Material in product design and development
Teacher
Gedela Sridevi
Category
Core Courses
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Course Name : Material in product design and development
Code(Credit) : ABC01 (1-1-0)
Course Objectives
- Identify and select suitable material for product design.
- Understanding various material selection for manufacturing processes
- Application of smart materials, shape memory metals, Nano materials.
- Understand the concept of bio materials.
- Understand concept of smart and hybrid materials.
Learning Outcomes
- Understand the concept of elastic and plastic deformation.
- Identify and select suitable material for product design.
- Understand manufacturing characteristics of materials
- Understanding various manufacturing process.
- Understanding Application of smart materials ,shape memory metal ,Nano material.
- Understood the concept of smart and hybrid materials.
Course Syllabus
Module I: Classification of materials ( 2 hrs)
Steel, Stainless Steel & Types, HSLA Steels, Dual Phase Steels, Tool and Die Steels. Nonferrous Alloys- Aluminum & Alloys, Copper & Alloys, Zinc & alloys, Nickel & Alloys , Magnesium Alloys, Titanium Alloys, Super Alloys.
Module II : Material behavior (10 hrs)
| Elastic and Plastic deformation- Mechanism of Plastic deformation-yield stress and shear strength-Perfect and Real crystals- Effect of strain rate and temperature on plastic behavior- Super plasticity- Deformation of non crystalline materials
Expt-1 - To study Creep transient for different materials using virtual lab. Expt-2: To study the effect of obstacle distance on the creep transient behavior of materials using virtual lab. Expt-3: To evaluate modulus of elasticity of materials using nano indentation using virtual lab. Expt-4: To find indent depth on materials using nano indentation. Expt- 5-To find out plastic work done during nano indentation. |
Module III: Material Selection for Process modeling and product design ( 4 hrs)
| Material selection- Cost and service requirement- Recycling- Selection of material for mechanical properties- Strength, toughness and fatigue- Material selection for durability and surface wear and Corrosion resistance- Functional relation between materials and processing- Manufacturing characteristics of metals- Material selection using Ashby charts and other aids material selection for aero, auto and nuclear application- Case studies in material selection.
Expt-6- Practice on material selection using Ashby charts Expt-7- Case study on material selection for bicycle frame using material chart. Expt-8- Case study on material selection for car brake using material chart. Expt-9- Case study on material selection for Knee implant. |
Module III: Shape memory Alloys and Nano materials (3 hrs)
| High strength alloy metals and its applications. Introduction to Smart materials and its applications, Shape memory metals and its applications, Introduction to Nano-materials, CNTs Production Process and Uses, Fibers Production and Uses. Introduction to bio materials.
t-10- To imagine the cytoskeleton of cells proliferation on bio materials Surface. |
Module IV: Polymer Composite materials (3 hrs)
| Polymer- Thermosetting, Thermoplastics; Elastomers- Natural & Synthetic Rubber; Composites Material- Classification Based on Matrix and Topology, Particle Reinforced Composites, Fiber Reinforced Composites. Structural Composites, Constituents of Composites, MMC, PMC and FRP. Ceramic Composites, Geo synthetics, Pre-stressed Hollow Concrete Panel, Carbon Composites Fullerenes, Bucky Ball Structures, Grapheme. |
Module V: Prefab materials ( 2 Hrs )
| Prefabricated Materials: Types and Applications, Autoclaved Aerated Concrete (AAC), Cellular Lightweight Concrete (CLC). |
Module VI: Developments in material processing (3 hrs)
| Introduction to Microelectro mechanical Systems (MEMS) ,Micro fabrication technologies- Tool for micro fabrication- Diamond and high speed machining- LIGA micro fabrication process- Multilayer X-ray lithography- |
Module VII: Introduction to smart /intelligent and Hybrid materials (3 hours)
| Overview of Smart / Intelligent Materials, Primitive Functions of Intelligent materials, Intelligence Inherent in Materials, Actuator Materials, Sensing Technologies, Micro-sensors, Intelligent Systems, Hybrid Smart Materials, Passive Sensory Smart Structures, Reactive actuators based smart structures, Active Sensing and Reactive Smart Structures, Smart Skins
Practice : 1. Virtual lab by IIT kanpur.
Text Books: 1. Materials Science and Engineering, W D Callister,2014, 2nd Edition, Wiley India Private Limited, India. Reference Books: 1. Material Science and Engineering, V Raghavan, 2013, 5th Edition, PHI publication, India. 2. Material Science and Engineering, S Chawla, 2011, 1st Edition, Dhanpat Rai & co Private Ltd., India.
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Course outline Prepared by; G.Sridevi
Date:21/05/2020
Source of reference; 1.Course era –Machine design-1 subject.
- NSQF syllabus for post graduation diploma in mechanical product design
Note: 1 credit theory=10 hrs lecture, 1 credit practice/project=12.5 hrs lab/workshop/field work in a semester
Session Plan
Session-1
Introduction to material classification, Steel, Stainless Steel & Types, HSLA Steels, Dual Phase Steels, Tool and Die Steel
Session-2
Nonferrous Alloys- Aluminum & Alloys, Copper & Alloys, Zinc & alloys, Nickel & Alloys , Magnesium Alloys, Titanium Alloys, Super Alloys.
Session-3
Introduction to Elastic and Plastic deformation
Session-4
Mechanism of Plastic deformation-yield stress and shear strength
S4-Mechanism of plastic deformation-converted
Session-5
Perfect and Real crystals- Effect of strain rate and temperature on plastic behavior- Super plasticity
Sessoin-6
Deformation of non crystalline materials
S6-Deformation of non crystalline materials-converted (1)
https://www.coursera.org/lecture/material-behavior/6-1-introduction-P2p9p
Session-7,8,9,10 and 11
Expt-1 - To study Creep transient for different materials using virtual lab.
http://mrmsmtbs-iitk.vlabs.ac.in/creep.html
http://mrmsmtbs-iitk.vlabs.ac.in/exp1.html
Expt-2: To study the effect of obstacle distance on the creep transient behavior of materials using virtual lab.
http://mrmsmtbs-iitk.vlabs.ac.in/exp2.html
Expt-3: To evaluate modulus of elasticity of materials using nano indentation using virtual lab.
http://mrmsmtbs-iitk.vlabs.ac.in/modulus.html
Expt-4 : To find indent depth on materials using nano indentation.
http://mrmsmtbs-iitk.vlabs.ac.in/indent%20depth.html
Expt- 5-To find out plastic work done during nano indentation.
Session-12
Material selection- Cost and service requirement- Recycling- Selection of material for mechanical properties- Strength, toughness and fatigue- Material selection for durability and surface wear and Corrosion resistance
S12- Material selection Cost and service requirement-converted
.https://www.romareng.com.au/material-selection-for-manufacture/
Session-13
Functional relation between materials and processing- Manufacturing characteristics of metals- Material selection using Ashby charts and other aids material selection for aero, auto and nuclear application- Case studies in material selection.
S13- Functional relation ship between materials and manufacturing process-converted
https://www.youtube.com/watch?v=NppPm4efsA8a
https://www.youtube.com/watch?v=8ETBAdEQr7M
Session-14,15 and 16
Expt-6- Practice on material selection using Ashby charts
https://www.youtube.com/watch?v=NppPm4efsA8
https://www.youtube.com/watch?v=Z3vdQCGuHSE
Expt-7- Case study on material selection for bicycle frame using material chart.
https://www.youtube.com/watch?v=eRaxjdijGPg
Expt-8- Case study on material selection for car brake using material chart.
https://www.youtube.com/watch?v=c1KJT4MWTms
Expt-9- Case study on material selection for Knee implant
https://www.coursera.org/lecture/machine-design1/module-6-ashby-plots-tKbge
Session-17
Introduction to Smart materials and its applications, Shape memory metals and its applications
S17-Smart materials and shape memory alloys-converted
Session-18
Introduction to Nano-materials, CNTs Production Process and Uses, Fibers Production and Uses
https://www.youtube.com/watch?v=IEfInRPdjAI&list=PLck1i7MsLtUneH5fz2npRj4AfX8II4f2c&index=3
Session-19
Introduction to bio materials.
https://www.youtube.com/watch?v=-jw8osY5QJM
Expt-10- To imagine the cytoskeleton of cells proliferation on bio materials Surface.
Session-20
Polymer- Thermosetting, Thermoplastics; Elastomers- Natural & Synthetic Rubber
Session-21
Composites Material- Classification Based on Matrix and Topology, Particle Reinforced Composites, Fiber Reinforced Composites. Structural Composites, Constituents of Composites, MMC, PMC and FRP
Session-22
Ceramic Composites, Geo synthetics, Pre-stressed Hollow Concrete Panel, Carbon Composites Fullerenes, Bucky Ball Structures, Graphene.
Session-23
Prefabricated Materials: Types and Applications
Session-24
Auto calved Aerated Concrete (AAC), Cellular Lightweight Concrete (CLC).
Session:25
Introduction to Microelectro mechanical Systems (MEMS) and its applications
https://www.youtube.com/watch?v=a334dfl8iN4
https://www.youtube.com/watch?time_continue=21&v=JB-kw7ws6yg&feature=emb_logo
Session-26
Micro fabrication technologies- Tool for micro fabrication- Diamond and high speed machining-
https://www.youtube.com/watch?v=TXD7CCnghT4
Session-27
LIGA micro fabrication process- Multilayer X-ray lithography-
Session-28
Overview of Smart / Intelligent Materials, Primitive Functions of Intelligent materials, Intelligence Inherent in Materials
Session-29 and 30
Actuator Materials, Sensing Technologies, Micro-sensors, Intelligent Systems, Hybrid Smart Materials, Passive Sensory Smart Structures Reactive actuators based smart structures, Active Sensing and Reactive Smart Structures, Smart Skins
https://www.youtube.com/watch?v=OfYdDEwe_mw
https://www.youtube.com/watch?v=ZIC5JFIHni4
https://www.youtube.com/watch?v=U2XepZNbWi8
https://www.youtube.com/watch?v=jUtsrN7C4Uo
Case Studies
Case Studies
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Assistant Professor ,School of Engineering and Technology , Centurion University of Technology and Management, Paralakhemundi, Odisha, India. She has over 6 years of teaching and 9 years of industrial experience in project management of EPC bulk material handling,Turnkey projects.. She is pursing her PhD in Centurion University of Technology and Management in the field of […]