Material in product design and development

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Gedela Sridevi

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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.

 

Course outline Prepared by;  G.Sridevi                                                        

Date:21/05/2020

Source of reference; 1.Course era –Machine design-1 subject.

  1. 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

Classification of materials -converted

https://www.youtube.com/watch?v=ZY7ziQesDOc

Session-2

Nonferrous Alloys- Aluminum & Alloys, Copper & Alloys, Zinc & alloys, Nickel & Alloys , Magnesium Alloys, Titanium Alloys, Super Alloys.

Non ferrous alloys-converted

https://www.youtube.com/watch?v=YbPWyXDt3TY

Session-3

Session-4

Session-5

Perfect and Real crystals- Effect of strain rate and  temperature on plastic behavior- Super plasticity

S5- Perfect and real crystals-converted

https://www.youtube.com/watch?v=lWr8fmUGXeE

Sessoin-6

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.

http://mrmsmtbs-iitk.vlabs.ac.in/plastic.html

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

https://www.youtube.com/watch?v=Tn6xKhQ61Vs

https://www.youtube.com/watch?v=5hYOxFFjZ-8

Session-18

Session-19

Introduction to bio materials.

bIO MATERIALS-s19-converted

https://www.youtube.com/watch?v=-jw8osY5QJM

Expt-10- To imagine the cytoskeleton of cells proliferation on bio materials Surface.

http://mrmsmtbs-iitk.vlabs.ac.in/fmbs.html

Session-20

Polymer- Thermosetting, Thermoplastics; Elastomers- Natural & Synthetic Rubber

.S19-Poymers

https://www.youtube.com/watch?v=lNS7TwWmlrg

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

S20 Composites

https://www.youtube.com/watch?v=JLnJ4Q-Y4kU

Session-22

Ceramic Composites, Geo synthetics, Pre-stressed Hollow Concrete Panel, Carbon Composites Fullerenes, Bucky Ball Structures, Graphene.

session-22-converted

https://www.youtube.com/watch?v=q7VAq8t2gj0

https://www.youtube.com/watch?v=Zc-VXHgGT5k

Session-23

Prefabricated Materials: Types and Applications

session-23-converted

Session-24

Auto calved Aerated Concrete (AAC), Cellular Lightweight Concrete (CLC).

SESSION-24-converted

.https://www.youtube.com/watch?v=EW3lzFHYBCE

Session:25

Session-26

Micro fabrication technologies- Tool for micro fabrication- Diamond and high  speed machining-

https://www.youtube.com/watch?v=TXD7CCnghT4

https://www.youtube.com/watch?v=Xcd8dHQHBM8

https://www.youtube.com/watch?v=brWE3Fk-aXY

Session-27

LIGA micro fabrication process- Multilayer X-ray lithography-

https://slideplayer.com/slide/5850112/

Session-28

Overview of Smart / Intelligent Materials, Primitive Functions of Intelligent materials, Intelligence Inherent in Materials

smartmaterial-S28-converted

https://nptel.ac.in/courses/112/104/112104251/

https://www.youtube.com/watch?v=3Tp6IC_SXu0

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

 

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Case Studies

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    Gedela Sridevi

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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 […]