MATERIALS SELECTION IN MECHANICAL DESIGN - 2024/5

Module Overview

A lecture and tutorial based module, which build on ENG1063 (Materials and Statics), and is complementary to ENG3164 (Engineering Materials). It provide a deeper and broader appreciation of methods for selecting materials as part of mechanical design.

Materials property charts are used throughout as a means to rapid appropriation of solutions from a wide range of engineering materials. The module includes the selection of materials processes in addition to selection of materials. Approaches that enable multiple constraints and conflicting objectives to be handled are explored. Materials selection and component shape is addressed as a pointer to more sophisticated contemporary approaches such as topological optimisation. The module concludes with an overview of designing hybrid materials.

Module provider

Mechanical Engineering Sciences

Module Leader

WHITING Mark (Mech Eng Sci)

Number of Credits: 15

ECTS Credits: 7.5

Framework: FHEQ Level 6

Module cap (Maximum number of students): N/A

Module Availability

Semester 2

Prerequisites / Co-requisites

None

Module content

• The basics of materials selection: the selection strategy, attributes and materials indices, the selection procedure. Case studies, including couplings, seals, safe pressure vessels and heat exchangers.


• Processes and their effect on properties. Shaping, joining, finishing. Subtractive and additive manufacture. Process-property trajectories. Process selection. Limitations and qualities.


• Multiple constraints and conflicting objectives: Selection methods for multiple constraints. Case studies: light pressure vessels, wafer-thin casings for hand-held technology, cost-effective bumpers and materials for disc-brake calipers.


• Selection of materials and shape: a refresher on shape factors. The limits to shape efficiency. Material indices that include shape. Architectured materials: microscopic shape. Case studies, including forks for racing bicycles, shapes that flex and ultra-efficient springs.


• Designing hybrid materials: cellular structures (foams and lattices). Sandwich structures and multi layers. Segmented structures. Case studies, including: designing metal matrix composites and exploring the efficiency of natural materials.

Assessment pattern

Alternative Assessment

N/A

Assessment Strategy

The assessment strategy is designed to provide students with the opportunity to demonstrate: (i) they understand how to use diverse engineering materials property data to select appropriate materials for structural applications in a variety of engineering contexts, (ii) can use engineering materials property data to justify the selection of materials, processes and component geometry against various design goals. Thus, the summative assessment for this module consists of: 1. Assignment [learning outcomes 1 and 2], and 2. Examination [learning outcomes 1, 2, 3 and 4].

Formative verbal feedback is given in tutorials. Written feedback is given on the coursework assignment.

Module aims

• To understand how to use diverse engineering materials property data to select, with critical insight, appropriate materials for structural applications in a variety of engineering contexts.
• To use engineering materials property data to justify, with critical insight, the selection of materials, processes and component geometry against various design goals.

Learning outcomes

Methods of Teaching / Learning

The learning and teaching strategy is designed to enable students to: (i) use materials property charts to make initial judgments about the selection of materials for diverse engineering design contexts, (ii) understand a broad range of processes for materials manufacture and their implications for materials and process selection, (iii) analyse the mechanics of a materials design problem so as to select materials and geometry to minimise weight, minimise environmental impact, etc., (iv) assess when a hybrid material might provide a better design solution than a monolithic engineering material. The learning and teaching methods include: captured content, lectures, tutorials, guided learning  and independent learning informed by the assessments.

Indicated Lecture Hours (which may also include seminars, tutorials, workshops and other contact time) are approximate and may include in-class tests where one or more of these are an assessment on the module. In-class tests are scheduled/organised separately to taught content and will be published on to student personal timetables, where they apply to taken modules, as soon as they are finalised by central administration. This will usually be after the initial publication of the teaching timetable for the relevant semester.

Reading list

https://readinglists.surrey.ac.uk
Upon accessing the reading list, please search for the module using the module code: ENG3206

Other information

The School of Mechanical Engineering Sciences is committed to developing graduates with strengths in Employability, Digital Capabilities, Global and Cultural Capabilities, Sustainability, and Resourcefulness and Resilience. This module is designed to allow students to develop knowledge, skills, and capabilities in the following areas:

Digital capabilities: The students will use MS Word in preparing their assessment. The assessment also makes use of data requiring the use of MS Excel. The underpinning principle for the module are property data charts which are generated by software made available to the students. The classroom elements will include some discussion about the use, strengths, and pitfalls of AI to generate narrative material and answer advanced technical questions.

Employability: The assessment is designed to enhance life-long learning research skills and making a narrative argument. Both skills are essential professional engineering careers.

Sustainability: The exploration of materials in this module makes frequent reference to the limitations posed on engineering materials posed by scarce resources as well as the impact of materials manufacture on the environment. Among the properties explored in this module are eco properties such as embodied energy. Life cycle analysis, whilst not examined in detail, is explored for each material class in terms of reuse, recycling, and end of life issues.

Resourcefulness and resilience: Students will discuss research methods for addressing their bespoke assessment. This will include evaluating a range of sources including textbooks, journals, blogs, AI chatbots, news articles and documentary archives.

Programmes this module appears in

Please note that the information detailed within this record is accurate at the time of publishing and may be subject to change. This record contains information for the most up to date version of the programme / module for the 2024/5 academic year.