CES EduPack Research Articles

Property investigation of functionally graded materials leaf spring plate fabricated through stir casting process by using new gradient evaluation method

AbstractAutomobile and aviation industries require lightweight solutions in the suspension system to improve overall performance and payload capacity. This can be achieved by materials having high strength to weight ratio. Fiber composites, known for their lightweight and high strength, face a major issue of delamination, which shortens the lifespan of fiber‐reinforced polymer leaf springs. Current researchers are emphasizing the use of functionally graded materials as a promising alternative to tackle this problem. In the present work, a functionally graded leaf spring plate was fabricated using stir casting technique with five layered gradations in the mid portion. The amount of molten material required for each gradation was ensured using a novel experimental technique. On the other hand, the matrix and reinforcement have been adopted from the output of the analysis conducted using CES EduPack 2019 software. Low density and high fatigue strength were primary focal point for the consideration of matrix and reinforcement materials. Aluminium 7075 and boron carbide were considered as matrix and reinforcement materials respectively. Stir casting technique, used in the present work, is simple, suitable and cost effective technique which creates a gradation at central part of the leaf.

Cumulative energy demand analysis in the current manufacturing and end-of-life strategies for a polymeric composite at different fibre-matrix combinations

Fibre Reinforced Polymers (FRPs) are finding more applications in different industrial sectors. From a sustainability point of view, a component made of FRPs reduces energy consumption and CO2 emissions during its use-phase due to the material's lightweight nature. However, the production of these materials impacts the global energy demand significantly. To mitigate this impact, circular economy strategies are essential. This study focuses on a Cumulative Energy Demand (CED) analysis for different End-of-Life (EoL) strategies of FRPs components. Three EoL routes were evaluated: i.e., combustion, recycling and reforming of continuous fibres reinforced thermoplastics. Different fibres and matrices and three Fibre Volume Fractions (FVF) were taken into account. Specifically, Glass Fibres, Carbon Fibres, Polypropylene, and Polyether ether ketone were examined while FVF of 11%, 23% and 45% were evaluated. A Life Cycle Inventory data was built combining literature review and CES Edupack database. The results provided some guidelines for optimising the product's EoL phase in terms of CED reduction underlining the advantages and high competitiveness of the reforming strategy especially if high-performance matrices and/or fibres are processed. Recycling results to be a valuable EoL alternative if FRPs made by high-performance fibres and high FVF are employed while combustion is the more advisable option if low-performance matrices and fibres are used.

Analysis of Selection of Alternative Materials Outer Support Solar Water Heater

In producing a product, the Manufacturing Industry always prioritizes safety, quality, and profit. One product that prioritizes these criteria is Outer Support on Solar Water Heaters. Currently, the material used in the outer support of the solar water heater is SS 304, the SS 304 material is considered too expensive, so the profits obtained by the manufacturing industry are very small. In addition, SS304 material from year to year is getting harder and harder to find. In this study, an analysis of the selection of alternative outer support materials for solar water heaters was carried out in order to obtain materials that can fulfill the outer support function at a relatively cheap price, do not reduce the outer support function and are easy to obtain or many on the market. The method used in this study uses the Analytical Hierarchy Process (AHP) and CES edupack software as the process of selecting materials. In this study, several tests of mechanical properties were carried out, namely tensile tests, hardness tests, and corrosion resistance tests to determine the mechanical properties of the material, and simulations of selected materials were carried out using Solidworks software, with the aim of knowing the maximum stress value and safety factor. The results obtained from this study obtained an alternative material, namely AISI 201 for the outer support. The results of the hardness test obtained the best hardness value in AISI 201 of 177.17 VHN. The results of the tensile test obtained a yield strength value of 390.35 MPa on AISI 201 material

NEW WOOD DUST REINFORCED RECYCLED POLYPROPYLENE COMPOSITE FILAMENT AND TRADITIONAL POLYPROPYLENE FILAMENT FOR FDM APPLICATIONS: LIFE CYCLE ASSESSMENT STUDY

Life Cycle Assessment (LCA) is an effective method for determining the environmental impact of a composite material over its lifetime. Consequently, it is important to the composites sector, particularly for Fused Deposition Modelling (FDM) filament manufacturers as a material selection tool when determining the usability of recycled material utilised in component design phases. This article investigates the LCA framework of utilising wood dust as reinforced material and recycled polypropylene material in the production of composite filament for the FDM sector. Eco Audit, a feature of the CES Edupack programme, was utilised to evaluate the LCA from an environmental standpoint for product makers. Using recycled polypropylene containing an increasing weight percentage of wood dust to produce new types of composite filament materials reduces energy consumption (MJ) and lowers the carbon footprint (kg). This is because the quantity of energy required for recycling is far less than that required for initial manufacture. When compared to the new polypropylene material that is used to create filament, this study reveals a 56% and 37% reduction in energy consumption and CO2 emissions, respectively. This is a considerable improvement from an environmental point of view.

Thermal expansion flow analysis in designing a sustainability computer personal unit casing

The material of computer personal unit is commonly used metal based. The problem occurs when waste of electronic device to be recycled. This paper describes the thermal expansion flow in designing a sustainability computer personal unit (CPU) casing based on the material selection technique. In this study, the design concepts were generated to be processed for screening matrix with criteria selection of comfortable, user friendly, ergonomic, flexible, functionality and material. Design concept 4 was selected to be further analyzed. The material selection technique was used in this study using CES Edupack and provide the material of Acrylonitrile butadiene styrene (ABS), Polyetheretherketone (PEEK), and Polyoxymethylene (Acetal, POM) for analysis based on criteria of recycle ability, price, hardness, density, and temperature maximum. The ABS material suits the design requirement toward sustainability computer personal unit. Based on the simulation result, the thermal expansion flow meets the design specification. In addition, the phenomena of heat dissipated from internal CPU shows significant information for design manufacturing to manage and place the electronic parts properly to reduce the risk of overheated and damaged.

Sound Quality Improvement of Dynamic Loudspeaker by Material Selection of Diaphragm

In terms of sound quality, mechanical stability, and cost, the moving coil speaker is exceptional to the moving iron and electrostatic speaker. The diaphragm in the speaker is crucial in reproducing the sound wave from the electrical signal input. The materials of the diaphragm should be both rigid and lightweight. However, there are few quantitative studies on the selection of diaphragm materials. Connecting the equation of mass and the deflection of a circular plate yields a performance index that maximizes Young’s Modulus and minimizes the density. A line graph in logarithmic can be generated from the index to select materials from various categories in the Ashby plot provided by the Granta CES Edupack software. The chosen materials would be simulated in COMSOL and their sound pressure level plots would be analyzed based on the numerical solution. The Ashby plot and the numerical solutions by COMSOL have indicated that paper is the best material among the selected materials with the most stable frequency response in the mid-range frequency range, a high-performance index, and a low price per unit volume.

Evaluation of polymers for upper limb orthosis through computer simulation

Material selection is one of the most relevant and challenging steps in engineering projects. In this study, we focused on selecting polymers with low density and stiffness for upper limb orthoses that help in the recovery of patients who have undergone cerebrovascular accident (CVA). CES EduPack 2011 software was used to compare the density and Young's modulus of different polymers. The merit index aided in the classification of these materials, which were applied to 3D orthosis models for computer simulations in FreeCAD 0.19.4 software. Using the simulation data, a decision matrix was developed using the Pahl & Beitz method to classify polymers according to the weighted property index. The decision matrix using the simulated and merit index data indicated polyethylene terephthalate (PET) and polylactic acid (PLA) as the best polymers for upper limb orthoses. The weighted property index values were 127.34 and 123.19, respectively. It is noteworthy that polyethylene terephthalate glycol (PETG - adaptation of PET) is an alternative to 3D printing filaments, and PLA is one of the main filaments.

Aging of Polyphenylene Sulfide-Glass Composite and Polysulfone in Highly Oxidative and Strong Alkaline Environments

Alkaline water electrolysis becomes increasingly important for the supply of renewable energy, and of raw material for the chemical industry. An attractive choice for the encapsulation of the electrolyte cell is an (advanced) engineering polymer. The objective of this paper is to find a suitable one that can withstand for many years: 30 wt% KOH solution and pure oxygen at a high pressure of 50 bar and at an elevated temperature of 90°C. Using CES EduPack, 12 possible thermoplastic polymers were selected, of which polyphenylene sulfide (PPS) and polysulfone (PSU) were further investigated using accelerated testing. The polymers have been exposed to three KOH concentrations (15, 30 and 45 wt%), two oxygen pressures (pure O2at 5 bar and air with pO2= 20%), and three temperatures (90°C, 120°C, and 170°C). Extensive characterization of the exposed samples has been carried out using various techniques, including weight, tensile, DMA, and creep-recovery measurements, as well as DSC, FTIR, XRD and SEM. After 12 weeks of aging, glass fiber reinforced PPS failed in a strong alkaline solution at high temperatures, due to the dissolution of the glass fibers. The PPS matrix itself and PSU turned out to be resistant to thermo-oxidative and chemical degradation under the conditions tested. Only marginal changes in mechanical, visco-elastic and thermal behavior were observed, which can be ascribed to physical rather than chemical aging. In view of the brittle nature of PPS, it could be concluded that PSU is the most promising candidate for the long-term application in alkaline electrolysis. Extrapolating the data using time-temperature superposition, it is predicted that PSU will retain its integrity and mechanical properties for a period of 20 years of operation.

Sustainable Development Assessment of Zinc Oxide Production focused on Agribusiness

Agribusiness sectors have evolved to a highly diversified level, the fertilizer being their main interest. These products are composed of macronutrients and micro ones essential to life. Zinc is an essential micronutrient, and it is present in fertilizers as zinc oxide. The present work is concerned with assessing, from the sustainable development viewpoint, the entire chain of production and transportation of zinc oxide. It is intended to establish an ecological audit of ZnO by the CES EduPack® software in six different scenarios. The scenario composed only of recycled material for furnace feeding was the one that spent the least energy of all and had the lowest carbon footprint. However, a scenario composed only of pure zinc was the one that spent more energy and had the highest carbon footprint. Transport was the highest consumer of energy and carbon footprint in all scenarios.

Methodology to Evaluate the Embodied Primary Energy and CO2 Production at Each Stage of the Life Cycle of Prefabricated Structural Systems: The Case of the Solar Decathlon Competition

The construction industry is responsible for a high percentage of the energy consumed on the planet and the emission of greenhouse gases, therefore it is considered necessary to rethink many of the processes that this industry carries out in order to reduce its environmental impact. For this, one of the paths could take into account the Life Cycle Assessment of the used materials, for which it is necessary to evaluate this aspect through indicators that allow the qualification and quantification of the weight of these environmental impacts. In this context, this article presents a methodological proposal for the quantitative evaluation of the embodied primary energy and CO2 production at each stage of the life cycle of prefabricated structural systems, taking as case studies eight prototypes from the “Solar Decathlon” competition in its editions of Europe (2014), United States (2015) and Latin America (2015), through a Simplified Life Cycle Analysis, using the Eco Audit tool from CES Edupack. Through this analysis, conclusions are drawn about the optimization of a structural system with lower environmental demand and the possibilities of transferring knowledge from this competition to be applied in innovative systems of new housing models.

Materials Selection for Aircraft Skin Panels by Integrating Multiple Constraints Design with Computational Evaluations

Among the principal load-carrying parts of an aircraft, the center wing box yields the main mechanical load-carrying area and is composed of many structural components and elements such as upper and lower skin panels, internal rods, ribs, stringers, front and rear spars. For the structural analysis of such real complex systems, simplified representations of the same sections would be used alternatively to determine whether components could withstand loadings without experiencing failure, thus stay in the margin of safety. Nevertheless, these components should contribute to weight efficiency while carrying in-plane loads and distribute out-of-plane loads to in-plane members safely. Materials selection plays a crucial role for the determination of such candidate materials along with their material properties in specific structural applications. It is usually performed by considering proper objectives, constraints and free variables with respect to functions of the components of a system. Since Composite Material Handbook (CMH-17), Metallic Materials Properties Development and Standardization (MMPDS), and Preliminary Material Properties Handbook (PMP-HDBK) databases are embedded in the materials selection software (CES Edupack), best candidate materials would be easily identified by using coupling constant(s) such as in multiple-constraints designs. In this study, Ashby’s methodology was applied to determine best candidate materials for constructing skin panels by considering them as bending plates. According to materials selection approach, continuous fiber reinforced epoxy composites was stipulated as one of the best candidate materials. Computational failure analysis was then carried out by referring the proper material properties from the materials selection software.

Engineering Material Selection for Automotive Exhaust Systems Using CES Software

The aim of this report is focused onreviewing the automotive exhaust system with respect to its in-service conditionsand selection of suitablematerials for exhaust manifold, downpipe silencer/ muffler box and tail pipe in an exhaust system. In doing this, the functions of each component were discussed, highlighting how they function as part of a system and CES Edupack software was employed in the material selection process. Mass, cost, high temperature (>800 o C for exhaust manifold and >400 o C for downpipe silencer/ muffler box and tail pipe) and high corrosion resistance were used as criteria for the material selection. Variety of materials including Nickel-based superalloys, stainless steel, Nickel-chromium alloys were obtained in the search result for exhaust manifold. Similarly, low alloy steels, stainless steel, grey cast iron,Nickel-based superalloys, Nickel-chromium alloys were obtained in the search result for downpipe silencer/ muffler box and tail pipe. Nickel-based superalloys and Nickel-chromium alloys possess suitable properties for this application, but were not selected due to their high densities and high cost. Low allow steels were not selected because they tends to exhibits poor corrosion resistance when exposed to salt on the road surface and condensate from the exhaust system. Grey cast iron has low tensile strength and elongation and therefore not exhibit enough toughness required to withstand the severe working conditions. However, stainless steel ( Ferritic stainless steel and Austenitic stainless steel) was selected due to its considerable price, low density, excellent corrosion resistant and acceptable strength at elevated temperatures.

W-11 Motivating Students to Learn about the Science of Materials

In order to innovate rather than just make incremental change to a product, engineers need a deep understanding of the science of materials. Engineering students, therefore, especially those who are not materials specialists, should be given the basic scientific knowledge and vocabulary to equip them to choose and use materials wisely. A connection must be made between the materials properties in which engineers are interested and the underlying science. In this study, a visual approach has been taken. Charts showing how atomic characteristics relate to materials properties have been created using the elements database in CES EduPack, (a world-leading materials teaching resource). Characteristics of the elements in the Periodic table are illustrated and other teaching examples for fundamental subjects are suggested.

Comparison between major repair and replacement options for a bridge deck life cycle assessment: A case study

Material production, manufacturing, transportation, usage, and end of lifeprocessing are usually the main contributors defining the life cycle assessment (LCA). Bridge infrastructure is important to the economy and the society. Over their life cycle, highway bridges experience several stressors that can significantly affect their structural performance and therefore require rehabilitation. This paper discusses the life cycle analysis of bridge rehabilitation decisions and demonstrates the analysis with a case study of a bridge located in Ontario, Canada. The LCA of the bridge deck is analyzed for two rehabilitation strategies: major repair and replacement. The study focuses on evaluating the different life cycle phases of the bridge deck by assessing their carbon dioxide emission, energy consumption and cost. Also, the paper presents the impact of the different elements within each phase to identify the most contributing elements. The LCA of the bridge deck is analyzed and estimated with the aid of CES EduPack 2016 software that includes a database of more than 4000 different materials and more than 200 manufacturing processes. Analysis of the case study shows that material phase causes significant life cycle impact. The study concluded that the deck replacement yields higher environmental impact and life cycle cost compared to repairing and strengthening the deck.

Simulation Aided Life Cycle Sustainability Assessment Framework for Manufacturing Design and Management

Decision making for sustainable manufacturing design and management requires critical considerations due to the complexity and partly conflicting issues of economic, social and environmental factors. Although there are tools capable of assessing the combination of one or two of the sustainability factors, the frameworks have not adequately integrated all the three factors. Case study and review of existing simulation applications also shows the approach lacks integration of the sustainability factors. In this paper we discussed the development of a simulation based framework for support of a holistic assessment of sustainable manufacturing design and management. To achieve this, a strategic approach is introduced to investigate the strengths and weaknesses of the existing decision supporting tools. Investigation reveals that Discrete Event Simulation (DES) can serve as a rock base for other Life Cycle Analysis frameworks. Simio-DES application optimizes systems for both economic and competitive advantage, Granta CES EduPack and SimaPro collate data for Material Flow Analysis and environmental Life Cycle Assessment, while social and stakeholders’ analysis is supported by Analytical Hierarchy Process, a Multi-Criteria Decision Analysismethod. Such a commonand integratedframework createsa platform for companies to build a computer simulation model of a real system and assess the impact of alternative solutions before implementing a chosen solution.

Material Selection for Heat Sinks in HPC Microchip-Based Circuitries

Heat sinks are integral components of high - powered computing system (HPC) microchips which are extensively used in modern electronics and power supply circuitries with intelligence and effective control capability. Integrated circuits typically generate la rge amount of heat sufficient to damage the chip and other sensitive electronic components of the circuitry. Heat sinks are applied to accomplish a continuous cooling of the microchip by conducting thermal energy away from it and dissipating same into the environment. Suitable materials for the heat sink are therefore important for effective protection of the microchip. In this study, material selection for heat sinks applicable in microchip - based circuitries was carried out using the CES EduPack software. Over 3,000

Material Selection for Axial Spring in a Prototype Cam-Follower Mechanism

A prototype cam-follower mechanism was designed and assembled using Pro-Engineer (Pro-E) software. The mechanismis meant for application in a forth -and-back Mode II Operation of a tribotester rig. The mechanism was dynamically simulated in Pro -E to ascertain the dynamic loading status of integral parts. CES EduPack software was applied to select the best material for the spring using the Function -ObjectivesConstraints approach. Candidate materials were first screened using design constraints after which shortlisted materials were ranked using design objectives. The final material choice made with reasonable trade-offs was found suitable for intended service environment requirements. OriginalResearch Article

THE RANDOM POROUS STRUCTURE AND MECHANICAL RESPONSE OF LIGHTWEIGHT ALUMINUM FOAMS

ABSTRACTLightweight porous foams have been of particular interest in recent years, since they have a very unique set of properties which can be significantly different from their solid parent materials. These properties arise from their random porous structure which is generated through specialized processing techniques. Their unique structure gives these materials interesting properties which allow them to be used in diverse applications. In particular, highly porous Al foams have been used in aircraft components and sound insulation; however due to the difficulty in processing and the random nature of the foams, they are not well understood and thus have not yet been utilized to their full potential. The objective of this study was to integrate experiments and simulations to determine whether a relationship exists between the relative density (porous density/bulk density) and the mechanical properties of open-cell Al foams. Compression experiments were performed using an Instron Universal Testing Machine (IUTM) on ERG Duocel open-cell Al foams with 5.8% relative density, with compressive loads ranging from 0-6 MPa. Foam models were generated using a combination of an open source code, Voro++, and MATLAB. A Finite Element Method (FEM)-based software, COMSOL Multiphysics 4.3, was used to simulate the mechanical behavior of Al foam structures under compressive loads ranging from 0-2 MPa. From these simulated structures, the maximum von Mises stress, volumetric strain, and other properties were calculated. These simulation results were compared against data from compression experiments. CES EduPack software, a materials design program, was also used to estimate the mechanical properties of open-cell foams for values not available experimentally, and for comparison purposes. This program allowed for accurate prediction of the mechanical properties for a given percent density foam, and also provided a baseline for the Al foam samples tested via the IUTM method. Predicted results from CES EduPack indicate that a 5.8% relative density foam will have a Young’s Modulus of 0.02-0.92 GPa while its compressive strength will be 0.34-3.37 MPa. Overall results revealed a relationship between pores per inch and selected mechanical properties of Al foams. The methods developed in this study can be used to efficiently generate open-cell foam models, and to combine experiments and simulations to calculate structure-property relationships and predict yielding and failure, which may help in the pursuit of simulation-based design of metallic foams. This study can help to improve the current methods of characterizing foams and porous materials, and enhance knowledge about theirproperties for novel applications.

Improving Materials Selection in a Mechanical Engineering Capstone Course

ABSTRACTThe Capstone Design course in the Department of Mechanical Engineering at Northeastern University requires students to build a physical prototype by the end of the two semester sequence. Although students have long been required to take an introductory materials science course as part of their curriculum, there was concern that materials selection was a weakness in the design process. Beginning in Fall 2011, the CES Edupack materials selection software was introduced into the Capstone Design class. The current work means to investigate: 1) how to assess designs for effective materials selection 2) whether the new software was actually used by the student teams and 3) whether there was evidence of improved materials selection in the projects that occurred after the new software was introduced. Final capstone design reports from 10 previous terms were examined to look for evidence of systematic materials selection procedures and clear discussion of materials properties as the basis for selecting a material. References to the software were also noted. Results show that 24% of the groups used the CES Edupack software in the first three terms that the software was available. In addition, there was an increase in the number of groups that used a systematic selection process based on research into published materials properties rather than choosing materials based on rough experimentation or convenience. Finally, there has been an increase in the number of projects which consider or incorporate composites, high temperature alloys, and advanced polymers as the software has increased awareness of these options.

Introduction of a New Software Package in Teaching Design Methodology for Material Selection

Material selection is an integral part of engineering design. As such, this topic is included in most advanced engineering design units in the Bachelor of Mechanical Engineering. However, students often find this topic difficult and confusing due to the lack of overall knowledge required for the task. This paper describes the introduction of a new software package in a design methodology unit for material selection that provides additional knowledge and hands-on experience to students, which can be applied in their professional lives. The software package introduced three forms of education delivery: lecture, tutorial, and assignment activities. It was found that the introduction of the CES EduPack software package for material and process selection significantly improved students' learning.