The document discusses selecting eco-friendly materials for bicycle handlebars. It analyzes carbon fiber, bamboo, titanium, stainless steel, and aluminum based on their environmental impact, physical properties, and manufacturability. Mathematical equations are used to determine the optimal thickness for each material to withstand the same bending moments as the original aluminum design. Analysis with the Eco Material Adviser tool shows titanium has the lowest embodied energy and carbon footprint despite its higher strength, allowing for a thinner-walled design using less material. In conclusion, titanium is identified as the most suitable eco-friendly material for the bicycle handlebars.
This presentation is for mechanical engineering/ civil engineering students to help them understand the different type of destructive mechanical testing of materials. The tensile testing, hardness, impact test procedures are explained in detail.
There are over 100,000 engineering materials to choose from. The typical design engineer should have ready access to information on 30 to 60 materials, depending on the range of applications he or she deals with.
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
This presentation is for mechanical engineering/ civil engineering students to help them understand the different type of destructive mechanical testing of materials. The tensile testing, hardness, impact test procedures are explained in detail.
There are over 100,000 engineering materials to choose from. The typical design engineer should have ready access to information on 30 to 60 materials, depending on the range of applications he or she deals with.
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
Engineering Materials are classified as metals , non metals.
metals are further classified as ferrous and non ferrous alloys. Nonmetals are classified as ceramics and plastics. Classification of advanced materials like composites are also discussed
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
WHAT IS PLASTIC?
A synthetic material made from a wide range of organic polymers such as polyethylene, PVC, nylon, etc., that can be molded into shape while soft, and then set into a rigid or slightly elastic form.
This Presentation gives the information of Manufacturing process-1 of Mechanical Engineering course as per VTU Syllabus. Please write to me at: hareeshang@gmail.com for suggestions and criticisms.
Disclaimer:
Contents are taken from several text books and compiled for academic purposes only. Author doesn't hold the copyright for the contents used in this presentation.
Product Development & Design for Additive Manufacturing (DfAM)Katie Marzocchi
Product Development & DfAM in the Dawn of Digital Transformation
Empire Group provides a glimpse into the future of product development and how an understanding of DfAM is critical to the success of PD professionals and manufacturers alike. You’ll learn some of the basic fundamentals of DfAM and see real-world design examples and optimizations from Empire Group’s Design & Engineering team.
Website: www.empiregroupusa.com
Phone: 508-222-3003
email: info@empirepd.com
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
Engineering Materials are classified as metals , non metals.
metals are further classified as ferrous and non ferrous alloys. Nonmetals are classified as ceramics and plastics. Classification of advanced materials like composites are also discussed
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
WHAT IS PLASTIC?
A synthetic material made from a wide range of organic polymers such as polyethylene, PVC, nylon, etc., that can be molded into shape while soft, and then set into a rigid or slightly elastic form.
This Presentation gives the information of Manufacturing process-1 of Mechanical Engineering course as per VTU Syllabus. Please write to me at: hareeshang@gmail.com for suggestions and criticisms.
Disclaimer:
Contents are taken from several text books and compiled for academic purposes only. Author doesn't hold the copyright for the contents used in this presentation.
Product Development & Design for Additive Manufacturing (DfAM)Katie Marzocchi
Product Development & DfAM in the Dawn of Digital Transformation
Empire Group provides a glimpse into the future of product development and how an understanding of DfAM is critical to the success of PD professionals and manufacturers alike. You’ll learn some of the basic fundamentals of DfAM and see real-world design examples and optimizations from Empire Group’s Design & Engineering team.
Website: www.empiregroupusa.com
Phone: 508-222-3003
email: info@empirepd.com
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
Radial Fatigue Analysis of An Alloy WheelIJERA Editor
Importance of wheel in the automobile is obvious. The vehicle (car) may be towed without the engine but at the same time even that is also not possible without the wheels, the wheels along the tyre has to carry the vehicle load, provide cushioning effect and cope with the steering control. The main requirements of an automobile wheel are; it must be strong enough to perform the above functions. It should be balanced both statically as well as dynamically. It should be lightest possible so that the unsprung weight is least. The Wheel has to pass three types of tests before going into production, they are Cornering fatigue test, Radial fatigue test and Impact test. In this thesis radial fatigue analysis is done to find the number of cycles at which the wheel is going to fail. The 2D of the wheel was created in MDT, the drafting package and the same was exported to ANSYS, the finite element package using IGES translator where the 3D model of the wheel is created. The wheel is meshed using SOLID 45 element. A load of 2500N was applied on the hub area of the wheel and a pressure of 0.207N/mm2 is applied on the outer surface of the rim. The pitch circle holes are constrained in all degrees of freedom. The analysis is carried under these constraints and the results are taken to carryout for further analysis i.e. fatigue module to find the life of the wheel.
Car door is one of the main parts which are used as protection for passengers from side
collisions. Presently steel is used for car doors construction. The aim of the project is to analyze the car
door with presently used material steel and replacing with composite materials like Aluminum, Carbon
Epoxy, S-glass epoxy, E-Glass epoxy. Impact analysis is conducted on door for different speeds by
varying the materials. Best of the result we will consider for the door design. Also we are going to reduce
weight of the door by using composite materials replacing with steel. By this we have to reduce the
damage percentage of the car and passenger protection. In this project, the Car door is modeled using
parametric modeling software Pro/Engineer. Pro/ENGINEER is the standard in 3D product design,
featuring industry-leading productivity tools that promote best practices in design. We have to variety the
materials of the car door and speed to impacting of door.
In this research work, suitable lightweight material is found for chassis frame by analyzing chassis with different
materials like structural steel, aluminum alloy and Epoxy E-Glass UD composite materials. The selected material should have the
sufficient strength to carry the load coming on to the chassis when it is supporting the vehicle. With reduction in the weight of the
chassis, reduces the overall weight of the vehicle, which leads to the reduction in fuel. Thus, the usage of lightweight materials in
manufacturing of chassis frame has the advantages. The materials used should help in reducing the weight of the vehicle while
maintaining the necessary strength for supporting the expected load acting on the frame under various operating conditions.
ANSYS finite element software is used to analyze the performance of the chassis with different materials. The 3D model of the
chassis frame is developed by SOLIDWORKS software and numerical analysis is carried out by ANSYS. The model of the ladder
frame is developed using generic specifications. The FEM analysis was done on chassis frame for its deformation and stresses by
applying maximum load. The von-misses stresses, strain and deformations of the chassis with structural steel, aluminum alloy and
composite materials are compared. Composite materials are observed to be better with less weight with similar performance. It is
found that composite (E-glass) is more preferable material for chassis frame.
IGNITE your…. Rapid Manufacture - in the real world.
Presenter – Stuart Offer, Sales Manager for 3T RPD Ltd in Newbury will present
"examples and cases studies from real world applications of rapid manufacturing with world beating clients"
3T RPD are an Additive Manufacturing company specialising in Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). Both technologies are full melting additive layer manufacturing methods used in a vast array of industries.
Automotive design with economy and safety has been a great challenge to design engineers. The safety of the
passengers and vehicle during vehicle crashes can be ensured to a certain limit by using good bumpers. Bumper is an
important part of vehicle which acts as one of the safety part of vehicle, now a day’s bumper is used in vehicle which
directly connected to chassis of vehicle. So that when accidents are happened the force that transfer to other parts of
vehicle through linkage There is no mechanism to drop that linkage and to absorb that impact forces. So that the
development of a new bumper system by springs. Spring is used to minimize the impact of accidents and it will
resists or absorbs impact forces. The new bumper system will be design in CATIA and structural analysis is done by
ANSYS. For structural analysis of the bumper materials like Glass mat thermoplastics (GMT), carbon fiber
composite and aluminum B390 materials are used.
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
Encryption in Microsoft 365 - ExpertsLive Netherlands 2024Albert Hoitingh
In this session I delve into the encryption technology used in Microsoft 365 and Microsoft Purview. Including the concepts of Customer Key and Double Key Encryption.
Le nuove frontiere dell'AI nell'RPA con UiPath Autopilot™UiPathCommunity
In questo evento online gratuito, organizzato dalla Community Italiana di UiPath, potrai esplorare le nuove funzionalità di Autopilot, il tool che integra l'Intelligenza Artificiale nei processi di sviluppo e utilizzo delle Automazioni.
📕 Vedremo insieme alcuni esempi dell'utilizzo di Autopilot in diversi tool della Suite UiPath:
Autopilot per Studio Web
Autopilot per Studio
Autopilot per Apps
Clipboard AI
GenAI applicata alla Document Understanding
👨🏫👨💻 Speakers:
Stefano Negro, UiPath MVPx3, RPA Tech Lead @ BSP Consultant
Flavio Martinelli, UiPath MVP 2023, Technical Account Manager @UiPath
Andrei Tasca, RPA Solutions Team Lead @NTT Data
Observability Concepts EVERY Developer Should Know -- DeveloperWeek Europe.pdfPaige Cruz
Monitoring and observability aren’t traditionally found in software curriculums and many of us cobble this knowledge together from whatever vendor or ecosystem we were first introduced to and whatever is a part of your current company’s observability stack.
While the dev and ops silo continues to crumble….many organizations still relegate monitoring & observability as the purview of ops, infra and SRE teams. This is a mistake - achieving a highly observable system requires collaboration up and down the stack.
I, a former op, would like to extend an invitation to all application developers to join the observability party will share these foundational concepts to build on:
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
zkStudyClub - Reef: Fast Succinct Non-Interactive Zero-Knowledge Regex ProofsAlex Pruden
This paper presents Reef, a system for generating publicly verifiable succinct non-interactive zero-knowledge proofs that a committed document matches or does not match a regular expression. We describe applications such as proving the strength of passwords, the provenance of email despite redactions, the validity of oblivious DNS queries, and the existence of mutations in DNA. Reef supports the Perl Compatible Regular Expression syntax, including wildcards, alternation, ranges, capture groups, Kleene star, negations, and lookarounds. Reef introduces a new type of automata, Skipping Alternating Finite Automata (SAFA), that skips irrelevant parts of a document when producing proofs without undermining soundness, and instantiates SAFA with a lookup argument. Our experimental evaluation confirms that Reef can generate proofs for documents with 32M characters; the proofs are small and cheap to verify (under a second).
Paper: https://eprint.iacr.org/2023/1886
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
The choice of an operating system plays a pivotal role in shaping our computing experience. For decades, Microsoft's Windows has dominated the market, offering a familiar and widely adopted platform for personal and professional use. However, as technological advancements continue to push the boundaries of innovation, alternative operating systems have emerged, challenging the status quo and offering users a fresh perspective on computing.
One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
Accelerate your Kubernetes clusters with Varnish CachingThijs Feryn
A presentation about the usage and availability of Varnish on Kubernetes. This talk explores the capabilities of Varnish caching and shows how to use the Varnish Helm chart to deploy it to Kubernetes.
This presentation was delivered at K8SUG Singapore. See https://feryn.eu/presentations/accelerate-your-kubernetes-clusters-with-varnish-caching-k8sug-singapore-28-2024 for more details.
GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
A tale of scale & speed: How the US Navy is enabling software delivery from l...sonjaschweigert1
Rapid and secure feature delivery is a goal across every application team and every branch of the DoD. The Navy’s DevSecOps platform, Party Barge, has achieved:
- Reduction in onboarding time from 5 weeks to 1 day
- Improved developer experience and productivity through actionable findings and reduction of false positives
- Maintenance of superior security standards and inherent policy enforcement with Authorization to Operate (ATO)
Development teams can ship efficiently and ensure applications are cyber ready for Navy Authorizing Officials (AOs). In this webinar, Sigma Defense and Anchore will give attendees a look behind the scenes and demo secure pipeline automation and security artifacts that speed up application ATO and time to production.
We will cover:
- How to remove silos in DevSecOps
- How to build efficient development pipeline roles and component templates
- How to deliver security artifacts that matter for ATO’s (SBOMs, vulnerability reports, and policy evidence)
- How to streamline operations with automated policy checks on container images
Alt. GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using ...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
This lesson plan can be useful to high school engineering/technology, physics, or environmental science teachers who are teaching sustainability. The lesson revolves around exploring the environmental impacts of different materials (aluminum, stainless steel, and titanium) that could be used for bike handlebars.It is designed to be completed in one to two standard class periods.The Eco-Material Adviser in Inventor is used for comparing different materials.An optional math-heavy engineering section explores how a material property (yield strength) can be used for calculating the thickness required for each material.
Begin a discussion of what “better” might mean in terms of the environment. Ask students which materiasl they think are “better” and why.
Continue the discussion around “better for the environment” for these three materials
Show the “Material Selection: Environmental Properties of Materials” video, which is 3:40 long video:http://www.youtube.com/watch?v=fNwyftI7e5cThe video discusses sustainability of materials -- sources, processing, embodied energy, and health impacts. It also mentions the Eco-Materials Advisor in Inventor, which is the tool that will be used in this lesson.
Discuss what each of these things means in terms of the environment:Carbon Dioxide Impact – global warming is caused by carbon dioxide buildup in the atmosphere, so the more CO2 that is emitted, the worse a material is for the environment.Recyclable – if a material can be turned into another product, it might offset some of its environmental downsidesSustainably Harvested/Extracted – this implies that the rate at which the material is taken from the earth is the same as the rate at which it is replenished. Wood and plants can be a good example.Toxicity – the material itself might not be toxic, but byproducts of manufacturing it might be.
Show the “Material Selection: Physical Properties of Materials” video, which is 3:18 long video: http://www.youtube.com/watch?v=54pQd1Jq4eYThe video discusses life-cycle analysis of materials, and addresses design tradeoffs for materials.
Discuss what each of these things means in terms of bicycle handlebars:Weight – the handlebars, along with the whole bike, shouldn’t be too heavy.Strength – the bike must withstand the forces put upon it during riding.Rust-proof – the handlebars should be able to get wet and not be affected.Manufacturable – if the material isn’t easy to shape, it won’t be easily manufactured.Cost – the cost must match who the bike is for (consumer? professional?)Not brittle – this is a material property that means the handlebars won’t easily break
Embodied energy represents the amount of energy used during the lifetime (i.e. “life cycle”) of the product --including the amount of energy “saved” in future products through recycling the product at the end of its life.The carbon footprint represents the amount of carbon dioxide emitted during the lifetime of the product.These are often two of the most important factors considered in environmental analysis of new products. Calculations of these two factors takes into account the four components shown. Using metal as an example:Extraction – this means digging metal ores out of the ground.Refining/Manufacturing – refining metals means separating them from their ore, and manufacturing usually involves heating up the metal and shaping it.Packaging – any additional materials that house the productsTransportation – getting the ores from the mines, and the metals from the factories.
While embodied energy and other resources required to extract, process, and dispose of materials should be considered, the amount of energy needed to USE a product must also be taken into account.In fact, it might be that most of the environmental impact comes from use, and the other stages become less critical in comparison. This is true of appliances, such as washing machines, that need water and electricity to run.
These two images are taken from the “Environmental Properties of Materials” video.It implies to mine and refine 1 kilogram of steel requires less energy, water, and other resources than 1 kilogram of aluminum. But then much less of those three things is required to recycle the aluminum.NOTE: the aluminum kilogram is shown as bigger than the steel one because steel is more dense than aluminum. Since the mass is 1 kilogram for both, the aluminum has a greater volume (density = mass / volume).
The Eco Material Adviser (EMA) is a tool for determining the environmental impact of material selection. The free version (in Inventor 2012 or later) has around 50 materials that can be assigned to parts and compared.
We will follow the recommended EMA Workflow for students. A downloadable PDF with more detail is available at http://sustainabilityworkshop.autodesk.com/sites/default/files/core-page-files/ema_quickguide.pdfHere is the additional detail from the PDF for each of the points:Establish design requirements and environmental priorities:Understand environmental goals, performancerequirements, and how the product will be usedSet baseline materials and processes: Identify parts to investigate, assign materials and processes, establish a baselineSearch for alternatives:Browse, search, reference material datasheetsWeigh trade-offs of alternative materials and processes:Apply alternate materials, compare results, develop reportsMake and document the material choice:Apply changes, make any resulting design changes, embed data in your model
This is step one of the workflow.Ask students what “design requirements” their handlebars should have. You can write their suggestions on the board, and then compare to the next slide. You can take a general list, and then try to distinguish between whether each suggestion is a “must have” or a “like to have” feature.
Actual handlebars might have different requirements from these, depending on who might buy them (e.g. consumer vs. professional).
This is step two of the workflow.We define the baseline to be handlebars made from a given material (aluminum) and process (forging/rolling), with the dimensions specified.
Engineering/technology teachers may wish to spend some time on what a “process” is, since it will be a choice in the Eco Materials Adviser.For other teachers, the main idea is that embodied energy and carbon footprint are determined in part by the manufacturing process (beyond extraction/refining). The image on the right shows red-hot metal being fed into a processing machine, which is an indicator of the high amount of energy needed to manufacture the metal.NOTE: Handlebars might be extruded, rather than rolled, but extrusion is not an option in the free, limited Eco-Materials Adviser.
“Functional Unit” is a term used in lifecyce analysis. The example used here is for a tire swing that might hang from a tree. Using more, thinner strands of rope can accomplish the same task as a single thicker strand – holding up the tire while someone swings from it. The “functional unit” of the rope is as an tire support that doesn’t break, and all different options must fulfill that requirement.Ask the class what the “functional unit” for bicycle handlebars is. ANSWER: Working handlebars that don’t break.References:http://books.google.com/books?id=Q1VYuV5vc8UC&pg=PA37http://books.google.com/books?id=Mcq-hYQSOwAC&pg=PA92
Another example might be a shopping bag, designed to hold 50 pounds of stuff. Paper bags need more material than plastic, so it’s not so clear which is better for the environment. NOTE: Point out that REUSABLE cotton bags might be better than either paper OR plastic.
This is step threeof the workflow.Alternative materials can be used to make an equivalent “functional unit” to the given aluminum handlebars.
This is an Ashby diagram, named after its inventor, engineer Mike Ashby from the UK. It can be a little intimidating at first. The main idea is that it compares two physical properties of a wide variety of materials. Since there are variations within each type of material, the bubbles show the approximate range of those variables.The three types of materials for this lesson are called out at the top – aluminum alloys, titanium alloys, and steels. They are the tall, skinny red bubbles, set within the larger lighter red bubble for metals.You can ask which of the three is the least desnse, and which can have the highest strength. ANSWER: Aluminum alloys are the least dense, titantium alloys can be the strongest (but note the vertical overlap between bubbles, such that three different metals could all have the same strength).MATH NOTE: This is a log-log plot, which means that the axes go up by a factor of ten, instead of the usual linear scale that students are probably used to.More Ashby charts:http://www.grantadesign.com/download/charts/new_strength_density.pdfhttp://www.rose-hulman.edu/~stienstr/em203/Ashby
Because different materials have different properties, we don’t have to use the same geometry for each one.Some tubes should be thicker, and some should be thinner.
Because different materials have different properties, we don’t have to use the same geometry for each one.Some tubes should be thicker, and some should be thinner.
Engineering/technology and physics teachers: We can “model” the handlebars as a cantilevered beam, which is a well understood engineering structure. This allows us to use the mathematical approximations to calculate the design of the handlebars.The force on the handlebar is from the rider. The moment generated where the beam is cantilevered depends on the force from the rider and the distance of the force from the fixed point, M = r * F.
It is worth pointing out that the cantilevered beam is how we are “modeling” the handlebar. This is another assumption, but a reasonable one given how bike handlebars are used. If the force was pushing in, instead of pushing down, a different model would be required. Learning how to model behaviors is part of learning science and engineering.
It is always good to make any assumptions in the design explicit.
Yield strength is acharacteristic of a material. It is the amount of stress (an engineering term) that the material can take before “bending out of shape.”The yield strengths for our three materials are given, as found in data sheets referenced below. The strongtest material is titanium, the weakest is stainless steel. NOTE: Austinitic is a materials science term that refers to the crystal structure of the material.Aluminum info:http://en.wikipedia.org/wiki/6061_aluminium_alloyDatasheet: http://www.matweb.com/search/DataSheet.aspx?MatGUID=3a2e111b27ef4e5d813bad6044b3f318Stainless Steel info: http://en.wikipedia.org/wiki/Austenitic_stainless_steel Datasheet: http://www.matweb.com/search/DataSheet.aspx?MatGUID=abc4415b0f8b490387e3c922237098daTitanium info: http://cartech.ides.com/datasheet.aspx?i=101&E=269 Datasheet: http://www.matweb.com/search/DataSheet.aspx?MatGUID=a0655d261898456b958e5f825ae85390
Since the strength order is titanium, aluminum, then stainless steel, we should need the least amount of titanium and the most amount of stainless steel to make the same “functional unit” of bike handlebars.
These next few slides are engineering and math heavy. Teachers can choose to skip these slides, or simply skim over them as an example of how engineers think about part design.In order to continue “modeling” our handlebars, we consider what it would take to break them. Another engineering term, the “section modulus,” relates the moment and the yield strength. The section modulus depends on the shape of the part.More info: https://en.wikipedia.org/wiki/Section_modulus
For a hollow tube, the section modulus is the equation given. Regardless of the math, the idea of an Outer Diamter and Inner Diameter is worth pointing out to students.Since the dimensions of the original aluminum tube are given, we can calculate the section modulus for it.
From the section modulus and the yield strength, the moment required for failure can be calculated for the aluminum handlebars.Since we are looking for equivalent functional units, we can assume that this is the same moment that the handlebars from ALL the materials will have to withstand.NOTE: Since we are assuming that the aluminum handlebars were properly designed, we can assume that this is the moment from the bike rider that they were designed to withstand.
This math trick allows the section modulus for different material to be related through their relative yield strengths. That is, the section modulus for stainless steel is 1.19 times greater than the section modulus for aluminum.
The assumption was that all of the materials need to have the same Outer Diameter to fit into the handlebar mount. This is fairly advanced algebra manipulation to calculate the Inner Diameter based on the new section modulus. This is optional to have students do on their own. MATH HINT: To take the fourth root on a scientific calculator, you can raise a number to the 0.25 power.Note that the Inner Diameter for stainless steel, 15.6mm, is smaller than the I.D. for aluminum, 17.8mm. This means that the thickness of the stainless steel will be greater, and fits with the earlier idea that the weaker stainless steel will require more material.
The section modulus for titantium is less than that for aluminum (0.29 times lower), which means the I.D. will be bigger (thinner wall), and less material than aluminum.
This is a summary of the results from the previous few slides. The Inner Diameters will be needed for the Inventor activity. But the main idea is that engineering formulas and math, based on the use of models, allow parts to be designed to meet certain performance requirements.
This is step four of the workflow.Inventor will help identify which materials are better for the environment given the requirements for the functional unit made from different materials.
This Is step five of the workflow – the final step.Stainless Steel is probably the worst choiceAluminum is similar to Titanium, and uses much more water, but is cheaperDoes this match what we know about what handlebars are actually made of?Yes it Does! Most handlebars are made of aluminum, although some are titanium or carbon fiberIn real life there are other considerations that make titanium a less appealing option [additional associated costs make it a much more expensive choice]