Materials and Processes

Code:

EDDP0016

Acronym:

MP

Keywords
Classification	Keyword
OFICIAL	Engineering and Related Techniques
OFICIAL	Engineering and Related Techniques

Instance: 2012/2013 - 1S

Active?	Yes
Responsible unit:	Metallurgy, Materials and Technological Processes Section
Course/CS Responsible:	Specialization in Product Design and Development

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
EDDP	15	Syllabus since 2010/11	1	-	4	36	108

Teaching language

Portuguese

Objectives

Give the students a global vision of all available materials for project and manufacturing technologies for conception and manufacturing a specific product.
Frequently, this goal is solved with the synthesis of theoretical and practical knowledge obtained in several fields. One can include not only the aesthetic aspects, ergonomics, identity and manufacturing costs, but also the aspects related to the decision relatively to the materials to be used.
The no empirical choose of the materials in design is more efficient as more measurable is that process, which must consider:
- identification of service specifications
- identification of parameters to compare materials
- pre-selection of materials, in an iterative process with the manufacturing technology.
To consider these two aspects, materials and technologies, with safety, basic concepts of materials resistance and mechanical behavior of materials should be previously studied.
It happens often that the improvement of a property is accompanied by the degradation of others. So will be studying the polymer matrix composites, ceramic or metals as good compromise solutions to overcome the weaknesses of each isolated group of materials.
Also the natural composites like wood and cork will be studied physically and mechanically. It will address also the study of these composites as matrix composites with natural cases of laminated wood and cork agglomerates.
The manufacturing technologies will be addressed over the course in an integrated perspective and associated with materials.
Skills to develop
Basic selection of large groups of materials depending on the projectual context, their applicability and cost (compared with estimated number of parts to produce)
(It is understood that the selection of fine materials is the responsibility of the Development Engineering and in extreme cases require the involvement of a specialist in Engineering Materials by advocates who, when necessary, to resort early in the project the analysis model and cooperative decision in these matters).

Program

Brief presentation of the different types of materials:
1. Metallic alloys
1.1. The pure metals and metallic alloys.
1.2. Properties of the main types of alloys.
2. Polymers and Rubbers
2.1. Classification of polymers: thermoplastics, thermosets and elastomers
2.2. Structures of polymers. Main properties of polymers
3. Ceramics and glass. Traditional and technical ceramics. Compositions and properties of use. Main types of glass.
4. Composite materials. Type of composite materials considering the matrix and the type of reinforcement. The fibrous composites, laminated and of particles.

II - Basic Concepts of Mechanics of Materials
2. Concept of stress and strain. Normal stresses and shear.
3. The tensile test
4. Techniques of the tensile test: specimens, testing machines, extensometers.
5. Conventional stress - strain curve
6. Examples of curves of various materials.
7. Measurements of stiffness, mechanical strength, ductility, resilience and toughness
8. Failure modes: the ductile and brittle rupture.
9. Tests of hardness, bending, twisting, toughness
10. Fatigue and creep tests

III – Construction materials in Industrial Design – metal alloys
1. Study of metal alloys: ferrous and non-ferrous alloys.
2. The ferrous alloys, steels and cast irons
3. Non-ferrous alloys: properties of aluminum alloys, copper alloys, zinc alloys and magnesium alloys
4. Titanium alloys
5. Finishing processes and protection or decoration, anodizing and galvanizing, chrome plating and enameling.

IV - Construction Materials in Industrial Design - Ceramics
1. Traditional and technical ceramics
2. Processing and correlation with conventional ceramic products to be manufactured
3. Main classes of ceramic products: electrical, abrasives and refractories
4. Main rules of tracing decorative ceramics and its correlation with manufacturing processes.
5. Types of Glass. Properties of use. Reference temperatures of the glass. Manufacturing processes for glass

V - The Construction Materials in Industrial Design - Polymers
1 - Polymers. Properties of use. Comparison with other groups of materials.
1.1. The thermoplastic and thermosetting polymers.
1.3 - Elastomers. Classification and properties.
1.4 - Processing of plastic materials
2 - The elastomers. Classification and properties.
3 - Processing of plastics: extrusion, injection molding, blow molding and rotation. Thermoforming, hot and cold compression, the transfer molding, casting.
4 - Reinforced polymers.
5 - Reinforcements: glass fibers, carbon and "Kevlar". Types and properties.
6 - Processes for molding reinforced plastics.

VI - Manufacturing Processes by plastic deformation, welding and foundry
1. Introduction to manufacturing technologies by plastic deformation and metal bonding processes.
2. The manufacturing processes for metal forming
3. Manufacturing processes for welding and brazing. Types of welding.
4. Foundry
4.1. Casting processes and design of castings

VII - Composite Materials
1. Reinforcements categories in composite materials: particles, fibers and lamellae
2. Natural. composites: wood and cork. Properties of use.

VIII - Case Study

Mandatory literature

Mike Ashby and Kara Johnson; Materials and design. ISBN: 0-7506-5554-2
Chris Lefteri; Metals. ISBN: 2-88046-762-4
Chris Lefteri; Glass. ISBN: 2-88046-569-9
Antunes, V.T.A.; Introdução aos Polímeros, 1999

Complementary Bibliography

Michael F. Ashby; Materials selection in mechanical design. ISBN: 0-7506-6168-2
Ashby, M.F., Jones,D.R.; Engineering Materials I e II, Pergamon Press
Donald R. Askeland, Pradeep P. Phulé; The science and engineering of materials. ISBN: 0-534-55396-6
Rob Thompson; Manufacturing processes for design professionals. ISBN: 978-0-500-51375-0

Teaching methods and learning activities

Lectures and demonstration of the issues covered by the program of the course.
Visits to laboratories.

Software

CES Edu PACK

keywords

Technological sciences > Engineering > Mechanical engineering

Evaluation Type

Distributed evaluation with final exam

Assessment Components

Description	Type	Time (hours)	Weight (%)	End date
Attendance (estimated)	Participação presencial	36,00
Exam	Exame	4,00		2013-02-08
Practical works	Trabalho escrito	43,00		2012-12-14
	Total:	-	0,00

Amount of time allocated to each course unit

Description	Type	Time (hours)	End date
Study	Estudo autónomo	25	2013-02-08
	Total:	25,00

Eligibility for exams

The student cannot exceeds 25% of the number of planned classes

Calculation formula of final grade

Final grade = 30% for practical work + 20% for application of the knowledge acquired in the course to the project + 50% for final exam

Examinations or Special Assignments

Not applicable

Special assessment (TE, DA, ...)

THe same as for the other students

Classification improvement

Feature of the exam counting 50% towards the final mark