SEJ103 Materials Engineering Project Assignment 2, T2 2020 (Individual submission) Experimental results vs Theoretical predictions Submission due on Friday 8:00 PM (AEST), 3rd September 2020 General information This assessment task will require students to achieve a clear understanding of the key mechanical properties for materials used in engineering applications. Skills and knowledge obtained by doing this assessment task will directly complement the final design of your project. Video demonstrations were used to provide in-depth knowledge of material testing and how those results could be translated into meaningful design parameters. Live practical workshops were conducted to provide clear understanding of how basic material properties are evaluated for use in real-life engineering applications. As part of this assignment, you will be given real test data collected from material tests, and you will analyse provided data sets to calculate relevant stresses and strains, and plot those results to determine key design parameters to complete the design task outlined in this assignment. All relevant calculations, graphs/ diagrams and discussions should be presented in the form of a technical report. This assessment task will contribute 25% towards the final grade, and your performance will be evaluated using a rubric.
Description of the design problem Based on the material data sheet supplied by the manufacturer of an expensive metallic alloy, a structural engineer suggested using a 350 mm (h) × 225 mm (b) rectangular section for a simply supported beam spanning 10 metres.
• Using the Material data sheet (XLER PLATE steel Data sheet ASNZS3678_450.pdf) find the minimum design strength of the material (the Density may be taken as 7850 kg/m3 .)
• The estimated working loads on the beam are as follows: Live load (LL) is 5 kN Dead load (DL) from adjacent reinforced concrete (RC) slabs is 4 kN (excluding the self-weight of the beam) As a consultant, you are required to do the following tasks to assess the adequacy of proposed design solution and suggest alternative solutions if you consider appropriate.
Task 1: Initial design check You are required to check if the design is adequate for strength and serviceability (deflection under working condition).
• For a simply supported beam under uniformly distributed loading (UDL) – Deflection at mid-span, δmax = 5wL4 /(384EI) where w is the magnitude of UDL (working load), L is the span of the beam, E is the Young’s Modulus of Elasticity, and I is the moment of inertia about axis of bending.
• For a simply supported beam, allowable deflection may be taken as L/360
• Following load factors may be used for strength: 1.5 for LL and 1.35 for DL Task 2: Design adequacy check based on material test results Once you completed Task 1, the actual material test data were made available to you (available in the assignment folder “Tension test data_MATERIAL A”). You were also made aware that “MATERIAL A” is an expensive metallic alloy that would cost $2500/ton, and the suggested thickness (250 mm) for the cross-section would require special order. You are now required to make design modifications, if you deem necessary, based on the actual material test data. Following are some of the key points that you should focus on: Strength, serviceability (deflection), alternative cross-section types (to ensure effective use of material) etc. Task 3: Final material choice Your client is inclined to use a relatively cheaper, lighter (Density = 6800 kg/m3 ) and easily available material which cost $1000/ ton.
You were also provided with the test data for this new material (available in the assignment folder “Tension test data_MATERIAL B”) to see if this material could offer better design options for this beam. You should prepare a concise design summary for your client to justify your final design decision. You should clearly identify the design parameters and highlight their significance to convince your client that you are worth the fee that he/she is paying for yourservice! Learning resources required for the problem task Submission requirements This is an individual submission and you will submit a technical report containing all three tasks as outlined in the “Description of the design problem”. We understand that load, stress, deflections etc. calculations may produce similar results but design solutions should ideally be different. You MUST be mindful of NOT copying any part of the report from each other.
The report must be no more than 10 pages and all pages must be numbered. Use size 10 Calibri or Arial fonts with single spacing for your report. Relevant Figures/ Graphs/ Tables must be reasonable in size (maximum 12 cm wide × 10 cm height) Evaluation of students’ performance Assignment 2 is designed to assess Unit Learning Outcomes (ULOs) 1, 2, 3 and 5 as you will have to demonstrate discipline specific knowledge and determine basic mechanical properties for various types of engineering materials. You shall also demonstrate clear understanding of the physical significance of those properties and apply critical thinking skills in engineering applications. Finally you shall present analysis and design outcomes in the form of a technical report. These ULOs are mapped to partially achieve Graduate Learning Outcomes (GLOs) 1, 2, 4, 5 and 7. Your performance will be evaluated using a rubric. Feedback on your performance and grades will be published once a lecturer appropriately assesses all submissions. This evaluation process will take approximately 1 to 2 weeks after all reports are submitted.
This assignment contributes a total of 25% towards the final grade. Technical report – suggested outline The technical report should be no more than 10 pages. Every student must prepare a report, which will contain brief description the scope, the significance and the outcome of the assessment task in his/ her own words. The report shall include clear and concise calculations, brief written sections and neat sketches in appropriate scale, if required. The report will be electronically typed and relevant drawings should be drawn using relevant CAD software. Students must use SI units at all times. Use of appropriate tables, figures and charts is a useful tool in technical report writing, and students are encouraged to make use of those techniques in an effective manner. Following are some guidelines on the content of the report.
Students are welcome to use these guidelines as a reference but are encouraged to present in their own way. 1. Title page On the first page of the submission, every student must include the following items:
• Unit code and unit title
• The title of the assignment with assignment number
• Student name with Student ID and Group number 2. Aim, scope and significance of the assignment You should include a brief introduction to explain the aim, scope and significance of the assessment task. This section will provide an overview of core analysis/ design tasks in a way so that the overall aim of the assignment can be clearly understood.
3. Task 1: Initial design check
3.1 Beam analysis Conduct a clear analysis to determine governing load cases, design actions (forces, moments etc.), assessment of the proposed design from strength, serviceability and any other relevant design consideration. Report all relevant calculations in a concise manner and highlight the key design parameters. State any assumptions that you make in the process and provide appropriate reference where applicable.
3.2 Assessment of the proposed design Critically assess all relevant design considerations and provide your opinion with justifications. Make reasonable assumptions citing reference, if required. 4.
Task 2: Design adequacy check based on material test results
4.1 Mechanical properties of the material Use the supplied experimental results to produce stress-strain diagrams to determine mechanical properties that are relevant to your task. Clearly plot stress-strain diagram(s) and show all necessary calculations in a concise and clear manner. Use appropriate units and make sure your calculated results are accurate so that your design decisions are reliable.
4.2 Assessment of the design based on actual material properties Assess the proposed design using mechanical properties obtained from test results. Identify any discrepancies in material properties that are relevant to your design task and highlight the significance of those parameters.
4.3 Critical assessment and suggested design modifications Critically assess the proposed design and suggest modifications, if required. All design modifications must be clearly justified using relevant calculations/ sketches/ assumptions etc. 5.
Task 3: Final material choice
5.1 Mechanical properties of the alternative material Use the supplied experimental results to produce stress-strain diagrams to determine mechanical properties for the alternative material (Material B). Clearly plot stress-strain diagram(s) and show all necessary calculations in a concise and clear manner. Use appropriate units and make sure your calculated results are accurate so that your design decisions are reliable.
5.2 Design solution using the alternative material Propose a rational design using the new alternative material. Show all relevant calculations, assumptions etc. in a clear, concise manner.
5.3 Critical assessment of design options Critically assess all design options considered as part of this assessment task. Compare those design options considering strength, serviceability, cost etc. and clearly identify your proposed solution(s) supported by relevant justifications. 6. Summary In conclusion, present a brief summary, in your own words, to highlight your understanding of how material properties could influence a simple structural design task. Constructive critical thoughts from design perspective will be highly regarded.