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1 MEE30001 Materials and Manufacturing 2 Final Assessment – 50 marks 1. General requirements 1.1 Study groups can be formed with one of the following categories. i) Category One – the maximum number of members in this category is 2 students and submit a report for one product from the list below. ii) Category Two - the number of members in this category is 3 - 4 students and submit a report for two products from the list below. Failure to comply with this requirement, your report will not be marked. Alternatively, if you do not wish to work in a group, you can work as an individual (Category One) and select a product. 1.2 Individual and/or group will need to select the product from the list below only. You are required to research the materials used for the products that are available commercially. You are to specify the manufacturing of the plastic component as well as the metal component. Basically, method of production of (plastic and metal) components need to be discussed. a) For the plastic component, it is compulsory that you need to include the recycling of the materials after end of life. b) For metal component, you will need to show only one set of calculations indicating the forces and pressures for making a metal part, if the product is made out of several metal parts. c) Finally, to describe the failure of the product (specifically the metal component only) based on the failure mode. You are required to identify at least 3 techniques that could be used to analyse the fracture surface morphology, chemical composition, microstructure, crystal structure, and mechanical properties of the failed components. You MAY need to calculate fatigue stress for some products and determine their fatigue life if the material used is supposed to be 1045 steel, or 2014-T6 Al alloy or red brass or some others. The S-N curves of these materials is available in your lecture notes. You are also required to briefly discuss possible fatigue fracture mechanisms, factors that affect fatigue life, and measures that can be taken to improve fatigue life of the failed product you selected. List of components 1. Spray can – metal can and plastic cover 2. Garden shovel- metal shovel and plastic handle 3. Screw driver – metal rod and plastic holder 4. Frying pan – metal pan and plastic holder 5. Plier – metal plier and plastic holder 2 6. Toilet roll holder – metal can and plastic base 7. Flask – metal container and plastic top 8. Knife – metal blade and plastic holder 9. Gear – metal shaft and plastic gear 10. Bush – metal thread and plastic bush 1.3 Each group (either Category One or Two) should submit a report in digital forms with supporting materials as appropriate to the research project. 1.4 A group project is the collective responsibility of the entire group, and the group should be able to reallocate responsibilities to keep to schedule. 1.5 Group project reports must be submitted with the project cover sheet and members must be satisfied that the work has been correctly submitted. Any penalties for late submission will apply to all group members, not just the person who submitted. 1.6 The length of the report for one product should be at least 3000 words but no more than 3500 words. Likewise for two products (Category Two - apply to group of 3 - 4 students only), the report should be at least 6000 words but no more than 7000 words. Reports must provide sufficient content material to demonstrate that students have fulfilled the assessment criteria for the unit. 2. Document specifications 2.1 In the main body of the report one-and-a-half line-spacing of typescript is required. The suggested font is Times Roman 12 point or its equivalent. Single spacing may be used only for appendices and footnotes. 2.2 The margins on each sheet shall be not less than 30 mm on the left hand side, 20 mm on the right hand side, 30 mm at the top and 20 mm at the bottom. 2.3 The title page shall contain the report title, names of all authors, date of submission. 2.4 Each copy of the report shall include an abstract of between 250-300 words bound into the report. The abstract should indicate the problem investigated, the procedures followed, the general result obtained and the major conclusions reached. The report should contain all the necessary illustrative material or tables. The table of contents should provide a comprehensive guide for readers. Beginning with the first page of Chapter 1, pages should be numbered consecutively using Arabic numerals (eg 1,2,3…). Preceding pages, except the title page, should normally be given lower case Roman numerals (eg I, ii, iii, iv etc.). 3. Submission of reports for examination 3.1 The digital version of the report is to be submitted into the Final Assessment folder in CANVAS by 23 June 2020. Failure to submit your report into digital dropbox by the due date will automatically result in penalty. 3.2 Marks will be awarded based on originality of work and report should display student knowledge, reasoning, ability to demonstrate an understanding of the title chosen. Proper referencing in the report is required. 3.3 Plagiarism of work: Student taking and submitting or presenting the thoughts, writings or other work of someone else as though it is your own work without full and appropriate acknowledgment to the original source(s) will be penalised. This could results in a zero mark awarded for the plagiarised assignment, failed the whole unit or exclusion from the university. 3.4 In the event of the group work, student(s) who is not contributing his/her fair shares of the work in the assignment, i.e, freeloaders will not be tolerated. Freeloading can be problematic in a group work and freeloaders fail to complete their agreed/allocated tasks will result in a different marking scheme instead of a group mark. This will results in individual marks and/or group marks with different weighting depending on the contribution of each individual into the assignment. 3 4 Marking rubrics Criteria Excellent Good Acceptable Unacceptable 10-8 marks 7-5 marks 4-2 marks 1-0 marks Introduction (2%) Clear evidence of knowledge used on the product chosen Evidence of knowledge used on the product chosen Some understanding of the product chosen No evidence of understanding of the product chosen Plastic component (14%) Comprehensive understanding of making of the component, choice of material used and recycling after life Good understanding of making of the component, choice of material used and recycling after life Some understanding of making of the component, choice of material used and recycling after life Limited understanding of making of the component, choice of material used and recycling after life Metal component (14%) Comprehensive understanding of making of the component, choice of material used with design and calculation Good understanding of making of the component, choice of material used with design and calculation Some understanding of making of the component, choice of material used with design and calculation Limited understanding of making of the component, choice of material used with design and calculation Fatigue/Failure mode (14%) Comprehensive understanding of the product failure mode with supporting evidence Good understanding of the product failure mode with supporting evidence Some understanding of the product failure mode with supporting evidence Limited understanding of the product failure mode with supporting evidence Discussion (3%) Detail reflection that identifies and analyses issues in the product Good reflection that identifies and analyses issues in the product Some reflection that identifies and analyses issues in the product Limited reflection that identifies and analyses issues in the product Conclusion (3%) Comprehensive and logical interpretation of the product Evidence of logical interpretation of the product Some understanding in interpretation of the product Limited understanding in interpretation of the product MEE30001 Materials and Manufacturing 2 1. General requirements 2. Document specifications 3. Submission of reports for examination