance.
4. Material properties and manufacturability of ceramics, plastics and composites.
5. Non-traditional manufacturing: laser beam machining, abrasive waterjet machining, electric discharge machining, plasma arc machining, electrochemical machining.

Approaches to Teaching and Learning

Teaching Mode:
Hours per week: 4
Lecture: 2
Tutorial: 1
Practicals and Group Project: 1

The technical content of the unit will be taught using the following teaching tools:

• Lectures: Formal lecture sessions will cover the theory and illustrate some practical applications of the material studied. The lectures will be used to guide you through the unit and show you how the material being studied each week is used by practising engineers, to describe and illustrate the basic concepts behind this material using demonstrations and visual aids, and to take care of matters involving the whole class. Lecture slides and some additional readings will be made available on blackboard website prior to lectures


• Tutorials: Exercises will be set to test and develop understanding of the subject. During tutorials problem solving related to metal cutting and joining, deformation and failure of engineering materials will be done.


• Project: You will participate in a group project to design and fabricate a component. Gaining teamwork and information retrieval skills will be a significant part of your time in the project as well as applying the theoretical principles to practice. A 3-hour machining demonstration session will take you through a show-and-tell laboratory session in a workshop where you will see different kinds of machining systems in action, their various features and operational conditions.


• Laboratories: Lab practicals will be used to introduce you to some standard material testing on how a material in service fails and how it is related to the manufacturing techniques. The laboratories will constitute:
  
  
  
  1. Fracture Mechanics Prac: a 2-hour session to examine the stress concentrating effects of cracks and notches and develop an understanding of crack propagation under monotonic loading and introduce materials failure in-service.
  
  
  2. Impact Fracture Testing Prac: a 2-hour session to examine the effects of temperature on Charpy impact test of plain carbon and alloy steels and aluminium alloy and observe the failed samples to determine type of failure.
  
  
  

Attendance will be taken during labs and project sessions.

Assessment

In addition to the set assignments and laboratory, an exercise integrating materials and manufacturing components of the unit, you will be involved in a group project activity which will entail the design for manufacture a component aimed to bring the importance of inter-relationship between design, manufacturing and materials together.

Assessment will be based on the following components.You will receive oral and written feedback on your pracs and assignment reports, and oral feedback of your progress in this unit during tutorial sessions.

Summative Feedback:
Assessment 1: Laboratory practicals
Mode of feedback: guidance and oral feedback during laboratory practical sessions and written feedback on your prac reports.

Assessment 2: Project
Mode of feedback:guidance and oral feedback during project class sessions, and individual and group written feedback on your project reports.

Assessment 3: Final Exam
Mode of feedback: oral as well as written feedback will be given on final exam scripts up on student's request.

Assessment name: Project
Description: This is a group activity in which each group will design a component from the given drawing/sketch and recommend appropriate and precise manufacturing and cutting conditions.

There will be a show and tell information session in the mechanical workshop laboratory. You will observe different metal cutting and finishing operations and use the information to answer a set of related questions with the project.
Relates to objectives: 1, 2, 4
Weight: 35%
Internal or external: Internal
Group or individual: Group
Due date: Week 6, Week 12

Assessment name: Final Exam
Description: You will answer questions and problems related to key concepts in materials and manufacturing covered in this unit during the semester.
Relates to objectives: 1, 2, 3
Weight: 50%
Internal or external: Internal
Group or individual: Individual
Due date: End of semester

Assessment name: Practical Sessions
Description: You will participate in a fracture mechanics testing and impact testing experiments to understand the fundamental theory of fracture mechanics.
Relates to objectives: 2, 4
Weight: 15%
Internal or external: Internal
Group or individual: Individual
Due date: Week 7, Week 10

Academic Honesty

QUT is committed to maintaining high academic standards to protect the value of its qualifications. To assist you in assuring the academic integrity of your assessment you are encouraged to make use of the support materials and services available to help you consider and check your assessment items. Important information about the university's approach to academic integrity of assessment is on your unit Blackboard site.

A breach of academic integrity is regarded as Student Misconduct and can lead to the imposition of penalties.

Resource materials

Type: Electronics resource
Author: Various
Web address: Blackboard website (www.blackboard.qut.edu.au )

Type: Prescribed Text Book
Author: Callister, William D.
Title: Materials Science and Engineering: an introduction
Year: Publisher: 2007, John Wiley & Sons
Edition: 7th Edition

Type: Prescribed Text Book (also required for ENB331)
Author: Kalpakjian S, and Schmid, S.R
Title: Manufacturing Engineering and Technology
Year: Publisher: 2006, Prentice Hall
Edition: 5th Edition

Type: Reference
Author: Smith, W. F. and Hashemi, J.
Title: Foundations of Materials Science and Engineering
Year: Publisher: 2006, McGraw-Hill
Edition: 4rd Edition

Type: Reference
Author: Askeland, D.R.
Title: The Science and Engineering of Materials
Year: Publisher: 2006, Thomson
Edition: 5th Edition

Type: Reference
Author: Shackelford, J.F.
Title: Introduction to Materials Science for Engineers
Year: Publisher: 2009, Pearson
Edition: 7th Edition

Type: Reference
Author: Armarego, E.J.A.
Title: Material Removal Processes - An Introductory Course
Year: Publisher: The University of Melbourne, 1995

Type: Reference
Author: M.F. Ashby
Title: Materials Selection in Mechanical Design
Year: Publisher: Butterworth-Heinemann, 2003
Edition: 2nd Edition

Risk assessment statement

You will undertake lectures and tutorials in the traditional classrooms and lecture theatres. As such, there are no extraordinary workplace health and safety issues associated with these components of the unit.

You will be required to undertake practical sessions in the laboratory under the supervision of the lecturer and technical staff of the School. In any laboratory practicals you will be advised of requirements of safe and responsible behaviour and will be required to wear appropriate protective items (e.g. closed shoes or steel capped shoes).

You will undergo a health and safety induction before the commencement of the practical sessions and will be issued with a safety induction card. If you do not have a safety induction card you will be denied access to laboratories.

Disclaimer - Offer of some units is subject to viability, and information in these Unit Outlines is subject to change prior to commencement of semester.

Last modified: 20-Jun-2012