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Instructions:
Discussion Paper on Advance Materials
ALL QUESTIONS MUST BE ANSWERED.
A1 QUESTION
I The British Plastics Federation (BPF) was founded in 1933 to promote the UK plastics sector and is the world’s oldest plastics trade group. BSF wants to work with an educational institution and an industrial partner to help universities establish polymer laboratories. A trial experiment on thermosetting plastics was undertaken while setting up the injection moulding equipment in UCLAN. A force, F, will inject a specified weight of epoxy thermosetting polymer into a complex injection moulding machine mold in two time and temperature scales, namely 30 seconds at 180 degrees Celsius and 85 seconds at 162 degrees Celsius. If the epoxy thermosetting polymer’s viscosity follows the Arrhenius equation of diffusion, with a rate of process proportionate to it,
2 seconds-1,
m exp m
Calculate the time it will take to complete the process at 237 degrees Celsius.
(6 points)
(ii) Compare and contrast the likely creep behavior of this material with the possible creep behavior of a thermoplastic, taking into account the main polymer structural characteristics of both. Compare and contrast the injection equation with the creep equation.
(4 points)
[Hint] Use no more than three decimal places in your replies.
(Total marks: 10)
A2 QUESTION
I Figure 1 depicts the phase diagram for the Al – Si system (the foundation of aluminum casting alloys). Explain what happens when the alloy Al 30 wt% Si is cooled to room temperature from 900 °C. You should think about phase.
Transformation, microstructure changes, temperature fluctuations, and composition are all factors to consider.
(6 points)
Figure 1: Al-Si binary system phase diagram
(ii) If nucleation is homogeneous, determine the critical nucleus radius, r*, and the activation free energy for the solidification of pure nickel. -2.53 x 109 J/m3 and 0.250 J/m2 are the latent heat of fusion and surface energy of nickel, respectively. Nickel has a supercooling curve of 319 °C. Nickel has a melting temperature of 1455 °C.
(4 points)
(Total marks: 10)
A3 QUESTION
ANALYSIS OF A CASE STUDY
Critically evaluate the following two case studies’ outputs, methodologies, and reported failures (maximum of 800 words):
1. Failure study of a reciprocating compressor’s failing connecting rod cap and connecting bolts, Engineering Failure Analysis, X. Zhu, J. Xu, Y. Liu, B. Cen, X. Lu, Z. Zeng
ISSN 1350-6307, Volume 74, Pages 218-227, https://doi.org/10.1016/j.engfailanal.2017.01.016.
http://www.sciencedirect.com/science/article/pii/S1350630716307488 ) ( http://www.sciencedirect.com/science/article/pii/S1350630716307488 )
2. Failure analysis and fatigue performance evaluation of a reciprocating air compressor’s failing connecting rod, Engineering Failure Analysis, M. N. Ilman and R. A. Barizy,
ISSN 1350-6307, Volume 56, 2015, Pages 142-149, https://doi.org/10.1016/j.engfailanal.2015.03.010.
(http://www.sciencedirect.com/science/article/pii/S1350630715000989)
[Hint 1]: To complete this job correctly, you will need to read more case studies from the same magazine and from books, as well as investigate the methodologies, structures, and failures mentioned in the articles but not explained, as the reader is supposed to be familiar with them.
[Hint 2]: You’ll need to look up the definitions of the technical phrases used in the articles to fully comprehend them. As part of your analysis, you will be expected to use appropriate technical phrases.
[Hint 3]: You could talk about failure modes or material phases, for example. You can talk about different procedures that could be used to verify the authors’ findings. Is there any other strategy that should have been included in the article but wasn’t? What gain may there have been? Why do you believe such methods were employed in the article? [Hint No. 4]: Was it possible to predict process failures when designing the process? Could the failures have been predicted with a good Finite Element Method analysis?
[Hint 5]: Make proper use of references, examples, and/or personal experience.
(20 Points)
SECTIONS B AND C
ALL QUESTIONS MUST BE ANSWERED.
B1 QUESTION
A RIPPER’S MATERIAL SELECTION
Choose the right material for a bulldozer’s ripper. The ripper functions as a distributed load beam. The ripper’s maximum operating depth is 0.6 m, and the maximum load is equal to the bulldozer’s traction force (60 kN). Figure 2 depicts ripper and bulldozer views, as well as a simplified version for this activity. This is a free-for-all exercise.
(a) (b) (c) (d) (e) (f) ( (c)
Figure 2: (a) ripper view, (b) ripper simplified schematic diagram, (c) bulldozer perspective.
You’ll need to decide on additional limits and figure out how to solve a beam’s equations. You’ll need to decide on a goal and compare the outcomes to real-world examples. You’ll have to translate the problem, calculate the performance index or indexes, choose a screening constraint, and graphically choose the actual material.
You must keep track of the entire selecting procedure.
[Hint 1]: You can choose materials with the lowest mass, lowest cost, or both as your goal. You’ll have to come up with your own ripper and constraint dimensions.
[Hint 2]: The clear statement of the problem and the writing down of the relevant equations employed in the problem will be worth 20% of the overall mark for this question.
[Hint 3]: The derivation of the material index with the right material performance equation will be worth 40% of the total score for this question.
[Hint 4]: The use of GRANTA EduPack for material selection will be worth 40% of the total mark for this question.
Reminder: Because this is an open exercise, each student is required to come up with their own answer because the problem will be defined differently.
(Total marks: 30)
B2 QUESTION
As seen in Figure 3, CPE Pressure Vessels Limited manufactures pressure vessels for the oil, gas, petrochemical, nuclear, and water industries (length L, diameter 2R, hemispherical ends). As a CPE design engineer, you’ve been tasked with creating a pressure vessel for the food processing industry. The major goal of the project is to find a suitable material for the pressure vessel’s exterior wall. When fully built, the pressure vessel resembles a cylindrical shape with an external pressure, p. The exterior wall of the cylindrical pressure tank, as well as the chosen material, should be able to withstand external pressure. The pressure tank has a radius of 10 meters. The pressure-containing outer wall, p, shall not fail due to yielding or rapid fracture. The possible greatest crack enclosed in the outside wall measures ac.
Figure 3: A food manufacturing company’s pressure vessel
The majority of pressure vessels are heavy and composed of high-strength alloy steel. You’ve been tasked with researching the possibility of different materials for lighter pressure vessels, while keeping in mind that there must be a trade-off between mass and cost – if it’s too expensive, even if it’s lighter, the manufacturing business won’t want it.
Density (); Yield strength (y); Critical stress intensity factor or fracture toughness of the material are some of the material parameters that can be used to rank materials ( ). The material volume can be calculated using the surface area and thickness of the cylindrical outer wall.
You’ll need to figure out your own dimensions and limitations, as well as the equations for pressure vessel yielding and quick fracture. Answer the following questions in order to turn the proper material selection for the food processing application into a real engineering problem:
(a) Problem translation with function, objective, restrictions, and free variables? You must give a precise definition of the issue.
(6 points)
(b) Calculate the failure performance material index and pick materials graphically. Discuss the implications of using two performance indices to choose a single material.
(10 points)
(c) Explain and justify what would happen to the performance index if both ends of the pressure vessel were closed with supporting evidence (both numerical and graphically).
(10 points)
(d) Demonstrate that the mass and material cost of the pressure vessel is provided by when compared to one made of high strength alloy steel.
,,,
= as well as
,
(4 points)
where is the density, y is the yield strength, and Cm is the material’s cost per kilogram, and the subscript “o” denotes values for high-strength alloy steel.
[Hint] Use the new material ratio over the steel.
m
= mass in milligrams per kilogram of high-strength alloy steel m0
C
and = price in comparison to high-strength alloy steel C0
Remember that because this is an open exercise, each student is expected to come up with their own solution because the problem will be defined differently.
(Total marks: 30)
RUBRIC |
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Excellent Quality 95-100%
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Introduction
45-41 points The background and significance of the problem and a clear statement of the research purpose is provided. The search history is mentioned. |
Literature Support 91-84 points The background and significance of the problem and a clear statement of the research purpose is provided. The search history is mentioned. |
Methodology 58-53 points Content is well-organized with headings for each slide and bulleted lists to group related material as needed. Use of font, color, graphics, effects, etc. to enhance readability and presentation content is excellent. Length requirements of 10 slides/pages or less is met. |
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Average Score 50-85% |
40-38 points More depth/detail for the background and significance is needed, or the research detail is not clear. No search history information is provided. |
83-76 points Review of relevant theoretical literature is evident, but there is little integration of studies into concepts related to problem. Review is partially focused and organized. Supporting and opposing research are included. Summary of information presented is included. Conclusion may not contain a biblical integration. |
52-49 points Content is somewhat organized, but no structure is apparent. The use of font, color, graphics, effects, etc. is occasionally detracting to the presentation content. Length requirements may not be met. |
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Poor Quality 0-45% |
37-1 points The background and/or significance are missing. No search history information is provided. |
75-1 points Review of relevant theoretical literature is evident, but there is no integration of studies into concepts related to problem. Review is partially focused and organized. Supporting and opposing research are not included in the summary of information presented. Conclusion does not contain a biblical integration. |
48-1 points There is no clear or logical organizational structure. No logical sequence is apparent. The use of font, color, graphics, effects etc. is often detracting to the presentation content. Length requirements may not be met |
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Discussion Paper on Advance Materials