Composite Materials MSc Course 2010/11 GROUP DESIGN PROJECT Procedure 1.

The design project will be carried out by groups of five students (see final page), with the students preallocated to a particular Group. The Group members have been chosen to give, as far as possible, a balance of background and experience. 2. The project will be supervised by Dr Greenhalgh, but to ensure the students get real world guidance, they will be able to draw on the expertise of an industrial consultant (Alpha Composites; http://www.alphacomposites.co.uk/). Alpha Composites Ltd is a multi-award winning company which specialises in the design and manufacture of carbon composite components for global defence and aerospace industries. Alpha Composites will be available during two surgeries over the period of the project, allowing the students to draw on practical design and manufacturing experience, not to mention the financial implications of the particular processes chosen. 3. The project will be discussed at a meeting of the whole class on Tuesday 17th January. Following this meeting, each group must elect a leader (Project Manager) to act as spokesperson and convener. Then, each member of the Group will have to be assigned two roles (Consultant and Champion), as detailed below. 4. Consultant; each Group must nominate one person with overall responsibility for each particular technical area (e.g., production, material properties, stress analysis, joining, deployment). 5. Champion; in addition, each member of the Group will lead the design of one component on the bridge (i.e. each student must be personally responsible for the design of a particular item(s) from the overall bridge structure). The design of these particular item(s) must include choice of material, fabrication method, stress analysis, and costing. Therefore, each student is ultimately responsible for all design aspects of their own item(s), although they can take advice from the Consultant within the group for any particular aspect. However, the Consultant can advise but shouldnt do it all. 6. On Tuesday 24th January each group must submit, in writing, a short Outline Summary onto Blackboard. This will include the scenario of the design specification, Consulting responsibilities, Champion responsibilities, milestones and deadlines (with a Gantt chart). This document will not be marked, but will form the basis of the future discussions with Alpha Composites and the supervisors. 7. On Friday 10th February and Thursday 8th March Alpha Composites will hold surgeries, with each Group having been allocated 30 minutes to discuss their designs and address any questions they may have. 8. During the duration of the project, four academics will be available to field technical questions about the designs; Dr Robinson, Dr Palacios, Dr Santer and Dr Taggarielli. However, it is suggested that you Email them to organise a time rather than turning up with ad-hoc queries. 8. On Thursday 23rd February there will be a mid-term review of each project, in which each Group will have to give a 30 minute presentation of their progress to date. This will start with a presentation by the Project Manager, and then presentations from each member of the Group describing their progress to date. Copies of the slides will need to be submitted on Blackboard by the end of that day and these presentations will be marked. Please ensure that each individual slide is labelled with the author. 9. On Thursday 20th March there will be a final presentation of each project, in which each Group will have to give a 30 minute presentation of their progress to date. This will start with a presentation by the Project Manager, and then presentations from each member of the Group describing their progress to date. The presentations should, overall, reflect the whole of the design process, from concept designs, through material selection, detail design, manufacture, costings and marketing, with all the relevant related issues being addressed at each stage. Copies of the slides will need to be submitted on Blackboard by the end of that day and these presentations will be marked. Please ensure that each individual slide is labelled with the author. 10. The deadline for submitting the report will be the last day of term (17:00 on Friday 23rd March). Each final report must include a one-page Executive Summary, a general section on the

groups design, plus the details of each individuals consulting and design work. Each individuals contribution must be clearly identified within the report. 11. The (40) marks available for the Design Study will be subdivided along the lines: 10/10/20 (i.e. 10 marks for the mid-term review, 10 marks for the final review and 20 marks for the final report. For the presentations, the marking will focus on the clarity of the slides (25%), clarity of the oral presentation (25%), technical content (40%) and ability to answer questions (10%). For the reports, 40% of the marks will be associated with the presentation quality of the report (structure, clarity, grammar, Figures, Tables, etc) and 60% will be associated with the technical content of the report (background literature and research, materials selection, stress analysis and sizing, detailed design). 12. Beware of your Project Manager being ill on the day of any of the oral presentations, somebody else will be expected to stand in. So, ensure you all know what is going on and are able to make the overall presentation, if necessary!! Technical Brief You will be required to undertake the design of a portable bridge fabricated (95% by weight) from fibre-reinforced plastics. When disassembled the bridge must be transportable in the back of one Transit van. When assembled the bridge must span a gap twice the length of the van, and should be wide enough for the van to drive across it. Two designs are required, the first predominately mechanically fastened, the second predominately adhesively bonded. Consideration must also be given as to how the bridge is to be deployed across the gap. The bridge must be designed such that it must be deployed with access limited to only one side of the gap. The internal dimensions of the van are 3.20m long x 1.50m high x 1.7m wide, its overall length 5.65m, and its overall width 1.97m. The vans net payload (the load it can carry) is 1552kg and the weight of the van (including a 75kg driver) is 1948kg. Your bridges should be designed to allow the fully laden van to cross over. The van can carry as many people as you wish, but the total weight including payload should not exceed 1948kg. You are not required to meet a specific cost for the bridge, but you should be aware that in reality, it is usually the lowest cost design which is awarded by a customer! Therefore, you should consider, analyse and justify the costs of your bridge. It is recommended to formulate a scenario for the bridge, such as a world location in which it will be situated. This will provide the background for the environment (temperature, humidity, etc) and loading on the bridge. There will be documents and standards put on Blackboard to provide you with background information for undertaking this project. However, you will need undertake further research to generate information for your bridge designs. Finally, you may find it useful to use the CES 2011 software and database during your material selection for the bridge.

GROUPS
Group 1 1 2 3 4 Surnam e Boden Rashid Cullinan Router Given Nam es Vincent Imran Jack Joshua Charles Subject Aeronautical Engineering Materials Mechanical Engineering Automotive Engineering Group 5 1 2 3 4 Surnam e Nereau Yuan Nagel Tang Given Nam es Guillaume Shilin Ulf Kunyao Subject Aerospace Engineering Materials Science Mechanical Engineering Mechanical Engineering Manufacturing Systems Design

Wu

Xun

Applied Physics

YOON

SUNG-HO

Group 2 1 2 3 4 5

Surnam e Dhankhar Deu Ding Tejada Ulla Oh

Given Nam es Vikrant Bhurpoor Siw en Sergio Seyoung

Subject Aeronautical Engineering Materials Science Mechanical Engineering Mechanical Engineering Manufacturing Systems Design

Group 6 1 2 3 4 5

Surnam e Radhakrishnan Xie Kopula Ragavan Zuber Wang

Given Nam es Arjun Ningbo

Subject Aerospace Engineering Materials Science

Navaneethakrishn Mechanical Engineering an Thomas Mechanical Engineering Lizhe Pow er Engineering of Aircraft

Group 3

Surnam e Gaite Hu Katafiasz Mudannayake Leclerc-Chalvet

Given Nam es Oliver Anthony Law rence Chen Tomas Jan Jude Anthony Anuradha Arthur

Subject Aeronautical Engineering Materials Science Mechanical Engineering Engineering Physics

Group 7

Surnam e Sheludko Wang Hunter Huyghe Pignatti

Given Nam es Oleksiy Linhuan Jonathan Nicolas Luca

Subject Aerospace Engineering Materials Science Mechanical Engineering General Engineering Engineering Materials

1 2 3 4 5

1 2 3 4 5

Group 4 1 2 3 4 5

Surnam e Gopal Tan Drouet Avgoulas Maduppully Balachandran

Given Nam es Jithin Bo Marc Christophe S l ain Evangelos-Ioannis Shinoy

Subject Aerospace Engineering Materials Science Mechanical Engineering Naval Architecture Plastics

Group 8 1 2 3 4 5

Surnam e Smith Tympel Giacalone Amorelli Wang Xie

Given Nam es Stephen Peter Oliver Guglielmo Enrico Fan Weitong

Subject Aerospace Engineering Materials Science Mechanical Engineering Civil Engineering Polymers Technology