materials and manufacture week 1
TRANSCRIPT
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GRAP1051Semester 1 2014
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Prue OConnor
Week 1 - Subject Intro
Industrial Design EngineeringMaterials, Mechanics, Processes and Principles of Production
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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
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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
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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
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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?
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Prue OConnor
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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.
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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
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Where will you end up?Design Consultancy?
Manufacturing Company?
Sculptor/Artist?
http://www.abc.net.au/acedayjobs/cooljobs/profiles/s2320502.htm
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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
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Example: Chindoguthe Japanese are of creating something useful yet useless at the same time
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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 -
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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
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Materials in history
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Materials production now
4.17 Raw MaterialsWorld Production
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Material Classifications
4.5 Material groupings by
mechanical similarity
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Metals
- Ferrous vs. Non-ferrous
- Alloys
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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
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Ceramics
http://www.youtube.com/watch?v=DIT7UILed1o&feature=share&list=PL2DB5368B17BBA682&index=7 -
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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
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Composites
- Combinations of metals/ceramics/polymers
- Designed to display a combination of the bestcharacteristics of both materials
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Composites
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Material Properties
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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)
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Mechanical Properties
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Mechanical Properties
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Electrical Properties
- Conductivity/Resistance
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Electrical Properties
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Thermal Properties
Thermal Expansion
FlammabilityMelting point
Specific heat
Thermal conductivity
Glassy transition point
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Other Properties
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Material Failure
Fracture
Fatigue
Creep
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Optical Properties
Colour
Glossiness
Transparency
Reflectivity
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Optical Properties
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Acoustic Properties
Resonance
Absorption (insulation)
Pitch
Timbre
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Acoustic Properties
Federation Bells
at Birruang Mar
By Neil McLachlan
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Tactile Properties
Temperature
Texture
Hardness
Stiffness
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Emotional/Cultural Properties
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How do products get into the market?
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Push Example
Pull Example
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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
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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?
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Process Classifications
Throughout the subject we will be using the following
terms (from the text):
Shaping
Joining
Surfacing
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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:
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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:
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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:
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Industrial Design EngineeringMaterials, Mechanics, Processes and Principles of Production
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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