Materials & Processes Selection Assignment

Swinburne University of Technology

HES1230: HES1230-Feb13 Materials and Processes

Team members:

• Adrian Tan Dai Shenq • Jerome Chin Joon Lung• Moaz Ahmed• Muhammad Jayyad

Overview

• Goals and Objectives• Prospective of selected materials• Comparison of prospective material – frame• Comparison of prospective material – rims• Processing Techniques and Sustainability

Goals and Objectives

• To study the different properties of materials– Example: density, strength, elastic modulus, resistance and etc.

• To conduct material selection– Select the most suitable materials to make the bicycle’s frame

and rims.– Racing bike (4,000MYR – 8,000MYR)

Prospective of selected materials (Part 1)

Aluminum alloysPredominantly silver colour

Good tensile strength & low density

Protective layer

Easy to recycle

Carbon fiber reinforced polymersMetallic-grey colour

High tensile strength & light weight

Expensive

Not really environmental friendly

Prospective of selected materials (Part 2)

Magnesium alloysPredominant metal with silver colour

Good tensile strength & extremely low density

Protective layer

Easy to recycle

Stainless steelChromium content

High tensile stress and density

Forms oxide layer

Environmental friendly

Prospective of selected materials (Part 3)

Titanium alloysMetallic-white colour metal

High tensile strength & light

Outstanding corrosion resistance

Consumes a lot of energy in production

Application of frame and rims

Frame• Supports the seat and the whole bicycle• Gives it a definite shape• Hold the different parts of the bicycle in one place

Rims• Hold the tires together

COMPARISON OF PROSPECTIVE MATERIAL – FRAME

Jerome

Requirement of materials properties -Bicycle’s frame

Low density High strength Intermediate elastic Modulus High resistance to corrosion High fracture toughness & fatigue limit Sustainable

Frame- General Properties

Frame - Mechanical Properties

Materials Young’s Modulus

Process Yield Strength

Tensile Strength

Percent Elongation

(GPa) (MPa) (MPa) %

Magnesium alloy

45 Rolled 220 290 15.0

Extruded 200 262 15.0

Stainless alloy

193 Annealed 205 515 40.0

Cold Worked

515 860 10.0

Carbon Fibre Reinforced Polymer (CFRP)

181 - - 1500 1.5

Frame – Fatigue Limit & Fracture toughness

Frame - Corrosion Resistance

Materials chosen for bicycle’s frames – Carbon fiber reinforced polymer

Advantages Low density High tensile strength

Young’s Modulus and corrosion resistance

Intermediate fracture toughness, and fatigue limit

Disadvantages• High cost• Low ductility

COMPARISON OF PROSPECTIVE MATERIAL – RIMS

Moaz

Requirement of materials properties -Bicycle’s Rims

Low density High strength Intermediate elastic Modulus High resistance to corrosion High fracture toughness & fatigue limit Sustainable

Rims- General Properties

Rims - Mechanical Properties

Rims - Fatigue Limit & Fracture toughness

Rims - Corrosion Resistance

Materials Sea water Organic solvents Strong acids

Aluminium alloy

Excellent Good Acceptable

Titanium alloy

Excellent Excellent Excellent

Stainless steel

Good Good Poor

Materials chosen for bicycle’s rims – Aluminium alloys

• Advantages

a) Lightb) Cheapc) Resistant to corrosiond) Moderate stiffness

• Disadvantages

a) Low strengthb) Low toughnessc) Low fatigue limit

PROCESSING TECHNIQUES AND SUSTAINABILITY

Mohammad Jayyad

Carbon Fiber Reinforced Polymer Processing Techniques

• Molding (Layering Process) • Sheets are cut and wrapped around latex balloons

(bladder)• Placed in molds and inflated by pressurized gas and

turns the fibers in a mold shape.

Carbon Fiber Reinforced Polymer Processing Techniques

• After extraction and refining, the parts are joined by applying strong aerospace adhesives

• The frame is left in oven to harden the adhesives• Polishing

Carbon Fiber Reinforced Polymer Sustainability

• Non-Renewable since it is made of carbon • 60% Recyclable • 40MJ/kg (Raw Materials Production)• 247MJ/kg (Processing& Assembly)

Carbon Fiber Reinforced Polymer Sustainability • 287 MJ/kg (Total energy)• Produces 3.1kg/kg of CO2

• 24.6MJ/kg energy consumed (recycle) & no CO2

• 3.4kg of CO2 are emitted for each kilogram of CFRP being incinerated

Aluminum Alloy Processing Techniques (1)

• 1st stage

- hot caustic soda mixed with bauxite

- dissolves aluminum oxide- impurities filtered- caustic solution is cooled to crystalize the aluminum oxide

Aluminum Alloy Processing Techniques (2)

• 2nd stage (Smelting)

- molten salt bath dissolves aluminum oxide

- aluminum & oxygen produced by passing current

- molten aluminum drawn off and made into ingots- casted & rolled into sheets

Aluminum Alloy Processing Techniques (3)

- cut and undergoes low temperature annealing heat treatment

- joined by welding and formed into rings- Shot peening & carburizing to suppress surface cracks - Polished and ready for sale

Aluminum Alloy Sustainability

• Non- biodegradable• Recycled easily• Low energy required for refining (5%)• Problems during recycling include separation and

contamination• 12.2kg/kg of carbon dioxide emitted• Global warming• 194.4MJ of energy consumed

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Edition: SI Version, Jan 10, John Wiley & Sons (Asia) Pte Ltd, Asia.• Ashby, MF 2010, MATERIALS SELECTION IN MECHANICAL DESIGN 2nd Edition, Oct 5,

Department of Engineering, Cambridge University, England,Butterworth, Heinemann.• ‘Aluminium Manufacturing and Recycling’ n.d., ASSURRE, p.1, viewed 14 May 2013.• http://www.out.ac.tz/avu/images/Chemistry/10_Industrial%20Chemistry/industrial_readings/

aluminium.pdf• ‘Magnesium Alloy Casting’ n.d., T-Mag CASTING TECHNOLOGY, pp.9-10, viewed 5 May 2013.• http://www.t-magcasting.com/pdf/T-MagOverview.pdf• ‘Materials for sporting goods: golf clubs, bicycles, scooters, shuttlecocks, and other sporting

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• http://go.galegroup.com/ps/i.do?id=GALE%7CA122769479&v=2.1&u=swinburne1&it=r&p=AONE&sw=w

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• BRITISH STAINLESS STEEL ASSOCIATION 2012, ‘Fatigue properties and endurance limits of stainless steels’, viewed 3 May 2013. http://www.bssa.org.uk/topics.php?article=104

• files/PDF/ISSF_Stainless_steel_and_co2.pdf• Cyma 2012, ‘Introduction to Carbon Fibre Reinforced Polymer’, GET ARBON FIBRE, 9 Jan, viewed 10

May 2013.• http://www.getcarbonfibre.com/carbon-fibre-vinyl/introduction-to-carbon-fibre-reinforced-polymer/• Suzuki, T & Takahashi, J 2005, ‘PREDICTION OF ENERGY INTENSITY OF CARBON FIBRE

REINFORCED PLSTICS FOR MASS-PRODUCED PASSENGER CARS’, The Ninth Japan International SAMPE symposium, 29 Nov, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, Tokyo, 113-8656, Japan.

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The EndThank you!