Engineers as managers
Great emphasis of teamwork and the efficient marshalling of
resources in the engineering education
Many senior engineers progress their careers into areas of
management because of their skills in problem solving and
organisation
Post-graduate courses in management are often used to
supplement engineering knowledge with skills in human
resources
Engineering courses are now placing greater emphasis on
broader communication and interpersonal skills
300 BC
o A crude device made to replace missing lower leg
o Metal plates hammered over a wooden core which was
then strapped to the stump of remaining leg
1560s
o First use of internal prosthetics
lowered
o The action of the triceps on the bones of the forearm
Second-class levers (few)
o Lifting the heel of the foot off the ground
Third-class levers
o Forearm and biceps
Engineering materials
Forming materials
Metal has been shaped by deformation processes for several
thousand years.
Forging, rolling, and wire drawing were performed in the Middle
Ages.
The Industrial Revolution allowed these processes to be done at a
higher level.
Forging
Shaping of a metal through the use of localised compressive
forces
Can either be hot or cold working process
o Hot working = metal is being worked at a temperature that
is above its recrystallisation temperature.
Open die forging
o Occurs when the metal is hammered or pressed by a
vertically moving tool onto a stationary tool.
o Dies are generally of simple geometric shape and the
material is not completely enclosed by the die.
o Applications:
Simple shapes
Short order to delivery cycle
Quantity too small to justify closed die
Forgings that are too large for closed die
Products whose mechanical properties cannot be
obtained by machining from billet/slabs
Drop forging
o Uses hydraulic pressure to operate a hammer that shapes
the metal. The hammer may operate directly onto the
metal or a press and die may be used to force metal into
shape.
The two halves of the forming die are shown. (1)
The die contains four different formers and the
component is formed in 4 stages, then finished to the
desired tolerances.
The excess material that is squeezed out between
the mating dies (flashing) is removed and can be
recycled. (3)
Casting
Pouring molten metal into a cavity that will produce an article
shaped to specifications
Most castings require some machining to produce the finished
part.
Not all metals are suitable for casting. Those that are possess
good fluidity which allows them to fully fill the mould cavity
before they begin to solidify.
Castings are commonly made from iron, steel, aluminium, zinc or
bronze.
Parts are made from castings instead of machining from stock,
for one or more of the following reasons:
o The most intricate of shapes, both external and internal,
may be cast. As a result, many other operations, such as
machining, forging, and welding, can be minimised or
eliminated.
o Too much material would need to be machined away from a
piece of stock, so the part would waste to much material
and be too expensive to produce by machining alone.
o The part is so large that stock of sufficient size is not
available.
o The part contains cavities (such as the internal water
cooling holes in an engine block) that would be impossible
to make by machining.
Corrosion
o Corrosion rate depends on the reactivity of the material in
the environment
Normally, it consists of the rate at which a protective
oxide is formed at the surface of the material
Passivated when the metal surface is protected by a
dense, tightly adherent oxide
A relative measure of resistance to corrosion can be
gained from a determination of the electrical
potential of the material in-situ
Strength
o Yield strength: the position on the stress-strain curve at
which deformation changes from elastic to plastic (or
permanent).
For structural applications, the yield stress is an
important property since once the yield point is
passed the structure has deformed beyond
acceptable limits
o Ultimate tensile strength (UTS): the maximum in the stress
strain curve
An increasing level of stress is required due to work
hardening until a maximum point is attained if plastic
deformation is to continue past the yield point
Fatigue resistance
o Fatigue: Cracking of a component occurring under cyclic
loading can occur at stresses well below yield stress
o Most common form of materials failure (accounts for up to
80% of machinery failure)
o A fatigue fracture always starts as a small crack, which
under repeated application of the stress grows in size
As the crack expands the load-carrying cross-section
of the component is reduced, with the result that the
stress on this section is raised
o Indicative fatigue data on materials is obtained from
standardised test pieces in a special test rig that applies a
cyclic load
A diagram is subsequently set built up of load cycles
to failure for a variety of applied loads
S/N diagram: S=stress; N=number of cycles
Dimensional stability
o Materials for biomedical applications need to be stable both
within the body environment and during pre-surgical
treatments such as sterilisation
Can be a concern for some polymers, that are prone
to swelling or degradation
Sterilisation compatibility
Ultra
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o
o
Electricity/electronics
Ohms law