Motivating students about materials in introductory and...

www.grantadesign.com/education/resources

Mike Ashby, 2013

Rémi DOUÉ - Education Manager - Granta Education, Cambridge

Motivating students about

materials in introductory and

advanced courses

Teaching examples in Design,

Science and Sustainability

EPFL 24th Sept. 2013

http://www.grantadesign.com/education/resources/


Mike Ashby, 2013

Provisional agenda

Overview of Granta’s resources

Introducing materials to 1st and 2nd year students in a visual way

Exploring the science behind materials properties

Case-study: simple materials selection project

Case-study: analysing the environmental impact of products or buildings

Simulating properties and performance of materials that your students

create (sandwich panels, composites, etc.)

Comparing “your” materials with existing ones and managing your own

data

Differences Education vs. Research versions



Mike Ashby, 2013

Granta Design

Founded in 1994 by Professor Mike Ashby and Professor David Cebon,

at the Engineering Department of the University of Cambridge

Owned by the founders, Granta employees, the University of Cambridge and ASM

International – the world’s largest professional society for materials engineering



Mike Ashby, 2013

What do we develop?

Supports materials teaching in

engineering, design, processing,

science and sustainability

Many of the world’s leading

companies and research labs

Industry and Research Education


http://www.google.co.uk/url?sa=i&rct=j&q=united+technologies+corporation&source=images&cd=&cad=rja&docid=pcsmeDFl-jlJ7M&tbnid=quwPfkex_V4efM:&ved=0CAUQjRw&url=http://www.mnn.com/money/sustainable-business-practices/stories/united-technologies-and-the-environment&ei=-7AKUfPlCIep4AS1qoHYDA&bvm=bv.41642243,d.d2k&psig=AFQjCNEfMuNNGk4ZYQe2Ww4yzgzpWfgj1g&ust=1359741557745274

http://www.google.co.uk/url?sa=i&rct=j&q=Thales&source=images&cd=&cad=rja&docid=bCcXVXRw7lrgWM&tbnid=e7Pzk-oh9DWXNM:&ved=0CAUQjRw&url=http://utswomeninengineeringandit.blogspot.com/2011/04/thales-site-visit-to-garden-island.html&ei=wLEKUY2nN-So4gT-64Ew&bvm=bv.41642243,d.d2k&psig=AFQjCNGDBfCFBDNgzQ4SFZdiZ_wgzIQQaA&ust=1359741744944019

http://www.google.co.uk/url?sa=i&rct=j&q=Airbus+logo&source=images&cd=&cad=rja&docid=Nnyobsd16ROxdM&tbnid=_Ae-OT4vTxAyAM:&ved=0CAUQjRw&url=http://www.yourlogoresources.com/airbus-logo/&ei=XLIKUf-6DcaY1AWtgoHQBQ&bvm=bv.41642243,d.d2k&psig=AFQjCNE2FjTd6hmvp06zt5vCQjKntUwtnw&ust=1359741908598804


Mike Ashby, 2013

Who uses CES EduPack worldwide?

Over 800 Universities and Colleges



Mike Ashby, 2013

Sharing Good Practices

US Symposium: University of Illinois Urbana Champaign, 20-21 March

International Symposium: University of Cambridge, UK, 10-11 April

Asian Symposium: National University of Singapore, 11-12 December

www.materials-education.com

2014 Materials Education Symposia


http://www.grantadesign.com/images/symposium/2011/corpus_1000.jpg


Mike Ashby, 2013

Approaches to materials teaching

Typically:

- Mechanical engineering

- Civil engineering

- Product design

- Environmental engineering...

Typically:

- Physics,

- Materials science

- Polymer science...

CES EduPack can support either a science-driven or a

design-driven approach of materials teaching.



Mike Ashby, 2013

Links to leading materials textbooks

Eco text

De

sig

n-l

ed

Elementary text Industrial text Advanced text

Callister

Askeland

Sc

ien

ce

-le

d

Budinski Shackelford



Mike Ashby, 2013

What is CES EduPack?

Software

Developed specifically for undergraduate materials related education

across engineering, design and science

Supporting Teaching Resources



Mike Ashby, 2013

200+ Different Resources

Only available to Educators

82 PowerPoint presentations / Lecture units

31 Separate sets of exercises with solutions

363 English language exercises

51 Resources contributed by academics in the

community

Online Teaching Resources

Architecture

Aerospace

Eco Design

Biomedical

Mechanical


Save time creating new courses

or simply updating your existing courses.



Mike Ashby, 2013

CES EduPack 2013 software

Level 1

1st year students: Engineering,

Materials Science, Design

69 materials, 77 processes

Simple user interface

Level 2

2nd - 4th year students of

Engineering and Materials Science

and Design.


Level 3

4th year, masters and

research students.


The

elements

Polymer

engineering

Eco design

Architecture

& civil eng

Aeronautical

engineering

Natural and

biomaterials Energy



Mike Ashby, 2013

Start screen



Mike Ashby, 2013

Other teaching tools

Hybrid Synthesizer Tool

Simulate the properties of composites

and hybrid materials

(sandwich panels, cellular structures and

composites)

Eco-Audit Tool

Introduces the students to key

concepts in sustainable engineering

(quickly calculates the energy and

carbon footprint of products)



Mike Ashby, 2013

For which courses?

Aerospace engineering Architecture Bio-engineering

Materials science General engineering Polymer engineering

Product design Environmental engineering Sustainability assessment



Mike Ashby, 2013

Cross-disciplinary resource

Research

4th year

3rd year

2nd year

1st year

CES EduPack

Engineering

design

Design for the

environment

Mechanical,

Manufacturing

and Bio

Engineering

Materials

science,

Polymer

science

Aerospace,

Sports

science

Product

design,

Industrial

design

Civil

Engineering

and

Structures

Architecture

and the Built

Environment



Mike Ashby, 2013

The

database

Links

Suppliers data-table

References data-table

Organizing information - Materials

Materials data-table

DATA FOR

Metals & alloys

Polymers

Ceramics &

glasses

Hybrids

Processes data-table

DATA FOR

Joining

Shaping

Surface

treatment

Select on

links

Select on

material

properties

Select on

process

properties

Save time accessing comparable and reliable data.



Mike Ashby, 2013

Organizing information: the MATERIALS TREE

Material records

Attributes

Al 6463

Density

Mechanical props.

Thermal props.

Electrical props.

Optical props.

Corrosion props.

Documentation

-- specific

-- general

Al 6060

Density

Mechanical props.

Thermal props.

Electrical props.

Optical props.

Corrosion props.

Documentation

-- specific

-- general

Al 6061

Density

Mechanical props.

Thermal props.

Electrical props.

Optical props.

Corrosion props.

Documentation

-- specific

-- general

Universe


Member

1000

2000

3000

4000

5000

6000

7000

8000

Class

Steels

Cu-alloys

Al-alloys

Ti-alloys

Ni-alloys

Zn-alloys

• Ceramics

& glasses

• Metals

& alloys

• Polymers

& elastomers

• Hybrids

Family



Mike Ashby, 2013

Datasheet for age-hardening Al-alloys

Age-hardening wrought Al-alloys

The high-strength ALUMINUM ALLOYS rely on age-

hardening: a sequence of heat treatment steps that causes

the precipitation of a nano-scale dispersion of intermetallics

that impede dislocation motion and impart strength. This can

be as high as 700 MPa giving them a strength-to-weight

ratio exceeding even that of the strongest steels.

General properties

Density 2.5e3 - 2.9e3 kg/m^3

Price * 1.49 - 1.63 GBP/kg

Mechanical properties

Young's modulus 68 - 80 GPa

Poisson's ratio 0.32 - 0.36

Yield strength 95 - 610 MPa

Tensile strength 180 - 620 MPa

Elongation 1 - 20 % strain

Hardness - Vickers 60 - 160 HV

Fatigue strength 57 - 210 MPa

Fracture toughness 21 - 35 MPa.m^0.5

Thermal properties

Thermal conductivity 118 - 174 W/m.°C

Specific heat 890 - 1.02e3 J/kg.°C

Thermal expansion 22 - 24 µstrain/°C

Typical uses

2000 and 7000 series: aerospace structures.

6000 series: cladding and roofing; medium strength

extrusions, forgings and welded structures.

+ Links to Processes



Mike Ashby, 2013

The

database

Suppliers data-table

References data-table

Links

Organizing information - Processes


DATA FOR

Metals & alloys

Polymers

Ceramics &

glasses

Hybrids


DATA FOR

Joining

Shaping

Surface

treatment



Mike Ashby, 2013

Attributes

Process records

RTM

Material

Shape

Size Range

Min. section

Tolerance

Roughness

Economic batch

Documentation

-- specific

-- general

Blow molding

Material

Shape

Size Range

Min. section

Tolerance

Roughness

Economic batch

Documentation

-- specific

-- general

Injection molding

Material

Shape

Size Range

Min. section

Tolerance

Roughness

Economic batch

Documentation

-- specific

-- general

Member

Compression

Rotation

Injection

RTM

Blow

Organizing information: the PROCESS TREE

Universe


Class

Casting

Deformation

Molding

Composite

Powder

Rapid prototyping

Family

Joining

Shaping

Surfacing



Mike Ashby, 2013

INJECTION MOULDING of thermoplastics is the

equivalent of pressure die casting of metals.

Molten polymer is injected under high pressure

into a cold steel mould. The polymer solidifies

under pressure and the moulding is then ejected.

Datasheet for Injection moulding*

Injection moulding (Thermoplastics)

*Using the CES EduPack Level 2 DB

Economic attributes

Economic batch size 1e+004 - 1e+006

Relative tooling cost high

Relative equipment cost high

Shape

Circular Prism True

Non-circular Prism True

Solid 3-D True

Hollow 3-D True

Physical attributes

Mass range 0.01- 25 kg

Roughness 0.2 - 1.6 µm

Section thickness 0.4 - 6.3 mm

Tolerance 0.1 - 1 mm

Cost modeling

Relative cost index

fxfx

+ Links to Materials

Typical uses. The applications, of great

variety, include: housings, containers, covers,

knobs, tool handles, plumbing fittings, lenses,

etc.

Heater Screw

Granular PolymerMould

Nozzle

Cylinder

No.8-CMYK-5/01



Mike Ashby, 2013

Introduction levels

Ceramics and glasses

Hybrids: composites etc

Metals and alloys

Polymers and elastomers

MaterialUniverse

+

+

+

+

MaterialUniverse

Edu Level 1

Table:

Subset:



Mike Ashby, 2013

Lots of pictures to illustrate

Metals,

alloys

Polymers,

elastomers

Ceramics,

glasses

Hybrids,

composites



Mike Ashby, 2013

Lots of pictures to illustrate

Hybrids,

composites

Polymers,

elastomers

Metals,

alloys

Ceramics,

glasses



Mike Ashby, 2013

Explore the science

Definitions and measurement. Figure 1 shows a typical tensile stress-strain

curve. The initial part is linear (Hooke’s law),

and it is elastic, meaning that the strain is

recoverable – the material returns to its

original shape when the stress is removed.

Stresses above the elastic limit cause

permanent deformation or fracture

………

The origins of moduli. Atoms bond together, some weakly, some strongly. If they

bind strongly enough they form solids; the

stronger the bond, the higher is the melting

point of the solid. Think of the bonds as little

springs (Figure 3). The atoms have an

equilibrium spacing ; a force pulls them apart

a little, to , but when it is released they jump

back to their original spacing.

. ……….

Young’s modulus

Measurement of Young’s modulus

Origins of the modulus

Definitions and measurement. Material subjected to repeated stress cycles

may fail even when the peak stress is well

below the tensile strength, or even below

that for yield. Fatigue data are measured

and presented as curves, where is the

range over which the stress varies and Nf

is the number of cycles to failure………

How do fatigue cracks propagate? Holes, change of section, cracks, and

surface scratches concentrate stress so

that, even when the sample as a whole

remains elastic (the “high-cycle” regime),

local plasticity occurs. The damage this

creates accumulates, finally developing into

a tiny crack. The crack propagates in the

way shown on the left of Figure 2. ……….

Fatigue strength at 107 cycles



Mike Ashby, 2013

Explore the science

Modulus and melting point



Mike Ashby, 2013

Explore the science

Normalised

(ferrite + pearlite)

As-quenched

(martensite)

Steels: Change of microstructure at constant composition



Mike Ashby, 2013

Search function

Much faster

Searches all data-tables

Operators AND, OR, NOT, * …

Ranks the results

Highlights search term in datasheet

Selection by analogy



Mike Ashby, 2013

Selection

Plotting and selection tools

Graph Limit Tree



Mike Ashby, 2013

Selection with a LIMIT STAGE

Young’s modulus GPa

Yield strength MPa

Hardness Vickers

Fracture toughness MPa.m1/2

Mechanical properties Min. Max.

General properties

Thermal properties Min. Max.

Max service temp C

T-conductivity W/m.K

T-expansion 10-6/C

Specific heat J/kg.K

Electrical properties

Eco properties

200

1

10

1600

100

50

70

16

Results

X out of 100 pass

Material 1 2230 113

Material 2 2100 300

Material 3 1950 5.6

etc...

Ranking

Prop 1 Prop 2

Limit



Mike Ashby, 2013

Pro

pert

y

Bar chart

Pro

pert

y 2

Property 1

Bubble chart

Selection with a GRAPH STAGE

Graph

1

Results

X out of 100 pass

Material 1 2230 113

Material 2 2100 300

Material 3 1950 5.6

etc...

Ranking

Prop 1 Prop 2

Selection by analysis



Mike Ashby, 2013

Easily create charts to compare properties

ABS



Mike Ashby, 2013

Using charts to introduce ideas of materials

science

Why the

differences?



Mike Ashby, 2013

Manipulating properties: modulus - density

Crystalline materials:

small “bubbles” –

modulus, density

insensitive to

microstructure

Foams:

Architecture –

cell structure

Composites

:

Architecture –

Components,

lay-up

Chemistry, microstructure and architecture

Polymers &

Elastomers

Chemistry –

controlled cross-

linking and chain

branching



Mike Ashby, 2013

Engaging students with simple projects:

aircraft wing

Stiff

Strong

Tough

Light

Not stiff enough (need bigger E)

Not strong enough (need bigger y )

Not tough enough (need bigger Kic)

Too heavy (need lower )

All OK !



Mike Ashby, 2013

Material selection using interactive charts

Stiff



Mike Ashby, 2013


Light



Mike Ashby, 2013


Stiff &

light

Results

X pass

Material 1 830

Material 2 720

Material 3 705

Material 4 679

etc...

Ranking

Prop 1

and MUCH MORE …



Mike Ashby, 2013

Powerful material selection capability

CE 2/1

and MUCH MORE …

Results X pass

Material 1 830

Material 2 720

Material 3 705

Material 4 679

etc...

Ranking Prop 1

Em

Mass

Wing spar

a light, stiff beam



Mike Ashby, 2013

Trade offs: mass vs. cost for given stiffness

Em

Mass

E

CC mMaterial cost

The light, stiff beam

Exchange

constant

a = 5 $/kg

Exchange

constant

a = 5 $/kg

Exchange

constant

a = 500 $/kg



Mike Ashby, 2013

Adding your own records

Motives: Make new records for material(s)

Allows comparison with rest of CES EduPack DB

Tool-bar

Add record

Eco Audit

Options…. Mechanical properties Min. Max.

General properties Min. Max.

Thermal properties Min. Max.

Name

Young’s modulus GPa

Yield strength MPa

Hardness Vickers

Fracture toughness MPa.m1/2

Density kg/m^3

Price $/kg

My Super Material

2300 2600

25 27

Project idea – Identify the

materials competition



Mike Ashby, 2013

Adding your own records

My Super Material



Mike Ashby, 2013

CES EduPack

Science Notes

Material and

Processes Records

Interactive Material

Selection

Hybrid Synthesizer

Eco-Audit tool

Supporting teaching



Mike Ashby, 2013

Where is CES EduPack now used?

Research

Senior

Junior

Sophomore

Freshman

Architecture

Aerospace

Mechanical

Engineering

Sustainability

Assessment

Eco Design

Energy

Material

Science

Polymer

Science

Manufacturing

Product

Design

Bioengineering

Civil

Engineering



Mike Ashby, 2013

Campus Wide use



Mike Ashby, 2013

En

erg

y (

MJ)

600

400

300

200

100

0

-100

Initial design

600

400

300

200

100

0

-100

Initial and re-design

En

erg

y (

MJ)

Introduce the Environment

Eco-audit tool

Fast, simple assessment of energy

and carbon footprint of products Enter bill of materials



Mike Ashby, 2013

Introduce the Environment

Landfill Combust



Mike Ashby, 2013

Eco-Audit: complementary to a Life cycle

assessment tool (LCA) Typical LCA output

Aluminum cans, per 1000 units • Bauxite 59 kg

• Oil fuels 148 MJ

• Electricity 1572 MJ

• Energy in feedstock 512 MJ

• Water use 1149 kg

• Emissions: CO2 211 kg

• Emissions: CO 0.2 kg

• Emissions: NOx 1.1 kg

• Emissions: SOx 1.8 kg

• Particulates 2.47 kg

• Ozone depletion potential 0.2 X 10-9

• Global warming potential 1.1 X 10-9

• Acidification potential 0.8 X 10-9

• Human toxicity potential 0.3 X 10-9

Roll up into an

“eco-indicator” ?

Full LCA time consuming, expensive, and requires detail –

and is subject to uncertainty

What can a designer do with these numbers?

Resource

consumption

Emissions

inventory

Impact

assessment

Unworkable as a design tool

ISO 14040 series



Mike Ashby, 2013

Analysing the design process

Life cycle

assessment

Material needs

Data for material family

(metals, ceramics, polymers..)

Data for material class

(Steel, Al-alloy, Ni-alloy…..)

Data for single material

(Al-2040, Al-6061, Al-7075…..)

Product specification

Concept

Embodiment

Detail

Market need

Problem statement

Production Use Disposal

Eco – audit

ability



Mike Ashby, 2013

The CES Eco-audit tool

User interface

Bill of materials

Shaping process

Transport needs

Duty cycle

End of life choice

User inputs

Eco database

Embodied energies

Process energies

CO2 footprints

Unit transport energies

Recycling / combustion

Data from CES

Eco Audit

model

Tabular data

Summary sheet

Detailed breakdown

Life phase energies

Life carbon footprints

etc

En

erg

y (

MJ

)



Mike Ashby, 2013

Strategy for material selection

Material

Manufacture

Transport

Use

Disposal

Assess energy / CO2

over life

Energ

y

1. Eco audit

Minimize:

• mass

• thermal loss

• electrical loss

Use Disposal

Select:

• non-toxic

materials

• recyclable

materials

Minimize:

• process energy

• CO2/kg

Manufacture

2. Design

Material

Minimize:

• material in part

• embodied energy

• CO2 / kg

Minimize:

• distance moved

• energy mode of

transport

Transport

Two tools



Mike Ashby, 2013

Bottled water (100 units)

Fossil to electric 0.12 kW 2 days 24 hrs/day

Use - refrigeration

1 litre PET bottle with PP cap

Blow molded

Filled in France, transported 550 km to UK

Refrigerated for 2 days, then drunk

Number Name Material Process Mass (kg) End of life

100 Bottles PET Molding 0.04 Recycle

100 Caps Polyprop Molding 0.001 Recycle

100 Water 1.0

Transport

14 tonne truck Stage 1 550 km



Mike Ashby, 2013

Energy, with recycling Carbon, with recycling

Energy, with combustion Carbon, with combustion

Outputs of Eco audit tool: explore ‘what if’ scenarios



Mike Ashby, 2013

Fast

Eco Audit

Industry-like projects and methodology

The steps

Analyse

results, identify

priorities

Use CES to

select new Materials

and/or Processes

Recommend

actions & assess

potential savings

Explore options

with “What if’s”

Material Manufacture Transport Use

Disposal

400

300

200

100

0

-100

-200

En

erg

y (

MJ) Initial design

Material Manufacture Transport Use

Disposal

400

300

200

100

0

-100

-200

En

erg

y (

MJ)

What if ..

Different material?

CES lets you find lighter or less

energy-intensive materials



Mike Ashby, 2013

Sustainability database

Sustainable Technology

Assessment tool Explore and debate contributions to

sustainable technology

Stakeholders

Fact-finding

Informed debate

Webinar – May 9th 2013

Electric cars

16 million/year by 2020

Materials with source-nation

Processes

Power generation systems

Energy storage systems

Regulation and legislation

Nations: people, governance, human

rights, economy, development

Linked data-tables

Prime objective:

Decarbonise road transport



Mike Ashby, 2013

Simulate properties & performance

Hybrid Synthesizer tool

Create data sheets for hybrid materials

with free choice of components

Foams and lattices

Fiber and particulate composites

Sandwich panels

Multilayers NEW

Controlled thermal expansion NEW

Webinar – later in the year



Mike Ashby, 2013

Interesting

HOLE

Material-property space: E and

Lecture

Unit 5



Mike Ashby, 2013

New Hybrid Material

Lecture

Unit 20



Mike Ashby, 2013

New Hybrid’s Position Within Material

Property Space



Mike Ashby, 2013



Mike Ashby, 2013

Level 3 of the Standard edition

Comprehensive and includes:

2988 bulk material records

(virtually all purchasable structural materials)

230 generic manufacturing processes

The result of over 60 man years work

Universal & comparable properties for bulk materials

Universal - properties are valid for all records

Comparable - All data in the same format (e.g. Hardness)

Complete data

Tried to reduce holes in data to prevent elimination due to lack of data

Estimating techniques used to fill holes (but highlighted)



Mike Ashby, 2013

Level 3 of the Standard edition now includes…

14 Automotive composites – Polyester matrix

– Polyamide matrix

8 Particulates and fibers – fillers (alumina, calcium carbonate ….)

59 Aluminum alloys for automotive panels (2008. 2036, 5182, 6111)

20 Magnesium alloys for automotive (AE44, AM60, AS41)

8 HS Automotive steels (Dual phase / HSLA / Mn-Boron steels)

101 new Materials records -

automotive alloys



Mike Ashby, 2013

Advanced databases



Mike Ashby, 2013

Overview of specialist databases

Design, Mechanical &

Manufacturing The Standard Edition with 3 levels (3798 materials & 230 processes)

Materials science

+ Elements (crystallographic, mechanical, thermal, and

electrical properties of elements across the Periodic Table)

Polymer engineering

+ CAMPUS, IDES (77,000 polymers)

Aerospace

Motor sport

+ MMPDS (Formerly Mil-Handbook-5, US Aerospace approved

alloys) + Mil-Handbook-17 (US Aerospace composites)

Architecture & Civil

engineering + Architecture and Structural sections

Environmental

engineering + Eco Design data (Geo-economic, production, processing, recycling)

Bio Engineering

+ Natural & Bio Materials data (+ new level 3 development database)

Low-carbon Power

+ Low-carbon and fossil fuel power systems



Mike Ashby, 2013

Strong initial introduction to materials and manufacturing processes:

simplicity and visual impact makes levels 1 & 2 easy to integrate with 1st year

teaching. Provides a strong introduction to environmental issues

Benefits of the CES EduPack

Motivation: students like it – can help re-invigorate the teaching of materials

and manufacturing processes to engineering and design students

Immediate integration with many other engineering subjects

Self-teaching enabled when each student has a copy of the software

Strong links with design: good fit with final-year “capstone” design courses,

project work and problem-based learning using levels 2 & 3. Material data can

be exported to CAD and FE programs

Exportable skills: all students leave University with skills in the use of a

professional-level materials selection system



Mike Ashby, 2013

Save time.

Benefits of the CES EduPack



Mike Ashby, 2013

Many universities also use our research and industrial

products for their advanced teaching.

Our main products are:

CES Selector

Datasets

Advanced Teaching & Research



Mike Ashby, 2013

Advanced Teaching & Research



Mike Ashby, 2013

Differences CES EduPack / CES Selector


Motivating students about materials in introductory and...

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