This course is designed to meet over a period of 7 weeks, 2 meetings per week, and 2 hours per meeting.

Transcription

1 Page 1 of 5 Syllabus: Design with Part 1: Course Information Description Design with materials is an introductory course focusing on students learning of properties, manufacturing processes, and design guidelines of fiberreinforced composite materials. The basics of composite properties, mechanics, and manufacturing processes are introduced. Design guidelines and drafting notations will be emphasized for composite components with various fiber-reinforcements such as unidirectional fibers, random short fibers, and laminate stacking sequences. The lecture handouts, together with homework assignments, course projects, and exams are designed to train the targeted students in community colleges with CAD experience, for associate degrees and/or certificate programs. This course is designed to meet over a period of 7 weeks, 2 meetings per week, and 2 hours per meeting. Prerequisites Entry-level CAD Reference Books M. W. Hyer, Stress Analysis of Fiber-Reinforced, DES Tech Publications, Inc, ISBN# , 2009 Siemens NX User Manuals Handbook Series, MIL-HDBK , 2002 Tools to be used Siemens NX9 or similar CAD Software Part 2: Course Learning Outcomes (CLOs) The course learning outcomes are to have students: 1. Understand the resultant of a force system acting on an object; 2. Determine the internal forces and support reactions of a structure using Freebody Diagrams (FBDs); 3. Understand the concepts of stress, stain, Hooke s Law and Young s Modulus; 4. Apply knowledge in statics and mechanics of materials in design; 5. Understand the main applications, pros and cons of composite materials; 6. Understand the fundamental properties of composite materials; 7. Understand the difference between isotropic and orthotropic materials;

2 Page 2 of 5 8. Understand the meaning of elastic constants of composite materials; 9. Understand the stress-strain relationship of composite materials; 10. Be familiar with laminate conventions and stacking sequence; 11. Understand the fundamentals of Classical Lamination Theory (CLT); 12. Understand the main manufacturing processes of composite products; 13. Perform research projects on manufacturing techniques using composites and present them to the class; 14. Apply knowledge in design of mechanical systems with composite materials; 15. Be able to redesign a steel part using composite materials; 16. Understand and apply the composite design guidelines; 17. Apply the notation/convention of composite materials in 3D visualization and engineering sketching; 18. Demonstrate effective communication and teamwork skills through technical presentations and reports in course projects. Part 3: Course Topics and Roadmap Topics covered 1. Introduction to Mechanics of Strain Poisson s Ratio Generalized Hooke s Law of Isotropic 2. Introduction to Fiber-Reinforced Fibers Carbon/Glass/Polymeric Matrices Thermoset/Thermoplastics 3. Properties of Fiber-Reinforced Deformation Orthotropic Material Properties -Strain Relations: Compliance and Stiffness Matrix 4. Classical Laminate Theory Laminate Matters Definition and Stacking Sequence 5. Manufacturing Processes of Close-Mold Processes Open-Mold Processes Processes for Short-Fiber Processes for Continuous-Fiber 6. Design Process and Methodology Functional Requirements and Economics Preliminary Design Detailed Drawings Determination of Optimal Material/Process

3 Page 3 of 5 Prototyping Tooling tryout 7. Design Guidelines Minimum Inside Radius Undercuts Molded-in Holes Recommended Draft Practical Thickness Ribs Molded-in Labels Surface Finishes Metal Inserts Cross-sectional Shapes Roadmap The following roadmap is recommended for instructors (Handouts 1-7 are the PowerPoint lecture slides): Week and Topic Lecture Topics CLOs 1 Introduction to Mechanics of 1, 2, 3, 4 2 Introduction to Fiber- Reinforced 5, 6 3 Properties of Fiber- Reinforced 7, 8, 9 4 Classical Laminate Theory 10, 11 5 Manufacturing Processes of Main Concepts, Terms, and Equations Strain Poisson s Ratio Generalized Hooke s Law of Isotropic Definition of Applications, Pros and Cons Fibers Carbon/Glass/Polymeric Matrices - Thermoset/Thermoplastics Deformation Orthotropic Material Properties -Strain Relations: Compliance and Stiffness Matrix Laminate Matters Definition and Stacking Sequence Close-Mold Processes Open-Mold Processes Processes for Short-Fiber Course, Homework & Projects Handout #1 HW1 Handout #2 HW2 Handout #3 HW3 Handout #4 HW4 Handout #5 HW5 Project 1

4 Page 4 of 5 12, 13 6 Design Process and Methodology 14, 15 7 Design Guidelines 16, 17, 18 Processes for Continuous-Fiber Functional Requirements and Economics Preliminary Design Detailed Drawings Determination of Optimal Material/Process Prototyping Tooling tryout Minimum Inside Radius Undercuts Molded-in Holes Recommended Draft Practical Thickness Ribs Molded-in Labels Surface Finishes Metal Inserts Cross-sectional Shapes Handout #6 Project 2 Handout #7 Project 2 (continued) Part 4: Grading and Assessment HW Assignments Homework assignments are related to the topics described above. Course Projects Two course projects are to be assigned. The first one is about the manufacturing processes, after Topic 5, around midterm time frame. The second one is the final project about design of a device assembly, after all the course topics are completed. Computer Usage CAD software and MS Office would be used. Grading Schedule Ø Homework (5) 50% Ø Pre Exam (1) 10% Ø Final Exam (1) 10% Ø Course Projects (2) 30% Prepared by Professor Yaomin Dong, Ph.D., Kettering University

5 Page 5 of 5 Date 07/10/2015 Revised 05/04/2016 ydong@kettering.edu Work Phone Office Location Mott Building