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Material Science and Engineering: How Are Carbon Fiber Bikes Made
Material Science and Engineering: How Are Carbon Fiber Bikes Made
Metals Metals
• metals and its alloys
• luster, high thermal conductivity, and high electrical Ceramics Advanced Ceramics
conductivity, ductile
Cost of material
Cost of fabricating
Product lifetime
Environmental
impact
Energy
requirements
Recyclability
Part 1: Properties (cont’)
To help evaluate the properties of engineering materials, a variety of standard tests have been developed .
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Part 1: Properties (cont’)
Physical Mechanical
Density Stress and strain
Melting point
- strength
Optical characteristics (transparency, -stiffness/modulus
opaqueness, color) = stress over strain
Thermal properties (specific heat,
thermal expansion, thermal
conductivity, electrical conductivity,
magnetic properties)
Stress/strain?
When a force or load is applied to
a material, it deforms or distorts
(becomes strained), and internal
reactive forces (stresses) are
transmitted through the solid
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Part 1: Properties - Testing
• mechanical loading of a material specimen or product up to a pre-determined deformation level or up to the
point where the sample fails
• further used to characterize the materials and product
Tensile
Compression
Flexural
Impact
Toughness
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Basic Manufacturing Processes
Rapid
Forming/metalworking
prototyping
Surface treatment
Machining (material removal)
(finishing)
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Process Details Advantage Disadvantage Types
Casting/molding/ Use molten metal to fill cavity materials can be Need follow-up 1. permanent mold
foundry converted from a process like (a mold can be used
Metal retains the desired shape of the mold cavity crude form into a machining repeatedly)
(plastics/composites) after solidification desired shape in a 2. nonpermanent mold
single step
excess or scrap
material can easily
be recycled
Metal Removal of certain selected areas from a part in machine tools are called
cutting/machining/ma order to obtain a desired shape or finish, shapers (and planers),
terial removal producing chips drill presses, lathes, boring
Cutting tools are mounted on in machine tools machines, milling machines,
which provide the required movements of the tool saws, broaches, and grinders
with respect to the work (or vice versa) to
accomplish the process desired
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Joining and The biggest; which includes:
assembly 1. Mechanical fastening 4. Press, shrink,
or snap fittings
2. Soldering and brazing 5. Adhesive
bonding
3. Welding 6. Assembly
processes
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METAL FORMING PROCESSES-
HOT FORMING
Metal Forming
• Metal forming includes a large group of manufacturing processes in which plastic deformation
is used to change the shape of metal workpieces
• Deformation results from the use of a tool, usually called a die in metal forming, which
applies stresses that exceed the yield strength of the metal
• The metal therefore deforms to take shape determined by the geometry of the die
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Metal Forming
Bulk Deformation Sheet-metal working/deformation
•severe deformation and massive shape changes •forming and cutting operations
•mostly done in hot working condition •performed on thin sheets (<6mm), thin strips or coils
•starting work shapes include billets and rectangular •tools include punch and die on machine tools called
bars stamping presses
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Metal Forming – Hot or cold
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Hot Working Processes
• Involves deformation of preheated material at temperatures above the recrystallization
temperature
• At elevated temperatures, metals weaken and become more ductile
• With continual recrystallization, massive deformation takes place without exhausting
materials plasticity
• Hot working processes includes rolling, forging, extrusion, drawing
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Part 1: Rolling
Flow chart for the production of various finished and semifinished steel shapes.
Note the rolling operations. 14
Rolling – Basic Rolling Process
• metal is passed between two rolls that rotate in opposite directions
• because the rolls rotate with a surface velocity that
exceeds the speed of the incoming metal, friction along the contact
interface acts to propel the metal forward
• metal is then squeezed and elongates to compensate for the decrease in
thickness or cross-sectional area
• amount of deformation that can be achieved in a single pass between a
given pair of rolls depends on the friction conditions along the interface
• If too much is demanded, the rolls cannot advance the material and
simply skid over its surface
• too little deformation is taken, the operation will be successful, but the
additional passes required to produce a given part will increase the cost
of production
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Hot Rolling Cold Rolling
Hot rolled metal
cleaned
• Temperature is keep at above recrystallization • Metal is fed into rolls at below recrystallization
temperature. For plain-carbon and low-alloy steels, the temperature
soaking temperature is usually about 2200 F (1200 C) • To provide smooth and bright finish
• To bring it to accurate size
• During the rolling there will be change in its grain • To obtain clean surface
structure, the temperature at recrystallization
temperature will prevent from work hardening
1. Metal is fed into rolls after being heated 1. Metal is fed into rolls after being heated
above recrystallization temperature above recrystallization temperature
2. Coefficient of friction between rolls and 2. Coefficient of friction between rolls and
metal is higher metal is higher
3. Heavy reduction in cross sectional area is 3. Heavy reduction in cross sectional area is
possible possible
4. Close dimensional tolerance cannot be 4. Section dimension can be obtain at close
obtained tolerance
5. Poor surface finish 5. Smooth and oxide-free surface
6. Does not show work hardening effect 6. Shows hardening effect
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Advantage of hot rolling
1. greatly reduce energy consumption and costs
- metal plastic deformation is high during hot rolling, and the deformation resistance is
low, which reduces the energy consumption of metal deformation
3. Hot rolling usually uses large ingots and large reduction rolling, which not only
improves production efficiency, but also creates conditions for increasing rolling
speed and achieving continuous and automated rolling process
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Limitation of hot rolling
1. Delamination
- due to non-metallic inclusions (mainly sulfides and oxides, as well as silicates) inside the steel are
pressed into thin sheets
delamination greatly deteriorates the tensile properties of the steel in the thickness direction
4. The thickness of the hot rolled product is difficult to control and the control precision is relatively poor
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Rolling (cont…)
Shape rolling
The work is deformed by a gradual reduction into a contoured cross section (I-beams, L-
beams, U-channels, rails, round, square bars and rods, etc.).
Ring rolling
Thick-walled ring of small diameter is rolled into a thin-walled ring of larger diameter.
Thread rolling
Threads are formed on cylindrical parts by rolling them between two thread dies.
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Rolling (cont…)
Defects in Rolled Plates and Sheets
1. Wavy edges on sheets – due to roll bending. The strip is
thinner along its edges than its center.
2. Cracks – poor material ductility at the rolling temperature
3. Alligatoring – due to non-uniform deformation during rolling or
defects in the original cast billet.
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Flat rolling
Rolling (cont…)
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Rolling (cont…)
The work is squeezed between two rolls so that it
thickness is reduced by an amount called the draft, d
d = to-tf
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Rolling (cont…)
The inlet and outlet volume rates of material flow must be the
same, that is,
towovo = tfwfvf
where vo and vf are the entering and exiting velocities of the work.
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