Materials and Manufacture Week 1

8/11/2019 Materials and Manufacture Week 1

1/56

GRAP1051Semester 1 2014

Margaux Hayes

Prue OConnor

Week 1 - Subject Intro

Industrial Design EngineeringMaterials, Mechanics, Processes and Principles of Production


2/56


Margaux Hayes

Prue OConnor


Content

Introduction to Lecturers

Why are we here?

What are we going to teach you?

Semester Outline History of Materials

Material Classifications

Material Properties

How do products get into the market?

Who buys products?

Design Considerations

Process Classifications

Next Week


3/56


Margaux Hayes

Prue OConnor


Margaux Hayes

Product Design Engineering degree from Swinburne

Internship with DEAM, designing tools for keyhole surgery

Now freelancing for both private clients and a product

development consultancy

Set up a community workshop and studios called NORM

Board member for the Brunswick Tool Library

Design, construction and curating of a portable performance

venue called The Tabernacle

Occasional work in wider fields such as construction, sound

and lighting design

Currently working on evacuation equipment, wearable

technology, furniture.

Uses SolidWorks, Adobe Suite


4/56


Margaux Hayes

Prue OConnor


Prue OConnor Product Design Engineering degree from Swinburne with honours

Spent 4thyear in The Netherlands6 months Uni, 6 months work at

Phillips

Graduated and worked for 3 years at Nylex

Worked on Wheelie Bins, Eskys, Water Tanks, Agricultural Tanks etc

Experience with Injection Moulding, Blow Moulding and Rotational

Moulding

Started my own design consultancy in 2005

Worked with many companies on small blow moulded bottles, spas,

medical products, outdoor blinds and awnings, baby bottles,

automotive transport cases, graphic design Experienced with testing to Australian Standards and ISO Quality

Systems

Uses SolidWorks, Photoshop, Illustrator and InDesign


5/56


Margaux Hayes

Prue OConnor


Why are we here?

So you want to be an Industrial Designer?

How do you decide what to design?

How do you decide what to make it from?

How do you decide how to make it?


6/56


Margaux Hayes

Prue OConnor


What are we going to teach you?

How products function and how they are made

How to choose and specify materials and a suitable

manufacturing process How to communicate to engineers, toolmakers,

manufacturers etc (and to some extent sales people

and marketers) in their language

How to express how you want a product to be made

(using presentations, technical drawings and reports)

How to consider and balance the many aspects ofproduct design. Including ethical, social, economic and

environmental concerns, not just the manufacture.


7/56


8/56


Margaux Hayes

Prue OConnor


What is considered good design practice?Good design insists that a product:

Is innovative and functions correctly and efficiently

is intuitive and suits its target market

enhances the users lifestyle

saves time and/or money is manufactured in an environmentally friendly way

or which helps the environment as its primary function

is easily assembled and disassembled using minimal parts

is reliable and durable and thought out to the last detail


9/56


Margaux Hayes

Prue OConnor


Where will you end up?Design Consultancy?

Manufacturing Company?

Sculptor/Artist?

http://www.abc.net.au/acedayjobs/cooljobs/profiles/s2320502.htm


10/56


Margaux Hayes

Prue OConnor


Example: Plastic Chair in Wood

Designed by Maarten Baas

Commissioned by Contrasts Gallery

Made from Elm Wood

2008

Maarten took the

traditional injection

moulded green

plastic patio chair, andredesigned using Elm

Wood and made by

Chinese woodcarvers


11/56


Margaux Hayes

Prue OConnor


Example: Chindoguthe Japanese are of creating something useful yet useless at the same time


12/56


Margaux Hayes

Prue OConnor


We want to teach you:

> Co.Design on Elizabeth Whelan

> Richard Feynman on Challengers o-rings

Imogen Houldsworth
http://www.fastcodesign.com/1672926/watch-a-low-tech-technique-for-making-high-tech-fabricshttp://youtu.be/8qAi_9quzUY


13/56


Margaux Hayes

Prue OConnor


Semester Outlineweek 1 IntroMaterials and Design C4

week 2 Form Follows Material - Materials and Design C6

week 3 Product breakdowns, reverse engineering and project 1

week 4 Polymers

week 5 Metalsweek 6 Ceramics, Glass, Fibres, Natural materials

week 7 Assignment 1 Presentations

week 8 Product Case StudiesMaterials and Design C8

week 9 Shaping Profiles

week 10 Joining Profiles. Assignment 2 Submission

week 11 Surface Profilesweek 12 Overview. Assignment 3 Submission

week 13 No Classes

week 14 Combined Assignment Submission


14/56


Margaux Hayes

Prue OConnor


Materials in history


15/56


Margaux Hayes

Prue OConnor


Materials production now

4.17 Raw MaterialsWorld Production


16/56


Margaux Hayes

Prue OConnor


Material Classifications

4.5 Material groupings by

mechanical similarity


17/56


18/56


Margaux Hayes

Prue OConnor


Metals

- Ferrous vs. Non-ferrous

- Alloys


19/56


Margaux Hayes

Prue OConnor


Ceramics

- Typically a combination of metallic and non-metallic

elements

- Includes clay minerals, cement, glass

- Typically insulative

- Resistant to high temperatures and harsh environments

- Typically very hard but brittle


20/56


Margaux Hayes

Prue OConnor


Ceramics
http://www.youtube.com/watch?v=DIT7UILed1o&feature=share&list=PL2DB5368B17BBA682&index=7


21/56


Margaux Hayes

Prue OConnor


Polymers

- Includes plastic, rubber, etc

- Typically organic compounds: based on carbon, hydrogenand other non-metallic elements

- Large molecular structures

- Low densities

- Can be extremely flexible


22/56


Margaux Hayes

Prue OConnor


Composites

- Combinations of metals/ceramics/polymers

- Designed to display a combination of the bestcharacteristics of both materials


23/56


Margaux Hayes

Prue OConnor


Composites


24/56


Margaux Hayes

Prue OConnor


Material Properties


25/56


Margaux Hayes

Prue OConnor


Mechanical PropertiesCompressive strength Maximum stress a material can withstand before compressive failure (MPa)

Ductility Ability of a material to deform under tensile load (% elongation)

Fatigue limit Maximum stress a material can withstand under repeated loading (MPa)

Fracture toughness Energy absorbed by unit area before the fracture of material (J/m^2)

Hardness Ability to withstand surface indentation (e.g. Brinell hardness number)

Plasticity Ability of a material to undergo irreversible deformations (-)

Poisson's ratio Ratio of lateral strain to axial strain (no units)

Resilience Ability of a material to absorb energy when it is deformed elastically (MPa)

Shear modulus Ratio of shear stress to shear strain (MPa)

Shear strain Change in the angle between two perpendicular lines in a plane

Shear strength Maximum shear stress a material can withstand

Specific modulus Modulus per unit volume (MPa/ m^3)

Specific strength Strength per unit density (Nm/kg)

Specific weight Weight per unit volume (N/m^3)Tensile strength Maximum tensile stress a material can withstand before failure (MPa)

Yield strength The stress at which a material starts to yield (MPa)

Young's modulus Ratio of linear stress to linear strain (MPa)

Coefficient of friction (also depends on surface finish)


26/56


Margaux Hayes

Prue OConnor


Mechanical Properties


27/56


Margaux Hayes

Prue OConnor


Mechanical Properties


28/56


Margaux Hayes

Prue OConnor



29/56


Margaux Hayes

Prue OConnor


Electrical Properties

- Conductivity/Resistance


30/56


Margaux Hayes

Prue OConnor


Electrical Properties


31/56


Margaux Hayes

Prue OConnor


Thermal Properties

Thermal Expansion

FlammabilityMelting point

Specific heat

Thermal conductivity

Glassy transition point


32/56


Margaux Hayes

Prue OConnor



33/56


Margaux Hayes

Prue OConnor


Other Properties


34/56


Margaux Hayes

Prue OConnor


Material Failure

Fracture

Fatigue

Creep


35/56


Margaux Hayes

Prue OConnor


Optical Properties

Colour

Glossiness

Transparency

Reflectivity


36/56


Margaux Hayes

Prue OConnor


Optical Properties


37/56


Margaux Hayes

Prue OConnor


Acoustic Properties

Resonance

Absorption (insulation)

Pitch

Timbre


38/56


Margaux Hayes

Prue OConnor


Acoustic Properties

Federation Bells

at Birruang Mar

By Neil McLachlan


39/56


Margaux Hayes

Prue OConnor


Tactile Properties

Temperature

Texture

Hardness

Stiffness


40/56


Margaux Hayes

Prue OConnor



41/56


42/56


Margaux Hayes

Prue OConnor


Emotional/Cultural Properties


43/56


Margaux Hayes

Prue OConnor


How do products get into the market?


44/56


Margaux Hayes

Prue OConnor


Push Example

Pull Example


45/56


Margaux Hayes

Prue OConnor


Who buys the products? Who is your target market? They are the ones who should be!

Your target market, audience, client, whatever you want to call them is who your are

primarily designing for

The more precise you are in defining a target the more suitable your product will be

However, in direct contrast to this, if you are too specific, you are also limiting yourability to sell to a wider audience

Consider the following to help define your target market:

Category: Example:

Age 20-50 years old

Gender male

Location Australia (metro areas)

Socio-economic status high $100k+Occupation lawyer, doctor, engineer

Personality conservative

Marital Status single

Lifestyle eats out, likes to play sport


46/56


47/56


Margaux Hayes

Prue OConnor


What do we think of before starting product design?

What mustwe consider when designing?

What is essential to make the product successful?

How do we balance all the requirements?

How do we decide between what are critical features/functions

and desirable ones?

Who is involved in the process?


48/56


Margaux Hayes

Prue OConnor



49/56


Margaux Hayes

Prue OConnor



50/56


Margaux Hayes

Prue OConnor



51/56


Margaux Hayes

Prue OConnor


Process Classifications

Throughout the subject we will be using the following

terms (from the text):

Shaping

Joining

Surfacing


52/56


Margaux Hayes

Prue OConnor


ShapingShaping processes give form to materials(Ashby, M & Johnson, 2nded 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

Different types of manufacturing processes are used to create the form required,

and different materials can use the same process.

Deciding on which process to use can depend on cost, volume, size and tolerancerequired

The following processes, or Shaping methods will be covered during this subject:


53/56


Margaux Hayes

Prue OConnor


JoiningThe manufacture of a product involves many steps, one of which

is that of assembly(Ashby, M & Johnson, 2nded 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

How can we join two parts together? How can we join many parts together?

Joining similar materials and joining dissimilar materials

Considerations for disassembly

The following processes, or Joining methods will be covered during this subject:


54/56


Margaux Hayes

Prue OConnor


SurfacingAlmost every component of a product has some sort of surface

process applied to it(Ashby, M & Johnson, 2nded 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

Coating a surface can enhance a products thermal, fatigue, friction, wear, corrosion

or aesthetic properties

Material choice is critical to surfacing success

The following processes, or Surfacing methods will be covered during this subject:


55/56


Margaux Hayes

Prue OConnor


Industrial Design EngineeringMaterials, Mechanics, Processes and Principles of Production


56/56


Margaux Hayes


Next WeekHomework Read chapter 4 to reinforce todays lecture

Read chapter 6 in preparation for next week

Organise yourself in groups of 2/3 before next week

Document 5 examples in your environment whereengineering sits behind design

Bring to Class Phone or tablet camera

Further Reading Everyday Engineering IDEO book at RMIT Library

Materials and Manufacture Week 1

Documents

Transcript of Materials and Manufacture Week 1