Module Title:   Materials Engineering and Design

Module Credit:   20

Module Code:   ENG2100L

Academic Year:   2015/6

Teaching Period:   Semester 1

Module Occurrence:   A

Module Level:   FHEQ Level 5

Module Type:   Linked 10+10

Provider:   Engineering

Related Department/Subject Area:   School of Engineering

Principal Co-ordinator:   Dr CS Wright

Additional Tutor(s):   Dr M T Martyn

Prerequisite(s):   None

Corequisite(s):   None

The aim of this module is to develop core technical knowledge and understanding of the intimate relationship between mechanical engineering design (form and function), manufacturing methods and materials selection.

Learning Teaching & Assessment Strategy:
Key concepts will be developed in lectures and tutorials and practised in laboratory and individual project work. Learning outcomes LO 1.1, 1.2, 2.1, 2.2, 2.3, 2.4, 3.1 and 3.2 will be assessed by individual project work whilst the examination will assess LO1.1, 2.5 and 2.6. Oral feedback will be given during practical/laboratory sessions. Written feedback will be via assessments.

Lectures:   36.00          Directed Study:   126.50           
Seminars/Tutorials:   0.00          Other:   0.00           
Laboratory/Practical:   36.00          Formal Exams:   1.50          Total:   200.00

On successful completion of this module you will be able to...

1.1. Select appropriate materials and manufacturing methods to achieve specific design requirements.

1.2. Explain the role CADCAM plays in product development.

On successful completion of this module you will be able to...

2.1. Create assembly models/virtual prototypes using 3D Solid modelling software.
2.2. Assign appropriate tolerances to component features to meet a specified functional requirement for simple assemblies.
2.3. Demonstrate practical skills in CADCAM.
2.4. Demonstrate practical skills in the steps needed to manufacture successfully a simple engineered product.
2.5. Describe how material microstructure and processing route influences mechanical properties.
2.6. Explain how Geometric Dimensioning & Tolerancing is used to control form & position.

On successful completion of this module you will be able to...

3.1. Communicate engineering design information in a clear, concise manner.
3.2. Use virtual prototyping tools to problem solve design errors before the final physical manufacture of engineering components.

  Coursework   60%
  Individual CADCAM assignment 2000wd equiv individual practical materials selection manufacturing assignment 500 wd equiv
  Examination - closed book 1.50 40%
  Examination - closed book

Supplementary Assessment:
As Original

Outline Syllabus:
1. Control of Form and Function
Tolerances: The ISO system of Limits and Fits and tolerance stack up. Tolerance chains & identification of functionally important dimensions Methods of allocating assembly tolerances to ensure correct assembly & desired function through the use of path equations to allocate tolerance values to functionally important dimensions. The use of the ISO system of Geometric Dimensioning and Tolerancing (GDT) to control form & position of component features.
2. The Engineering of Materials Performance Characteristics
The correlation between product performance requirements & how these can be achieved through the selection of appropriate materials & materials processing routes. Overview of plastic deformation in metals & alloys. Introduction to crystal defects, principles of alloying, brief overview of processes used to strengthen metals & alloys. Introduction to fracture; brittle & ductile fracture processes. Annealing of metals, heat treatment of steels; TTT & CCT transformation diagrams. Relationship between structure & mechanical properties in polymers. Composite materials, fibre reinforcement, effects of fibre orientation, volume fraction & aspect ratio Ceramic materials, related forming processes & their physical and mechanical properties.
Principles of parameter design/assembly modelling/virtual prototyping
Selection of correct manufacturing sequence, material factors affecting cutting tool selection, calculation of cutting speed & feed rates. CNC machining. CNC programming & cutter path simulation

Version No:  5