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Composite Materials MSc Course 2010/11

GROUP DESIGN PROJECT

Procedure

1. The design project will be carried out by groups of five students (see final page), with thestudents preallocated to a particular Group. The Group members have been chosen to give, asfar as possible, a balance of background and experience.

2. The project will be supervised by Dr Greenhalgh, but to ensure the students get real worldguidance, they will be able to draw on the expertise of an industrial consultant (AlphaComposites; http://www.alphacomposites.co.uk/). Alpha Composites Ltd is a multi-award winningcompany which specialises in the design and manufacture of carbon composite components forglobal defence and aerospace industries. Alpha Composites will be available during twosurgeries over the period of the project, allowing the students to draw on practical design andmanufacturing experience, not to mention the financial implications of the particular processeschosen.

3. The project will be discussed at a meeting of the whole class on Tuesday 17th January.Following this meeting, each group must elect a leader (Project Manager) to act as spokespersonand convener. Then, each member of the Group will have to be assigned two roles (Consultant

and Champion), as detailed below.

4. Consultant;each Group must nominate one person with overall responsibility for each particulartechnical area (e.g., production, material properties, stress analysis, joining, deployment).

5. Champion; in addition, each member of the Group will lead the design of one component on thebridge (i.e. each student must be personally responsible for the design of a particular item(s) fromthe overall bridge structure). The design of these particular item(s) must include choice ofmaterial, fabrication method, stress analysis, and costing. Therefore, each student is ultimatelyresponsible for all design aspects of their own item(s), although they can take advice from theConsultantwithin the group for any particular aspect. However, the Consultantcan advise butshouldnt do it all.

6. On Tuesday 24th January each group must submit, in writing, a short Outline SummaryontoBlackboard. This will include the scenario of the design specification, Consultingresponsibilities,Championresponsibilities, milestones and deadlines (with a Gantt chart). This document will notbe marked, but will form the basis of the future discussions with Alpha Composites and thesupervisors.

7. On Friday 10th February and Thursday 8th March AlphaComposites will hold surgeries, witheach Group having been allocated 30 minutes to discuss their designs and address anyquestions they may have.

8. During the duration of the project, four academics will be available to field technical questionsabout the designs; Dr Robinson, Dr Palacios, Dr Santer and Dr Taggarielli. However, it issuggested that you Email them to organise a time rather than turning up with ad-hoc queries.

8. On Thursday 23rd February there will be a mid-term review of each project, in which eachGroup will have to give a 30 minute presentation of their progress to date. This will start with apresentation by the Project Manager, and then presentations from each member of the Groupdescribing their progress to date. Copies of the slides will need to be submitted on Blackboard bythe end of that day and these presentations will be marked. Please ensure that each individualslide is labelled with the author.

9. On Thursday 20th March there will be a final presentation of each project, in which each Groupwill have to give a 30 minute presentation of their progress to date. This will start with apresentation by the Project Manager, and then presentations from each member of the Groupdescribing their progress to date. The presentations should, overall, reflect the whole of thedesign process, from concept designs, through material selection, detail design, manufacture,costings and marketing, with all the relevant related issues being addressed at each stage.

Copies of the slides will need to be submitted on Blackboard by the end of that day and thesepresentations will be marked. Please ensure that each individual slide is labelled with the author.

10. The deadline for submitting the report will be the last day of term ( 17:00 on Friday 23rd

March).Each final report must include a one-page Executive Summary, a general section on the

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groups design, plus the details of each individuals consulting and design work. Each individualscontribution must be clearly identified within the report.

11. The (40) marks available for the Design Study will be subdivided along the lines: 10/10/20 (i.e. 10marks for the mid-term review, 10 marks for the final review and 20 marks for the final report. Forthe presentations, the marking will focus on the clarity of the slides (25%), clarity of the oralpresentation (25%), technical content (40%) and ability to answer questions (10%). For thereports, 40% of the marks will be associated with the presentation quality of the report (structure,clarity, grammar, Figures, Tables, etc) and 60% will be associated with the technical content ofthe report (background literature and research, materials selection, stress analysis and sizing,detailed design).

12. Beware of your Project Manager being ill on the day of any of the oral presentations, somebodyelse will be expected to stand in. So, ensure you all know what is going on and are able to makethe overall presentation, if necessary!!

Technical Brief

You will be required to undertake the design of a portable bridge fabricated (95% by weight)from fibre-reinforced plastics. When disassembled the bridge must be transportable in the backof one Transit van. When assembled the bridge must span a gap twice the length of the van,and should be wide enough for the van to drive across it. Two designs are required, the firstpredominately mechanically fastened, the second predominately adhesively bonded.Consideration must also be given as to how the bridge is to be deployed across the gap.

The bridge must be designed such that it must be deployed with access limited to only one sideof the gap.

The internal dimensions of the van are 3.20m long x 1.50m high x 1.7m wide, its overall length5.65m, and its overall width 1.97m.

The vans net payload (the load it can carry) is 1552kg and the weight of the van (including a75kg driver) is 1948kg. Your bridges should be designed to allow the fully laden van to crossover. The van can carry as many people as you wish, but the total weight including payloadshould not exceed 1948kg.

You are not required to meet a specific cost for the bridge, but you should be aware that inreality, it is usually the lowest cost design which is awarded by a customer! Therefore, youshould consider, analyse and justify the costs of your bridge.

It is recommended to formulate a scenario for the bridge, such as a world location in which it willbe situated. This will provide the background for the environment (temperature, humidity, etc)and loading on the bridge.

There will be documents and standards put on Blackboard to provide you with backgroundinformation for undertaking this project. However, you will need undertake further research togenerate information for your bridge designs. Finally, you may find it useful to use the CES 2011

software and database during your material selection for the bridge.

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GROUPS

Group 1 Surname Given Names Subject Group 5 Surname Given Names Subject

1 Boden V inc ent Aeronautic al Engineering 1 Nereau Guillaume Aerospace Engineer ing

2 Rashid Imran Materials 2 Yuan Shilin Materials Science

3 Cullinan Jack Mechanical Engineering 3 Nagel Ulf Mechanical Engineering

4 Router Joshua Charles Automotive Engineering 4 Tang Kunyao Mechanic al Engineering

5 Wu Xun Applied Physics 5 YOON SUNG-HOManufacturing Systems

Design

Group 2 Surname Given Names Subject Group 6 Surname Given Names Subject

1 Dhankhar V ikrant Aeronautical Engineer ing 1 Radhakr ishnan Arjun Aerospace Engineer ing

2 Deu Bhurpoor Materials Science 2 Xie Ningbo Materials Science

3 Ding Siw en Mechanical Engineering 3 Kopula Ragavan Navaneethakrishn Mechanical Engineering

4 Tejada Ulla Sergio Mechanical Engineering 4 Zuber Thomas Mechanical Engineering

5 Oh Seyoung Manufacturing SystemsDesign

5 Wang Lizhe Pow er Engineering ofAircraft

Group 3 Surname Given Names Subject Group 7 Surname Given Names Subject

1 GaiteOliver Anthony

LawrenceAeronautical Engineering 1 Sheludko Oleksiy Aerospace Engineer ing

2 Hu Chen Materials Science 2 Wang Linhuan Materials Science

3 Kataf iasz Tomas Jan Mechanical Engineer ing 3 Hunter Jonathan Mechanical Engineer ing

4 MudannayakeJude Anthony

AnuradhaEngineering 4 Huyghe Nicolas General Engineering

5 Leclerc-Chalvet Arthur Physics 5 Pignatti Luca Engineering Materials

Group 4 Surname Given Names Subject Group 8 Surname Given Names Subject

1 Gopal Jithin Aerospace Engineering 1 Smith Stephen Aerospace Engineering

2 Tan Bo Materials Science 2 Tympel Peter Oliver Mater ials Science

3 Drouet Marc Christophe Mechanical Engineering 3 Giacalone Amorelli Guglielmo Enrico Mechanical Engineering

4 Avgoulas Evangelos-Ioannis Naval Architecture 4 Wang Fan Civil Engineering

5 Maduppully Shinoy Plastics 5 Xie Weitong Polymers Technology