Lab 1 - CES EduPack - Basic Tools for Materials Selection - Note

Lab 1: CES EduPack – Basic Tools for Materials Selection

300965 Engineering Materials (2014)

School of Computing, Engineering and Mathematics 300965 Engineering Materials

Lab 1: CES EduPack – Basic Tools for Materials Selection 1. Aims 1.1 Be familiar with materials selection software – CES Edupack 1.2 Be able to use the basic tools (e.g., Browse, Search, and Select) to search information able materials and select materials with specific properties or processes that meet the requirements.

2. Materials and Equipment 2.1 CES Edupack 2013

3. Introduction CES EduPack software incorporates a textbook-style data resource on materials, manufacturing and shapes of about 4000 materials with a materials selection tool that allows the selection of particular materials, based on their properties, by plotting graphs, inputting property criteria data or by selecting specific manufacturing and forming processes that the material should be able to undergo. There are three levels to the database, each contains information about a greater number of materials and in greater detail than the preceding level. It is a very valuable tool to engineers a wide range of engineering disciplines as well as materials and physics. More information is available at http://www.grantadesign.com/. Watch the following video tutorials before you attend this Lab. They are available under the Help menu of CES EduPack or at http://www.grantadesign.com/education/resources/videotutorials/2013/index.htm • Browse Level 1 and Level 2 • Search • Selection • Limit Stage • Graph Stage – Selection Tools • Graph Stage – Plotting Charts • Graph Stage - Formatting • Tree Stage • Getting Help

4. Experimental Procedure Bring to the laboratory: A4 workbook and drawing tools (e.g., pencils, erasers, rulers, drafting triangles, and protractor or circle templates). Complete the following tasks and answer the questions in your workbook for marking at the end of the laboratory by your supervisors/demonstrators. There are 25 questions with total of 25 marks. Each question has 1 mark, i.e., a correct answer will receive 1 mark and an incorrect answer will receive 0 mark. Your total mark of this lab will convert to a mark out of 10. Page 1 of 5

Lab 1: CES EduPack – Basic Tools for Materials Selection

300965 Engineering Materials (2014)

4.1. BROWSING materials and process records Browsing lets you explore records, starting from the content list or “tree”. Open the CES EduPack at Level 1.

Question 1.1 Find the record for the thermoplastic polymer Polycarbonate, PC, a thermoplastic. What, approximately, does it cost? What is it used to make? Question 1.2 Find the record for the ferrous metal Stainless steel. What is the value of its thermal conductivity? Is it a better or worse conductor than Aluminum alloy or Copper alloy? (All three are used to make cooking pans.) Question 1.3 Find the record for the Borosilicate Glass, commonly known as PYREX. What is the value of its “maximum service temperature” (the highest temperature at which it can be used in a product)? What is Pyrex used for? Question 1.4 Find the records, first for Titanium alloys and then for Aluminum alloys. Which has the higher tensile strength? Which has the lower density? Question 1.5 Find the records, first for the composite CFRP (Carbon-fiber reinforced polymer) in the family HYBRIDS, under Composites and then for magnesium alloy in the family METALS AND ALLOYS, under Non-ferous. Which has the higher tensile strength? Which has the lower density? Click on the ‘ProcessUniverse’ link at the bottom of the CFRP record. Can CFRP be shaped by Drilling? (Double click on any name in the list to see the record.) Question 1.6 Find by Browsing the record for the nickel-chromium alloys called Nichromes. What are their main applications? Question 1.7 Find by Browsing (in the Process Universe under Surface Treatment, not the Materials Universe) the record for Polymer powder coating. What are the three ways of applying a polymer powder coating? Question 1.8 Find the Composite shaping record for Filament winding, a way of making high quality composite structures. What are its typical uses? Question 1.9 Find the shaping record for Injection molding, one of the most commonly used of all polymer shaping processes. Find materials that can be injection molded by clicking on the LINK button, labeled ‘MaterialUniverse’, at the bottom of the record. Can thermoplastic

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Lab 1: CES EduPack – Basic Tools for Materials Selection

300965 Engineering Materials (2014)

polymer Polyethylene be injection molded? (Double click on any name in the list to see the record.) Question 1.10 Find the shaping record for Die casting, one of the most-used ways of shaping metals. What sorts of products are made by die casting?

4.2. SEARCHING materials and process records Searching lets you pull up any record that contains the word or word-string you enter in the search box. It is really useful when you only know the trade name of a material or process, or when you want to search for materials that are used to make a particular product. Change to the Database to Level 2 for the following questions.

Question 2.1 Find the record for Plexiglas by searching. What is its proper name? Can it be injection molded? (Click on the ‘ProcessUniverse’ link at the bottom of the record to find out.) Question 2.2 What is Gore-Tex made of? Question 2.3 What are spark plugs made of? Search on the name and find out. Question 2.4 Search in CES Level 2 on cutting tool to find materials that are used to make industrial cutting tools. You will find that some are metals, but others are ceramics – hard ceramics are good because they don’t wear, but they are expensive and hard to make. Question 2.5 Find in CES Level 2 what the process RTM is all about by searching on RTM. Draw a process schematic. Question 2.6 Find in CES Level 2 what the process SLS is all about by searching on SLS. Draw a schematic for polymer SLS. Question 2.7 Use the “Search” facility in CES Level 2 to find materials for scissors. Question 2.8 Use the “Search” facility in CES Level 2 to find materials for heat exchangers. Question 2.9 Use the Search facility in CES Level 2 to search materials for electrical conductors. Are the following materials electrical conductors? Copper, lead alloys, wood, metal foam, cement

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Lab 1: CES EduPack – Basic Tools for Materials Selection

300965 Engineering Materials (2014)

Question 2.10 Use the Search facility in CES Level 2 to find materials for lenses. Write down which polymers can be used for lenses.

4.3. SELECTING materials and process records There are three selection tools: GRAPH, LIMIT, and TREE. We will start with the LIMIT STAGE tool. It lets you find materials or processes that meet requirements that you enter in a Limit Stage. To do this, set the CES EduPack to select from Level 1 Materials (choose ‘Edu Level 1: Materials’ from the dropdown list) or otherwise indicated. Then click on the Limit button.

Selection/Limit

Selection/Graph

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Lab 1: CES EduPack – Basic Tools for Materials Selection

300965 Engineering Materials (2014)

Question 3.1 Find in Level 1 for materials that cost less than $1/kg and are good electrical conductors. Enter the upper limit on Price and the constraint that the material must be a good conductor. Then click APPLY at the top of the Limit window. The materials that do not meet the constraints are removed from the RESULTS window on the lower left, leaving those that do. Question 3.2 The property Fracture toughness is a measure of how well a material resists fracture. A brittle material like glass has a low value of fracture toughness – around 1 in the units you will use (MPa.m1/2). Steel used for armor has a very high value – over 100, in the same units. Many engineers, when designing with metals, avoid material with a toughness less than 15. Use Level 1 and a Limit stage to find materials with a fracture toughness greater than 15 and that are good electrical insulators. Question 3.3 Use a Limit stage to find materials with modulus E > 180 GPa and price < 3 $/kg. Question 3.4 Use Level 2 and a Limit stage, applied to the Surface treatment data-table, to find surface treatment processes that enhance fatigue resistance. To do this, (a) select table Level 2 Surface treatment, open a Limit stage, scroll down to Function of treatment and click on Fatigue resistance – Apply. Write down the results. (b) Repeat, using the Level 3 Surface treatment data-table. Now we’ll do a GRAPH stage. It lets you plot properties and select those materials that lie in a chosen part of the plot. Delete the Limit stage (right-click on the stage name and select “Delete”). Question 3.5 If you want to make a high-quality cooking pan to go on the top of a gas stove, you need a material with a high thermal conductivity. The high conductivity is to spread the heat, preventing hot-spots where the flame hits the pan. The material must have enough Elongation to be shaped to a pan (requiring elongation > 15%), and a Maximum service temperature of at least 150°C. User a Level 2, first make a Limit stage and put these (lower) limits on elongation and maximum service temperature. Then make a graph with thermal conductivity on the Y-axis. To do this, click on the Graph button. On the Y-axis tab, find Thermal conductivity in the Attribute list and click to select it. When you click OK you get the graph shown. Use a Box selection (the little box icon in the toolbar just above the graph) to select and write down materials with the highest thermal conductivities.

Note: 1. At the end of the Lab class, write down your name, student number, and date of the Lab class on the 1st page of your workbook of this Lab, and then sign on it; 2. Submit your workbook with the answers to lab demonstrator for marking before you leave the class.

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