Units
Materials and Manufacturing 1
Unit code: ENB231
Contact hours: 4 per week
Credit points: 12
Information about fees and unit costs
Materials and their engineering applications, Manufacturing systems and technology, material properties and manufacturing, material selection, failure, graphical communication.
Availability
| Semester | Available |
|---|---|
| 2013 Semester 1 | Yes |
Sample subject outline - Semester 1 2013
Note: Subject outlines often change before the semester begins. Below is a sample outline.
Rationale
Engineers need to understand the fundamental relationships between the microstructure and mechanical properties of different engineering materials in order to deliver robust designs and/or manufacturing methods. ENB231 extends the introductory unit of ENB110 to introduce the deformation of materials at the micro-scale and how certain mechanical properties can be tailored to facilitate easy manufacturing. This knowledge along with a range of manufacturing processes (bulk material deformation) is an important tool for graduate engineers in evolving a robust design process. This unit will also become the platform to understand the more complex deformation mechanics and material removal processes which will be studied in ENB331.
Aims
The aim of this unit is to introduce you to the important inter-relationships between the microstructure of engineering materials, their mechanical properties and manufacturability along with critical aspects of choice of materials vis-à-vis manufacturing processes in theory and practice. You will apply the different theoretical aspects to study a simple assembly (small engine or gear box) and develop a logical basis for the selection of various materials and the manufacturing techniques used to produce different components in the assembly.
Objectives
On completion of this unit, you will be able to:
- Infer the mechanical properties of engineering materials by analysing their microstructures using different heat treatment techniques
- Describe the fundamentals of bulk deformation of common engineering materials and applications in different manufacturing industries and engage in some of the processing methods
- Use standard engineering methods to systematically select materials for design and manufacture
- Generate ideas, and critically appraise and communicate them in written and oral form
Content
- Microstructure and mechanical properties of engineering materials (ferrous and non-ferrous alloys)
- Heat treatment and principles of solidification, dispersion strengthening, hardening
- Deformation mechanisms - dislocations and slip systems
- Bulk Deformation Processes in metallic alloys - Sand casting, Metal Casting, Rolling, Sheet metal forming, Forging and Shaping, Drawing and Extrusion, Deep Drawing
- Plastics Processing - Extrusion and Drawing, moulding
- Joining Processes - welding, soldering, brazing
- 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. Lecture slides and some additional readings will be made available on-line using the Black Board website prior to lectures.
- Tutorial sessions will be used to solve pre-selected numerical problems related to materials and manufacturing that will assist understanding of the subject.
- Project will be used to develop information retrieval skills and to integrate learning across the unit through materials selection in design and manufacturing. This is a group project that requires disassembling of a given product (e.g. small gearbox or engine) and performing a comprehensive analysis of the various components from design, material selection and manufacturing perspectives.
- Laboratories will be used to investigate and analyse given materials using some standard analytical techniques, and to be able to select materials and processing for a given application using material selection software. There will be two practicals (each 2~3 hour) focused on microstructure of steels, casting of metallic alloys, and selection of materials and processing. A tutorial on the principles of material selection will help you evolve a strategy to analyse and solve project tasks.
Approaches to Teaching and Learning
Teaching Mode: 5 hours per week
Lectures: 2 hrs per week
Tutorial: 1 hr per week
Laboratories and Team Project: 1 hr per week
The technical content of the unit will be taught using the following teaching tools:
Attendance is expected at all lectures, tutorials, pracs and project sessions.
Assessment
Assessment in the unit consists of practical laboratory tasks, a project and final exam.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:
Laboratory/Practical
Description:
You are expected to engage in the practical sessions and from your observations and activities you will compelte a lab worksheet. You should compelte the worksheets for the three labs and submit a portfolio through Assignment Minder. Final submission of the practical worksheets is due in Week 11.
Relates to objectives:
1. Infer the mechanical properties of engineering materials by analysing their microstructures using different heat treatment techniques.
2. Describe the fundamentals of bulk deformation of common engineering materials and applications in different manufacturing industries and engage in some of the processing methods.
Weight:
20%
Internal or external:
Internal
Group or individual:
Individual
Due date:
Week 11
Assessment name:
Project (applied)
Description:
Students will be involved in a group project that will disassemble a product (e.g. small gearbox or engine), identify the material of each component, determine why this material was chosen, how it was manufactured, sketch the components and also produce drawings. The project will start in week 2 and a progress report should be submitted through Assignment Minder in week 6. The submission of the final group report is in week 10 through Assignment Minder.
Relates to objectives:
3. Use standard engineering methods to systematically select materials for design and manufacture.
4. Generate ideas, and critically appraise and communicate them in written and oral form.
Weight:
30%
Internal or external:
Internal
Group or individual:
Group
Due date:
Week 10
Assessment name:
Examination (Theory)
Description:
Students will answer questions and problems related to key concepts in materials and manufacturing covered in this unit during the semester.
Relates to objectives:
1. Infer the mechanical properties of engineering materials by analysing their microstructures using different heat treatment techniques
2. Describe the fundamentals of bulk deformation of common engineering materials and applications in different manufacturing industries and engage in some of the processing methods
3. Use standard engineering methods to systematically select materials for design and manufacture
4. Generate ideas, and critically appraise and communicate them in written and oral form
Weight:
50%
Internal or external:
Internal
Group or individual:
Individual
Due date:
Examination period
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 (Same textbook applies to ENB331)
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 (Same textbook applies to ENB331)
Year: Publisher: 2009, Prentice Hall
Edition: 6th 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: 22-Oct-2012
