EGB214 Materials and Manufacturing

Unit Outline: Semester 1 2024, Gardens Point, Internal

Overview

This unit introduces the fundamentals of engineering materials and their manufacturability, defects of materials at the micro-scale and how mechanical properties of materials (e.g. steel) can be tailored by processing (deformation, diffusion) and heat treatments. This knowledge along with a range of complex manufacturing processes (casting, rolling, forging, extrusion) and sheet metal forming processes such as blanking, piercing, bending, drawing and deep drawing. This knowledge is important for graduate engineers in their engineering study. This unit develops appreciation to engineers around design and how to make a product out of materials using both primary and secondary production methods with minimum environmental impact and costs. They will improve their understanding about the interactions and interrelationship between processing, microstructure, properties and performance of various engineering materials in order to utilize new designs and fabrication.

Learning Outcomes

On successful completion of this unit you will be able to:

1. Relate manufacturing processes in materials and manufacturing, to the mechanical behaviour of materials, at a developed level.
2. Solve material behaviour problems in materials and manufacturing, with regard to manufacturing processes, at a developed level.
3. Communicate engineering analysis methods and procedures in materials and manufacturing, with relation to the mechanical behaviour of materials, at a developed level.

Content

Learning Approaches

In this unit you can expect to experience the following timetabled activities:

• Formal lectures will cover the theory and illustrate some practical applications of the material studied. The lectures will be used to guide you through the unit and show you how the material being studied each week is used by practising engineers, to describe and illustrate the basic concepts behind this material using demonstrations and visual aids. Lecture recording and slides as well as some additional readings will be available on the Canvas website.
• Tutorial classes will be used to solve pre-selected numerical problems related to materials and manufacturing that will assist you in understanding the unit.
• Laboratories will be used to interpret and analyse the microstructure of given materials using some standard analytical techniques such as optical microscopy, explore the effect of processing (heat treatment) of steel, and materials manufacturing by casting. There will be two pracs for this unit:
  i. Microstructures and Heat Treatments of Steels: a 2-hour prac session to examine the microstructure of various steels and be able to relate to the mechanical properties of steels; to observe the heat treatment of various steels using Jominy-end quench, and examine the hardness profile of these materials.
• ii. Investment Casting: a 2-hour prac session to cast ornament out of copper using lost wax investment casting process and identify the various types of cast defects.
• Group project will be offered to study the symbiotic relationship between materials and manufacturing and how it shapes the design and fabrication of a real assembly product – a worm drive gearbox. This learning is facilitated and enriched by giving you hands-on interaction to disassemble the gearbox product, carefully analyse the system and its parts before re-assemble.
• To complement timetabled activities, you can expect to be provided with learning resources including videos and readings on a unit Canvas site that you can access flexibly to complete your learning in this unit. Success in this unit will require you to manage your time to ensure you have focused time each week (beyond timetabled activities).

At the beginning of the unit, you will be made aware of the ways in which you can ask questions or seek clarification from the Unit Coordinator and Tutors.

You are expected to:

• Engage with timetabled activities such as grearbox project on campus and ask questions.
• Manage your time to engage with online resources outside of timetabled activities. These will be available on the unit Canvas site. You will receive regular email announcements regarding release of these resources.
• Engage with your peers in a learning community to practise problem solving and then work independently to complete your assessment tasks.
• Prepare for timetabled classes and activities and follow up on any work not completed.
• Complete assessment tasks by working consistently across the semester and meeting the due dates that are published via the unit Canvas site.

Feedback on Learning and Assessment

You will receive written feedback on practicals and gearbox project reports. Oral feedback on your progress in this unit will be given during tutorials and project sessions and discussions throughout the semester. Additional formative feedback will be available in practical lab sessions.

Assessment

Overview

Assessment will be based on laboratory practicals, project and final exam. In addition to integrating materials and manufacturing components of the unit in laboratory space, you will be involved in group project (e.g. small gear box project) to disassemble the product, identify the material of each component, reason why this material was chosen, how it was manufactured, sketch the components and also produce drawings.

Unit Grading Scheme

7- point scale

Assessment Tasks

Assessment: Laboratory/Practical

You are required to engage in a laboratory practical sessions, take your own measurements and write a report using acquired data. Please note, you can’t use data collected by others to write the report. Please read the health and safety information and the risks that may be associated with this prac.

No makeup for missed pracs unless you have medical certificate and received approval from the student service.

This is an assignment for the purposes of an extension.

Assessment: Project (applied)

You will involve in a group project that will allow you to disassemble/assembly of a real gearbox product in a workshop. You will then identify the material of each component, reason why this material was chosen, how it was manufactured, sketch the components, and also produce drawings. Your learning about the gearbox operation, assembly procedures, part relationships, material selection and manufacturing processes will then be compiled into a group report, with clearly defined individual roles and responsibilities.

This is an assignment for the purposes of an extension.

Assessment: Examination (Written)

You will answer questions and problems related to key concepts in materials and manufacturing covered in this unit during the semester.

“If campus access is restricted at the time of the central examination period/due date, an alternative, which may be a timed online assessment, will be offered. Individual students whose circumstances prevent their attendance on campus will be provided with an alternative assessment approach.”

Academic Integrity

Students are expected to engage in learning and assessment at QUT with honesty, transparency and fairness. Maintaining academic integrity means upholding these principles and demonstrating valuable professional capabilities based on ethical foundations.

Failure to maintain academic integrity can take many forms. It includes cheating in examinations, plagiarism, self-plagiarism, collusion, and submitting an assessment item completed by another person (e.g. contract cheating). It can also include providing your assessment to another entity, such as to a person or website.

You are encouraged to make use of QUT’s learning support services, resources and tools to assure the academic integrity of your assessment. This includes the use of text matching software that may be available to assist with self-assessing your academic integrity as part of the assessment submission process.

Further details of QUT’s approach to academic integrity are outlined in the Academic integrity policy and the Student Code of Conduct. Breaching QUT’s Academic integrity policy is regarded as student misconduct and can lead to the imposition of penalties ranging from a grade reduction to exclusion from QUT.

Resources

Resource Materials

Reference book(s)

Askeland, D.R.,  Fulay P.P., Wright W. J., The Science and Engineering of Materials, 2011, PWS Publishing, 6th Edition.

Author: Armarego, E.J.A.
Title: Material Removal Processes - An Introductory Course
Year: Publisher: The University of Melbourne, 1995

Callister, W.D. and Rethwisch D.G., Materials Science and Engineering – Introduction, 2018, John Wiley & Sons, 10th Edition.

Safety and protective equipment

Closed shoes or steel capped shoes

Risk Assessment Statement

You will be informed of any requirements pertaining to a safe workplace. In lectures, tutorials and such, the information will include location of fire exits and meeting points in case of fire. If you do not follow legitimate instructions or endanger the safety of others or do not act in accordance with the requirements of the Workplace Health and Safety Act, you will be required to leave the session.

You will be required to undertake practical sessions in the laboratory and workshop under the supervision of members in the teaching team and technical staff. Prior to entry to a laboratory space you must complete the Undergraduate Health, Safety and Environment Induction (annual completion requirement). You will be advised of requirements of safe and responsible behaviour and will be required to wear appropriate protective items (e.g. closed shoes or steel capped shoes, and safety glasses). The unit’s Canvas site will provide you with a copy of the risk assessment and will provide you with details on how to perform the laboratory tasks safely.

Standards/Competencies

This unit is designed to support your development of the following standards\competencies.

Engineers Australia Stage 1 Competency Standard for Professional Engineer

1: Knowledge and Skill Base

1. 
   Relates to: Laboratory/Practical, Examination (Written)
2. 
   Relates to: Laboratory/Practical, Project (applied), Examination (Written)
3. 
   Relates to: Project (applied)

2: Engineering Application Ability

1. 
   Relates to: Laboratory/Practical, Project (applied), Examination (Written)
2. 
   Relates to: Project (applied)
3. 
   Relates to: Laboratory/Practical, Examination (Written)

Course Learning Outcomes

EN01 Bachelor of Engineering (Honours)

1. Make decisions ethically within the social, cultural, and organisational contexts of professional engineering practice.
   Relates to: Laboratory/Practical
2. Engage stakeholders professionally and communicate the outcomes of your work effectively to expert and non-expert audiences using appropriate modes.
   Relates to: ULO3, Project (applied), Examination (Written)
3. Display leadership, creativity, and initiative in both self-directed and collaborative contexts of professional engineering practice.
   Relates to: ULO2, Laboratory/Practical
4. Manage projects to solve complex engineering problems, using appropriate information, engineering methods, and technologies.
   Relates to: ULO1, ULO2, Laboratory/Practical, Examination (Written)
5. Demonstrate coherent knowledge and skills of physical, mathematical, statistical, computer, and information sciences that are fundamental to professional engineering practice.
   Relates to: ULO1, Laboratory/Practical, Examination (Written)
6. Demonstrate a thorough understanding of one engineering discipline, its research directions, and its application in contemporary professional engineering practice.
   Relates to: ULO1, ULO2, ULO3, Laboratory/Practical, Project (applied), Examination (Written)

EV01 Bachelor of Engineering (Honours)

1. Make decisions ethically within the social, cultural, and organisational contexts of professional engineering practice.
   Relates to: Laboratory/Practical
2. Engage stakeholders professionally and communicate the outcomes of your work effectively to expert and non-expert audiences using appropriate modes.
   Relates to: Project (applied), Examination (Written)
3. Display leadership, creativity, and initiative in both self-directed and collaborative contexts of professional engineering practice.
   Relates to: Laboratory/Practical
4. Manage projects to solve complex engineering problems, using appropriate information, engineering methods, and technologies.
   Relates to: Laboratory/Practical, Examination (Written)
5. Demonstrate coherent knowledge and skills of physical, mathematical, statistical, computer, and information sciences that are fundamental to professional engineering practice.
   Relates to: Laboratory/Practical, Examination (Written)
6. Demonstrate a thorough understanding of one engineering discipline, its research directions, and its application in contemporary professional engineering practice.
   Relates to: Laboratory/Practical, Project (applied), Examination (Written)