Individual Design Report: Materials - Assignment Example

Material Report Name: Course: Instructor: Institution: Date of Submission: Individual Design Report Report Section QUESTION ONE The material used for the component is the Aluminium 6061, T6. The material was chosen after several strength and hardness tests were done. Of all the products tested such as the tensile test, it proved that aluminium 6061 used was the material that had the highest strength based on the yield and ultimate tensile strength of the material. QUESTION TWO The tensile test was effective since it helped in showing the ultimate strength of the material showing the mechanical properties of the material, which are important in determining how to use the product or how to apply it in different fields (Davies, 2004). The Spectroscopy test was also used, it worked through showing the components in the material. However, the results were given since the schools lab is not equipped to conduct the experiment. It would have worked better if we conducted the experiment. The Vickers’s hardness test also worked for the experiment showing that the material’s hardness was high. The 3-point bend test was also used and was important in showing that the ultimate flexural strength of the material was high as well. What I would have done differently is that I would have used more tests to understand the material’s strength more. It would include engaging in a work hardening process to see if the strength of the material could be increased or the material deforms with such a process. This would also have given an outline on the strength of the material. QUESTION 3 My contribution to the group included participating in performing the tensile test to determine the strength of the material. I clipped the tensile machine, and gripped the material to perform the tensile test (Hashemi, 2006). I also participated in the Vickers hardness test partially, mainly making the report of the measured dimensions. QUESTION 4 a. The maximum load of the material is also given through the Ultimate Tensile Strength of the material. The ultimate tensile strength of the material was given as 306.93MPa to 308.8416Mpa. The UTS gives the part when material has reached its breaking point, which would still be the same at 7mm. b. The material would have extended at an equal length since though the wire was long, the elongation at break point would have been equal since the thickness, and width were equal. The elongation at break point would have been 18.9 on the maximum side, extending the wire from 63 to 81.9mm long. QUESTION 5 The main function requirements of the component include ensuring safety of the biker, endurance, comfort and speed. The speed of the bicycle is influenced by weight, where the weight should also be in response to the other factors. The material used should be light to guarantee speed, but durable and strong to endure rough phases and ensure safety among other requirements The mechanical requirements of the component is tensile loading, which considers the strain and stress of the material, and tensile strength and compression to guarantee the mechanical performance of the component. QUESTION 6 Based on the tests completed, the mechanical properties of the material determined are given as presented in the table below. The properties presented above show that Aluminium alloy 6061, T6 is the best component, and none of the properties need to be changed. For instance, in regard to a polycarbonate material, the Aluminium has the best properties based on the table below. Mechanical Properties Comparison Property Aluminium 6061, T6 Polycarbonate Alloys Steel Yield Strength 260MPa   241 MPa Ultimate tensile strength 306.93 - 308.8416 MPa 72.4MPa 310 MPa Uniform Elongation 10% 100% Total Elongation 18.4% - 18.9%   Young Modulus 58.770 Gpa - 64.131Gpa 2.41 Gpa Spectroscopy 97.7   Average HV 106.6667   177 Flexural Yield Point 490MPa 89.6 Mpa Ultimate Flexural Strength 597.66 - 588.21 Mpa   Density     Volume 3730.68mm3   Weight 9.78g   Aluminium has a better UTS and flexural yield point which brands Aluminium 6061, T6 as the best product for this component. QUESTION 7 The material selected is the best option for the racing mountain bike. The material was selected as best based on the life cycle assessment through the strength of the material. The mountain bike function leads to the demand of a material with the highest ultimate tensile strength, where the material chosen had the highest compared to others such as steel or polycarbonate materials. The strength of the material given through the tensile test and 3-point bend test brands Aluminium as the best material for the component development. It does not break easily, which is one of the main needs of the material that is needed to develop the component. The function of the component requires a material that can support a large load prior to breaking, where the tension load of the Aluminium 6061 is high. This is supported by the fact that the objective is to ensure the mass of the material is low to support the speed of the bicycle. Based on the density test, the mass of the material will support the speed. The material is a free variable, as well as the cross-sectional area of the component. The constraints to be regarded include the length of the product and the load factor. Aluminium stand out as the best material for the component. 7b. On the stipulation that the product to be developed was a minimal cost mountain bike been developed, the selection process of the material would change. For instance, the life cycle of the material would not be a concern. As such, since Aluminium has a life cycle based on the properties of the material and is an expensive material, it would not have been chosen. Thus, the selection of the material would have majorly been done in relation to the cost of the materials. The units used to produce aluminium are higher than those of steel or others. Thus, if it was between steel and aluminium, the steel material would have been selected. QUESTION 8 Based on the information in question 6, the stainless steel material is the best for the development of a simple mountain bike. That is; the product has a higher life cycle, not more than aluminium, but higher and is cost-expensive. QUESTION 9 The alternative design proposed included using different materials for different components of the entire product. In each component, the function and objective such as load tension and load factor would be considered. The benefit of this design is that the end product will meet the objectives of the component at a friendly material application. That is; the cost, economic and life cycle of each component will be determined to select the material to be used, rather than determining the material for the entire component. The limitation is that each material selected for the different parts must be evaluated to ensure it can perform effectively with the other materials chosen for different components of the end product. Questions based off the Weekly Practical’s. 1. QUESTION 1 Fe-C alloy, which is the ferrite phase 2. QUESTION 2  Ferrite (BCC), which is the average melting point (IIT, 2017) 3. QUESTION 3 The stable phase = δ ­iron; BCC The equilibrium phase = γ ­iron; FCC 4. QUESTION 4 Ductile fracture 5. QUESTION 5 The water quenched 1045 sample had a higher hardness and tensile strength compared to when cooled due to the fact that when quenched or tempered the microstructure has an extremely small cementite sphere in the form of martensite matrix, with large phase boundaries (MIT, 2004). Thus, the results were due to the size of the cementite spheres of the sample, which vary with temperature changes and time (Kim, et al., 2016). The 1045 sample through water quenching experienced an improved elongation, due to the spheroidization time. 6. QUESTION 6 The DSC heat state of melting is 44.9 J/g Heat given/ measured during the cold crystallinity is 42.9 J/g. Percentage of crystallinity = [44.9 – 42.9] / 140.1 * 100% % crystallinity = 1.4% (0% crystallinity) 7. QUESTION 7 The high (HDPE) and low (LDPE) Polyethylene have different densities because of their mechanical properties. The polyethylene has some organic compounds with the chemical formula of (C2H4)n. The molecular weight of the polyethylene also determines the density, which is contrasted using the spectrum application of plastics. The process in which the molecular align determines and leads to the different densities of the polymers. The HDPE are closely packed and straighter while the LDPE have many branches and are apart from each other. Thus, density is determined by the physical, and chemical properties of the polymers. 8. QUESTION 8 Service temperature for polycarbonates stipulates that polycarbonate has high glass transition temperatures. Therefore, tools for this materials should be held and used at high temperatures, to ensure the final product is stress and strain free. High impact polystyrene means a low cost plastic materials that can be machined and fabricated using low strength when the impact resistance and machinability are low. 9. QUESTION 9 Both the nylon and the polycarbonate have similar melting points since they both follow the same principle that when the environment is hotter, the temperature of the material is hotter as well. However, during glass transition the molecular arrangement found in either the nylon or the polycarbonate affects the temperature increase or decrease (Donth, 2013). References Davies, J., 2004. Tensile Testing. New York: ASM International. Donth, E.-J., 2013. The glass transition: relaxation dynamics in liquids and disordered materials. New York: Springer Science & Business Media. Hashemi, S., 2006. Foundations of materials science and engineering. New York: McGraw-Hill. IIT, 2017. Phases and Microstructure. Knowledge Incubation for TEQIP IT Kanpur, pp. 1-42 Retrieved from:https://www.iitk.ac.in/tkic/slides/Microstructure/L-4.pdf. Kim, M., Shin, J.-H., Choi, Y. & Lee, S.-J., 2016. Improvement of Mechanical Properties of Spheroidized 1045 Steel by Induction Heat Treatment. Metallurgical and Materials Transactions A, 47(4), pp. 1761-1769. MIT, 2004. Heat Treatment of Plain Carbon and Low­Alloy Steels: Effects on Macroscopic Mechanical Properties.. Mechanics and Materials II, pp. 1-17 Retrieved from: https://ocw.mit.edu/courses/mechanical-engineering/2-002-mechanics-and-materials-ii-spring-2004/labs/lab5_s04_1045new.pdf. Read More

b. The material would have extended at an equal length since though the wire was long, the elongation at break point would have been equal since the thickness, and width were equal. The elongation at break point would have been 18.9 on the maximum side, extending the wire from 63 to 81.9mm long. QUESTION 5 The main function requirements of the component include ensuring safety of the biker, endurance, comfort and speed. The speed of the bicycle is influenced by weight, where the weight should also be in response to the other factors.

The material used should be light to guarantee speed, but durable and strong to endure rough phases and ensure safety among other requirements The mechanical requirements of the component is tensile loading, which considers the strain and stress of the material, and tensile strength and compression to guarantee the mechanical performance of the component. QUESTION 6 Based on the tests completed, the mechanical properties of the material determined are given as presented in the table below. The properties presented above show that Aluminium alloy 6061, T6 is the best component, and none of the properties need to be changed.

For instance, in regard to a polycarbonate material, the Aluminium has the best properties based on the table below. Mechanical Properties Comparison Property Aluminium 6061, T6 Polycarbonate Alloys Steel Yield Strength 260MPa   241 MPa Ultimate tensile strength 306.93 - 308.8416 MPa 72.4MPa 310 MPa Uniform Elongation 10% 100% Total Elongation 18.4% - 18.9%   Young Modulus 58.770 Gpa - 64.131Gpa 2.41 Gpa Spectroscopy 97.7   Average HV 106.6667   177 Flexural Yield Point 490MPa 89.6 Mpa Ultimate Flexural Strength 597.66 - 588.21 Mpa   Density     Volume 3730.

68mm3   Weight 9.78g   Aluminium has a better UTS and flexural yield point which brands Aluminium 6061, T6 as the best product for this component. QUESTION 7 The material selected is the best option for the racing mountain bike. The material was selected as best based on the life cycle assessment through the strength of the material. The mountain bike function leads to the demand of a material with the highest ultimate tensile strength, where the material chosen had the highest compared to others such as steel or polycarbonate materials.

The strength of the material given through the tensile test and 3-point bend test brands Aluminium as the best material for the component development. It does not break easily, which is one of the main needs of the material that is needed to develop the component. The function of the component requires a material that can support a large load prior to breaking, where the tension load of the Aluminium 6061 is high. This is supported by the fact that the objective is to ensure the mass of the material is low to support the speed of the bicycle.

Based on the density test, the mass of the material will support the speed. The material is a free variable, as well as the cross-sectional area of the component. The constraints to be regarded include the length of the product and the load factor. Aluminium stand out as the best material for the component. 7b. On the stipulation that the product to be developed was a minimal cost mountain bike been developed, the selection process of the material would change. For instance, the life cycle of the material would not be a concern.

As such, since Aluminium has a life cycle based on the properties of the material and is an expensive material, it would not have been chosen. Thus, the selection of the material would have majorly been done in relation to the cost of the materials. The units used to produce aluminium are higher than those of steel or others. Thus, if it was between steel and aluminium, the steel material would have been selected. QUESTION 8 Based on the information in question 6, the stainless steel material is the best for the development of a simple mountain bike.

That is; the product has a higher life cycle, not more than aluminium, but higher and is cost-expensive.

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