Engineering Studies Notes
Engineering Studies Notes
Engineering Studies Notes
e(extension m)
L(originallength m)
No units (ratio)
Shear stress
A measure of the internal reaction that occurs in response to an
externally applied load
Stress ( Pa )=
Strain ( )=
P( Load N )
2
A ( Aream )
FOS=
FOS=
Yield stress
max . allowable stress
UTS
max . allowable stress
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Stress/strain diagram
Truss analysis
- Method of joints
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-
Methos of sections
Bending moment
The bending moment is the amount of bending that occurs in a
beam
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beam.
My
I
Where:
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Crack theory
- Crack formation and growth
Cracking begins with micro cracks (crack initiation phase)
Cracking then leads to crack propagation, that phase in which
the crack grows in size under cyclic loading to ultimate part
failure
Crack initiation can be long and develops from repetitive
stresses at stress concentrations
Dependant on material and method of component manufacture
Surface cracks can be detected using visual inspection
techniques such as magnetic particle add dye penetration tests
Sub surface cracks require ultrasonic or radiographic methods to
be detected
- Failure due to cracking
Cracking can occur at stresses below yield stress, known as
fatigue
Fatigue fracture begins as small crack, that grows in size from
repeated stress
As a crack expands, the load carrying cross-section of the
component is reduced, with the result that the stress on this
section is raised
- Repair and/or elimination of failure due to cracking
For metallic materials: welding can repair crack. However doing
this will repair crack but micro structural changes will appear
around the weld and weaken the material, with weld being a
point of stress concentration. Heat treating the material after
welding will avoid this
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Testing of materials
- Compressive testing
Used to determine the compressive strength of materials
Test piece is compressed and load deformation is recorded
- Transverse beam testing
Many materials used are not only in compression or tension at the
same time. They can be exposed to bending stresses
Used to determine bending and shear in materials
Transverse beam testing involves placing a test piece between two
supports and then gradually applying a load
- Concrete testing
The water/cement ratio in concrete effects the workability of the
mix and also the final strength of the concrete
Slump test measures the workability of concrete. Wet concrete is
placed in a mould. When the mould is removed, the amount of
deformation of the shape is measures and is used to describe the
workability of the concrete
Compression test compression testing of concrete is measured
after 28 days. This is done to test the strength of the concrete.
Ceramics
- Structure property relationships, applications
Hard, brittle, chemically inert, electrical/thermal insulation,
durable
Compressive strength
- Glass
Non-crystalline ceramics
3 basic ingredients are: silica, limestone, soda ash
Soda-lime glass: accounts for 90% of glass windows, bottles
etc.
Borosilicate glass: used for ovenware, telescopes
Lead glasses: optical components, radiation shielding
Main properties: transparent, brittle, compressive strength
Properties can be improved by: thermal toughening (air
quenching), chemical toughening, laminating
- Cement
Bonding material
Compressive strength
Low toughness
Easily casted
Excellent workability
Composites
- Timber
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Organic materials
Structure: cellulose tubes bounded together by glue lignin
(wood grain)
Factors affecting strength of timber: loading duration, moisture
content, defects (within grain)
Exposure to chemicals
Concrete (reinforced and pre-stressed)
Concrete is a compound of sand, gravel, cement and water
Reinforced concrete: steel bars imbedded in concrete to add
tensile strength
Pre-stressed: concrete is poured over steel wires or cables that
are placed in tension. After concrete is hardened, tensile stress
on cables is released
Asphalt
Consists of aggregate, bitumen and air voids
Aggregate held together with bituminous binder
Adding small amounts of materials, such as rubber, alter asphalt
properties
Toughness
Durability
Resistance to moisture, heat etc. (weather resistant)
Laminates
Consists of materials that are sandwiched together
Plywood: layers of timber with adhesive
Laminated glass: two layers of glass with PVB polymer in middle
adds strength
Fibre glass: glass fibres bonded with polymer resin
Geotextiles
Woven polymers or ceramic fibres
Used to stabilise road base, geotextile is placed underneath
asphalt prevents potholes
Corrosion
- Corrosive environments
Availability of oxygen to enable reactions to proceed
Temperature
- Dry corrosion, wet corrosion, stress corrosion
Dry corrosion occurs through chemical reactions with gases, at
high temperatures i.e. in furnaces
Wet corrosion occurs when material is in contact with fluid or
moisture
Stress corrosion when a material is subjected to stress (i.e.
cyclic loads) and cracks begin to form. The material will
eventually degrade due to fatigue
Recyclability of materials
- Steel
B.O.F (basic oxygen furnace) 25% recycled steel possible
E.A.F (electric arc furnace) 100% recycled steel possible
- Concrete
Recycled concrete weaker that original product
Usually used as rubble
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Static friction
- Concept of friction and its use in engineering
Friction is the resistance to motion and efficiency
Friction always acts opposite to the direction in which the body
moves
Static friction frictional force present when two bodies are at
rest
Limiting friction - frictional force present when two bodies are at
the point of moving
Dynamic friction frictional force while a body is moving
- Coefficient of friction amount of friction that materials develops
between them ()
FF
Frictin force
=
R N Normal reaction
Normal force
Reaction force
Always perpendicular to supporting surface
Equal to, but opposite direction to weigh force
Balances out forces
Friction force
Force that prevents movement
Force that is exerted between contacting surfaces
Always opposes direction of motion
Increases as applied force increases
Angle of static friction ()
Resultant force (of friction force and normal force) makes
with the normal
The angle that the resultant force makes with the normal
reaction
tan =
Angle of repose
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The angle when the angle of static friction will equal the
inclination of the plane
When the gravitational force down an inclined slope
equals the frictional force, i.e. the system is an equilibrium
Energy, power
Potential energy
Stored energy within an object with the ability to do work
The PE is equal to the work done in lifting a bodys weight
(mg) through a vertical height (h).
PE =mgh
Hydro electricity uses PE
Kinetic energy
Energy a body possess due to its motion
KE = Energy a body possess due to its motion
KE =
1
2
mv2
Work
W=KE or W=Fs or W=Fscos
When a force causes motion
Total work multiple forces acting on a body
Power
The rate at which work is done
P=w/t = Fs/t = Fv
Engineering materials
Testing of materials
Visual testing
Dye penetration
Dye or coloured liquid is placed on the surface of a
component and excess is wiped clean
Any cracks or imperfections on surface of component will be
highlighted by the dye remaining
Fast, simple, inexpensive
Used for small specimens and various materials
Difficult to detect small cracks
UV light is also used to help show up any imperfections
Radiographic examination
X-Rays
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Gamma Rays
Effective when testing thick structures, i.e. steels
Can be used to examine joining methods, i.e. welds
Exposure to radiation can be harmful to humans
Ultrasonic testing
Detects sub-surface defects
A probe transmits high frequency vibrations throughout the
component as it passes over the surface of a component
Any imperfections within the component causes the vibration to
be reflected without travelling to the bottom
Results are displayed on detection machine
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Hardening
Hardening steel depends on carbon content
Heat above 800C
Soak
Quench (cool very quickly) water, oil, brine can be used
Quenching causes stress to build up in steel becomes extremely
hard
Quenching produces martensite hard + brittle material that needs
further treatment to increase toughness
Tempering
Remove internal stresses from material that have been quenched
(martensite)
Retains hardness and replaces brittleness with toughness
Heat steel between 200 - 600C
Soak
Cool in air
Tempered martensite produced
Structure property relationships
Annealed coarse grain structure soft with moderate strength
Normalised fine grain structure higher strength
Hardening stressed grain structure hardness + brittleness
Tempering very fine grain structure toughness + hardness
Structure/property relationship in the material forming processes
Forging
Shaping a metal through use of force
Can be done above recrystallisation temp. (hot forging) or below
(cold forging)
Extrusion
Drop forging technique that uses hydraulic pressure to operate a
hammer that shapes metal
o Dimensional accuracy not good
o Grain flow/direction is major advantage grain flow follows
profile of part, no points of weakness. Contrasting to
machined part where grain flow does not follow profile and
provides points of weakness
Rolling
Metal pressed into shape between rollers
Can be done as hot or cold rolling
Cold rolling
o Compressed grains result in specific directional
properties
o High strength
o Grains in material remain stressed
o Increased harness
Hot rolling
o Unstressed finished product
o Easily performed than cold rolling
o Favourable directional grain flow
Casting
Pour molten metal into a mould to form a specific shape
Good dimensional properties close to finished product
Cheap
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Brass
Alloy of copper and zinc
Corrosion resistance
Cannot spark
Low coefficient of friction
Bronze
Alloy of copper and tin
Excellent corrosion resistance from oxidization
Hard
Brittle
Structure/property relationship
Annealing, strengthening
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Polymers
- Structure/property relationships and applications
Basic structure consists of molecules composed of repeating
atoms of the same element that are joined together by chains.
The basic unit of any polymer is the carbon atom - forms the
backbone of the polymer chain.
Different polymers with different properties can be produced
when replacing the hydrogen atom with another element.
Thermoplastics - covalent bonds (atoms sharing same electrons
and hence fusing them together) form the polymer chains but
only weak secondary bonds between the chains elastic,
malleable
Thermosets - covalent bonds (atoms sharing same electrons and
hence fusing them together) form both the polymer chains and
secondary bonds between the chains rigid, strong, less elastic
Applications thermoplastics - In transportation systems,
thermoplastics are mainly used as interior components
(dashboards, linings etc.)
Applications thermosets - In transportation systems,
thermosets are mainly used as interior components and textiles,
however in some modern transportation systems composite
thermosets (more than 2 substances combined) can be used to
make exterior parts such as body panels. Exterior components of
boats waterproof, rigid, buoyant, hard, tough
- Engineering textiles
Thermosets act as binder for textiles adds tensile and
compressive strength and durability to textile
- Manufacturing processes for polymer component
Injection moulding - plastic is heated from granular form and
melted into resin form and then injected through a die by way of
a ram into a cavity or cast usually thermoplastics
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Engineering electricity/electronics
Power generation/distribution
Power generation
To produce electricity and power, generators are used to convert the mechanical
energy of rotation into electrical energy. In Australia, electricity can be produced
in a number of ways that include:
-
Steam
Takes place in a coal fire power station
This production process includes burning finely crushed coal in a furnace.
The heat generated from this heating process is used boil pure fresh
water, which produces high pressure steam and turns a series of turbines
that are connected to generators.
The steam used to rotate the turbines can reach 540C
Steam pressure turns the generator shaft at up to 50rps (=50hz AC
frequency in domestic power supply)
Advantages: coal is an abundant, relatively cheap and an easily
transportable substance. Production process re-uses the steam (or rather
the water that is boiled)
Disadvantages: mining the coal damages the environment greatly, burning
the coal produces polluting gases (i.e. sulphur dioxide), releases mass
amounts of greenhouse gases which contribute to global warming
Hydro-electric
Involves harnessing the potential energy of dammed water by allowing the
water to run through a water turbine and generator.
Advantages: does not produce atmospheric pollution, renewable energy
source (sources that are naturally replenished)
Disadvantages: expensive production method (i.e. erecting infrastructure),
affects surrounding environment, only possible in particular areas (such as
mountainous regions)
Wind
Involves using the wind to turn large blades which turn turbines connected
to generators.
Advantages: does not produce atmospheric pollution, renewable energy
source (sources that are naturally replenished)
Disadvantages: high initial costs (to erect infrastructure), to produce high
amounts of electricity; a lot of wind turbines are needed, consumes large
amounts of land.
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Nuclear Power
Involves using the heat from a nuclear reaction to drive a steam turbine.
The turbine connects to a generator that is spun, producing electricity.
Advantages: efficient production method, doesnt contribute to global
warming
Disadvantages: produces very harmful by-products to the environment,
nuclear waste disposal is an issue.
Power distribution
From the generation of electricity at a large scale, a number of processes occur
during the distribution to the consumer to provide safe and manageable
amounts. These processes include:
20 kV
supply
(district
transform
er
station)
(Local
transform
er
station)
66 kV
(substatio
n)
Industry
132 kV
Industry
(generat
ing
station)
500 kV
11 kV
(Pole or
undegrou
nd
transform
er
415/24
0 kV
(Consum
er)
AC/DC Circuits
-
AC
AC (alternating current) is where they electrons oscillate back and forth in
the circuit meaning the current direction alternates
The rate of oscillation is called the frequency
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Single phase
-
The distribution of AC in which the power supply varies over time (i.e. at
some instances power is at max and other instances it is at 0)
Has an average output of 50%
Does not produce a consistent power output, instead has power lapses
(when the current is alternating)
Used when loads are most likely heating, and not heavy loads such as
machinery and electric motors etc.
Ideal for residential consumers and not the industry
Common in rural areas
Three phase
Rectification
-
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-
DC electric motor
A DC electric motor works by passing a DC electric current through the
rotor (coils) that produces a magnetic field. When this rotor is placed
within an external magnetic field, the magnetic field from the rotor
interacts with the external magnetic field, causing either a force of
repulsion or a force of attraction on the rotor, causing it to rotate. This
rotation is known as torque. To maintain this torque and produce constant
rotation, a commutator is used to change the current supply into the rotor
after every half turn. This changing current will in turn produce a changing
magnetic field from the rotor and alternate its polarity. This reversed
magnetic field will ultimately change the forces produced due to the field
interactions and cause constant rotation (when this process is repeated).
AC electric motor
An AC electric motor works on the same principle as a DC electric motor,
in that current through the rotor causes rotation when in an external
magnetic field, however in this case an AC electric currant is provided as
oppose to DC. The supply of an AC electric current into the rotor means
that the current will already be alternating, therefore eliminating the need
for a commutator. The input of AC will cause for the current through the
rotor to alternate at 50 times per second and therefore causing the
magnetic field produced by the rotor to alternate also. This changing
current and magnetic field means that constant torque and rotation is
produced.
Induction motor
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