1. Project Report 1 (30%) – Due Week 7 (9am, Friday, 1st May 2020) Background Metal additive manufacturing (AM) or 3D printing, a process of creating a 3D object by adding materials layer by layer,...

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1. Project Report 1 (30%) – Due Week 7 (9am, Friday, 1st May 2020)


Background


Metal additive manufacturing (AM) or 3D printing, a process of creating a 3D object by adding materials layer by layer, continues to make deep inroads into the manufacturing sector. However, the lack of performance consistency of additively manufactured metal parts due to microstructural inconsistency precludes its wider application, especially to those that require reliable and repeatable mechanical properties. Building an ability to create reliable parts on a consistent basis will assure quality metal AM production of mission-critical components for use in the most demanding industries such as aerospace, defence and healthcare.


Purpose of Assessment


You are a manufacturing engineer at Digital Factory working on AM of metallic components for automotive and aerospace applications. Recently, one client has approached you for suggestions on the feasibility of manufacturing components used in jet turbine engine (Figure 1) and automotive engine (Figure 2) by additive manufacturing. The components in consideration for AM are: fan case, fan blade, low pressure turbine blade, high pressure turbine blade, shaft for the jet turbine engine; intake manifold, exhaust manifold, connecting rod, cylinder block for the automotive engine. Metallic materials available to you for AM include Ti-6Al-4V, AlSi10Mg, Inconel 718, 316L stainless steel and 17-4PH stainless steel.


Considering working environment and performance requirement, you are required in this project to 1) select one of the aforementioned components of your interest; 2) select and evaluate an appropriate metal for the manufacture of this component using selective laser melting (SLM) or laser engineered net shaping (LENS); 3) justify the feasibility of manufacturing the component with required performance.You will be provided one SLM- or LENS-fabricated sample for microstructure analysis and Vicker’s microhardness measurement and one SLM- or LENS-fabricated dog-bone specimen (either vertically or horizontally built) for tensile testing. These analyses and testing will be performed by you in the Materials Lab under the supervision of an experienced technical specialist.(Note: owing to the lab closure and cancellation of pracs, experimental data needed for Project Report 1 will be acquired by Lab Technical Staff and then uploaded to the Unit Site. With these data and information from the literature, you will perform your own analysis and prepare your Project Report 1)


This project aims to develop a comprehensive and critical understanding of existing issues confronting the metal AM community for a specific metallic alloy that has been made by AM techniques. With the results produced in this project and your own literature review, a project report of approximately 2000 words (excluding abstract & references) with up to 8 figures and 2 tables will be developed by demonstrating in-depth understanding of the metal AM process, theory/literature, experimental results and the process-microstructure-property relationship. Upon your critical analysis, you are required to justify:



  • Whether the selected metallic material can be used to fabricate the selected engine component with necessary mechanical performance using SLM or LENS

  • If it is not feasible, what are the main issues? It is more desirable to provide possible solutions.


This project report is worth 30% of the total mark for this unit. With the initial support of several review/overview journal articles, you will be required to create your own project report topic, conduct a comprehensive literature search/review, evaluate and analyse the experimental results, and write a report in a professional manner including:



  • Appropriate section headings and document layout

  • Appropriate referencing in IEEE format

  • Captions for all figures and tables used

  • Consistent professional document style (e.g. same size font, bold titles)

  • Correct use of formal and academic language

  • The use of spelling checker/grammatical checker

  • Valid signed/named/dated SEBE Assignment Coversheet



Jet Turbine Engine


Figure 1 Jet turbine engine (from Rolls Royce)




Automotive Engine


Figure 2 Volvo four-stroke cycle petrol engine (from The Science and Technology of Materials in Automotive Engines, 2005)


Project Report Format


The project report should use the format below as well as an appropriate referencing in IEEE format and should conform to the University plagiarism policy.



  • Project title

  • Abstract (up to 150 words)

  • Literature review

  • Research problem statement

  • Methodology and experimental

  • Results and discussion

  • Feasibility and justification

  • Conclusions

  • References

slm-ti-6al-4v-optical-image-side-view-longitudinal-low-mag-uevpkpwq-sb5tn0zo.jpg slm-ti-6al-4v-optical-image-side-view-longitudinal-low-mag-uevpkpwq-tx0j2cyg.jpg slm-ti-6al-4v-sem-image-top-view-transverse-1-hcftpxvk-l3oqc1tf.jpg slm-ti-6al-4v-sem-image-top-view-transverse-3-ikrpefyh-tg40t3sh.jpg slm-ti-6al-4v-sem-image-top-view-transverse-2-4ma052ug-321p0hnd.jpg
Answered Same DayApr 28, 2021Deakin University

Answer To: 1. Project Report 1 (30%) – Due Week 7 (9am, Friday, 1st May 2020) Background Metal additive...

Kshitij answered on May 01 2021
147 Votes
Connecting rod in jet
Student name
Student ID
Abstract
In the rest report study have been made on the function of the connecting rod bearing made up of the metallic, material commonly used for making the rod. The metallic material consists of Ti-6Al-4V, AlSi10Mg, Inconel 718, 316L stainless steel and 17-4PH stainless steel. By making proper and accurate examination of the performance of the various connecting rods like radial journals rods and the rod designers. Using various tools the analysis was conducted and making use of the mobility method which helped the user to provide with accurate and quick solutions for better and efficient results. The bearing of the loaded rod directly depends upon the speed of the shaft. It was being observed from the various examinations and results of the research that the speed of the shaft increases with the same crank angle, it has also been observed that the least clearance has been increased too.
Literature review
According to the author it is of paramount importance for the professionals to understand that the connecting rod in the jet plays a key role in the housing shaft in a different field like diesel, petrol, jet engines, compressors, piston pumps, gears, rolling mills, mechanical presses etc. the performance related to the dynamically connected rod also have a great impact on the industries and firms dealing in engines. From the recent studies two various approaches to various approaches have been approached for the purpose of developing the design of connecting rods and making detailed analysis of the same [1]. On one hand there is the requirement in the industry for an instant and quick method or algorithm by the engineers who are having the desire of an accurate, reliable and quick design of the tool. While on the other hand more interested and involved researchers wanted to explore the phenomena of lubrication in a comprehensive depth by making use of the complicated methods of mathematics, this was desired to resolve the practical problems and issues relating to rod. The theory of lubrication is mathematically complex and complicated technique. As compared to the same the finite element methods was compared to be more reliable, accurate and versatile, but turn out to be very time consuming and requires a professional with high skills and great knowledge level as the same is not accessible by the casual or the normal designers. Therefore, to overcome the issue there is a need for the simple and easy accessible methods which can be effectively operated by the normal engineers and designers to work conveniently and to achieve the best and accurate results for the methods undertaken.
Research problem statement
The connecting rod made up of Inconel 718, 316L stainless steel and 17-4PH stainless steel is considered to be one of the most significant and crucial component of the engine of the jet or engine of any other automobile. A lot of analysis and research wok have been done to mend the functioning and quality of the connecting rod. After all the amendments and improvements yet there are probabilities of optimization in the design, working and efficiency of the connecting rod [3]. The method of optimization that is commonly named as topology optimization is the best available option for the purpose of increasing the strength and to reduce the wright of the same. In addition t this the vibrational level of frequency of the rod was also analysed to evaluate its natural frequency level at various mode shapes. The designing and optimizing of the connecting rod can be done under a load range comprising tensile load, maximum speed of the engine as one of the most important and extreme load, and the various comprehensive load which is corresponding to the peak of the gas pressure just as the several other extreme loads. Further, to increase the efficiency of the rod the old one can be replaced with a new connecting rod....
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