Materials and Manufacturing Process Selection (Brake Disc)

Deliverables.

(1). Component Function and Operating Environment.

(1.a). Review the function (or role) of your chosen component including the context of the larger assembly to which it belongs (8%).

(1.b). Outline the service conditions that are caused by the component’s function and the environment in which it functions which the component will be designed to withstand (e.g., types of stresses, temperatures, service atmospheres etc.) (8%).

(2). Material Properties and Selection

(2.a). Discuss and justify the material property requirements for the component by relating the material property requirements to the service conditions & requirements identified in your answer to section 1b (12%).

(2.b.). Identify the material or materials used to make the components on the physical model (ignore any small brackets, bolts and other small components attached to the component). Using the identified material properties from question 2a, perform a material selection analysis (using CES software) to justify the material used on the physical model. Use relevant performance indices to aid you CES selection. Hence justify the material used on the model (12%).

(3). Component Manufacturing Route

(3a). Manufacturing route selection: Discuss several potential suitable manufacturing routes for your component in the selected material. Perform a CES process selection exercise relevant to your component and your selected material and in order to downselect and justify a final process route (10%).

(3.b). Review & explain the selected manufacturing route in detail (10%).

(4). Alternative Materials and Manufacturing Routes

(4.a). List alternative materials that are also used to make the component you have selected. For each material make reference to your CES analysis from Section 2b and compare properties (both materials & physical). Select what you believe to be the “best” alternative material and explain why it is the best alternative (10%).

(4.b). Describe the main differences between the component on the physical model and the same component made from your best alternative material in terms of: its structure, the means of joining the component to the rest of the vehicle, the manufacturing routes required to make it (10%).

(other). Report structure presentation, referencing & technical writing style, adherence to the requirements contained in this document (20%).