PracticalReport_MEM30007A_Task2_Student_190915-2

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Industrial Engineering

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Dec 6, 2023

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Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 1 of 21 STUDENT STUDENT - PRACTICAL ASSESSMENT TASK Task Number 2 of 3 . Task Name Practical Report National unit/s code MEM30007A National unit/s title Select Common Engineering Materials National qualification code 22228VIC National qualification title Advanced Diploma of Engineering (Civil) RMIT Program code C6162 RMIT Course code PROC5277C Section A - Assessment Information Duration and/or due date: 60 minutes duration / 2 weeks after completion of the laboratory activity. Task Instructions Summary and Purpose of Assessment: This unit applies to technician level activities in manufacturing and engineering environments. Work is carried out under supervision. The purpose of this practical and report writing task is to: • Identify common engineering materials by their principal properties • Identify the principal properties of ferrous metals • Select materials for specific application • Verify selected material as fit for purpose Student instruction 1. This is an individual laboratory-based assessment task to be conducted in the RMIT laboratory. 2. You will be provided with a scenario of a simulated work environment. 3. You are required to write the report using the format provided in Section B and answer the questions. 4. You will be assessed according to the criteria outlined in the Section B Marking Guide. 5. All criteria identified must be addressed to satisfactorily complete this Assessment Task. Conditions for assessment Instructions to Students: 1. You must be observed undertaking this task by a qualified assessor 2. Your assessor will negotiate a suitable time and location for assessment at least one week prior to the assessment taking place 3. You must complete the task within the maximum allowed duration 4. This is an individual task that you must complete with minimal support from others (allowed support would be questions related to the location of equipment needed) 5. Please make arrangements with your assessor at least one week prior to the assessment due date if you feel you require special allowance or allowable adjustment to carry out this task
Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 2 of 21 STUDENT 6. You must complete all the actions as listed in the observation checklist to the standard described in Section B to be deemed satisfactory in this assessment 7. Please ensure your full and correct name is written on the student version of this assessment task (do not use nicknames or abbreviations) 8. You will be assessed as satisfactory or not satisfactory 9. You can appeal the assessment decision according to the RMIT Assessment Policy and Procedures Additional Instructions to Students: 10. Performance requirement: a. Satisfactory (S) performance – satisfactorily complete ALL performance criterions and responses for questions b. Not Yet Satisfactory (NYS) performance – unable to satisfactorily complete one or more performance criterions. The result of being deemed competent in this course will only apply if the result is satisfactory (S) from all of the assessment tasks (all three). Instructions on submitting your Assessment Evidence Submission requirements: Report is to be upload to Canvas through Turnitin Equipment/resources students must supply: Submission requirements: • Pen and paper • Personal protective equipment Equipment/resources to be provided by RMIT or the workplace: • Computer and RMIT Internet Access • Microsoft Office Suite • Workshop • Hard copies of the student version of this assessment task OR access to access soft copies
Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 3 of 21 STUDENT Tensile and Hardness Testing of a Ferrous alloy and the determination of whether the tested Material is fit for purpose Scenario and Background Information: The hip is one of the most important joints that supports our body, having the task of joining the femurs with the pelvis. The hip joint (Fig.1) is subjected to high daily stresses, having to bear the weight of the upper part of the body. Thus, especially with advancing age, these stresses can jeopardize its function. Since its first application, the development of design and materials of hip prosthesis continuously progressed. Several materials were used for this scope: glass, polymers, metal alloys, ceramics, composites, etc., trying to combine biocompatibility and fatigue resistance, stiffness, toughness, withstanding static and dynamic loads, and high resistance to mechanical and chemical wear [1, 2 , 3 ]. Fig. 1 Components of total hip replacement [5] The design limiting properties for the selection of hip joint materials includes: Stiffness: Moderate elastic modulus of approximately 110 Gpa which leads to more physiologically sound stress distribution in the implant bone is required. The goal is to have less stress on the bone due to modulus of elasticity mismatch. The elastic modulus of Ti – 6Al – 4V (1.10 * 10 5 MPa) is closer to that of bone (1.4 * 10 4 MPA) than is cobalt – chrome (2.42 * 10 5 MPa) [4]. Strength: During daily activities bones are subjected to the stress of about 4MPa. The peak load on hip joint during jumping time may be up to 10 times body weight. These stresses are repetitive and fluctuating depending upon the activity to be performed [5]. Wear resistance: To avoid the release of wear particles into the body, since the release of potentially harmful metal ions such as aluminum (Al) and vanadium (V) from the Ti alloy has been reported to be associated with long term health problems such as peripheral neuropathy, osteomalacia and Alzheimer’s disease [7,8]. The Rockwell hardness C of Ti – 6Al – 4V is 36. Your task 1. You are presented by an orthopaedist with a hip joint implant which has fractured in its midsection after 15 years in a patient. Research what is the most likely cause for this failure? Using your knowledge to date would you expect a hip joint implant fracture to be more brittle or ductile like in character? Justify your answer. Fig. 1.1 Fractured hip implants https://oatext.com/The-current-approach-to-research-and-design-of-the-artificial-hip-prosthesis-a-review.php [6]
Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 4 of 21 STUDENT 2. Based on the above incident it has been agreed that the hip joint implant material used more than 20 years ago is not suitable for a femoral stem. You are provided with a rod specimen of a new material, and instructed to test and determine: a) the maximum stress possible to apply to this material before it fails for this application. b) the ultimate tensile strength for this material. c) the modulus of elasticity for this material. d) the hardness of the material. 3. Analyze the test results and establish based on the known design limiting properties whether the new material is suitable for hip joint implants (i.e. fit for purpose). References: 1. Merola M., and Affatato S. Materials for Hip Prostheses: A Review of Wear and Loading Considerations. Materials (Basel). 2019 Feb; 12(3): 495. doi: 10.3390/ma12030495 2. Aherwar A., Singh A.K., Patnaik A. Current and future biocompatibility aspects of biomaterials for hip prosthesis. AIMS Bioeng. 2015;3:23 – 43. doi: 10.3934/bioeng.2016.1.23. 3. Affatato S. In: Perspectives in Total Hip Arthroplasty: Advances in Biomaterials and Their Tribological Interactions. Affatato S., editor. Elsevier Science; Amsterdam, The Netherlands: 2014. 4. Shackelford, James F. Materials Science and Engineering Handbook Ed. James F. Shackelford & W. Alexander Boca Raton: CRC Press LLC, 2001 5. Ghalme S., Mankar A., and Bhalerao Y. Biomaterials in Hip Joint Replacement. International Journal of Materials Science and Engineering. 2016; Volume 4, Number 2. doi: 10.17706/ijmse.2016.4.2.113-125. 6. Colic K, Sedmak K., The current approach to research and design of the artificial hip prosthesis: a review. DOI: 10.15761/ROM.100010 7. Walker, P.R.; Leblanc, J.; Sikorska, M. Effects of aluminum and other cations on the structure of brain and liver chromatin. Biochemistry 1989, 28, 3911 – 3915. [CrossRef] [PubMed] 8. Rao, S.; Ushida, T.; Tateishi, T.; Okazaki, Y.; Asao, S. Effect of Ti, Al, and V ions on the relative growth rate of fibroblasts (L929) and osteoblasts (MC3T3-E1) cells. Bio-Med. Mater. Eng. 1996, 6, 79 – 86. 1.0 Introduction Materials are enablers. However, due to the complex interdependence between material structure, properties and manufacturing processes, the selection of materials which will ensure the integrity of the design, is by no means a straightforward task. The tensile test has become the basic test for determining the mechanical properties of materials and is used for the following purposes: (a) To provide data for acceptance or rejection of a sample of a material on the basis of specified properties. (b) To provide essential data for engineering design. (c) To provide data on the likely behaviour of a material during fabrication processes The functions indicated in (b) and (c) above are only partially met by the tensile test since the shape of the component and the stress distribution may be quite different in practice from those operative during a tensile test. In the tensile test a specimen of standard shape and size on which a gauge length is marked is extended and the load measured. The data obtained may be represented on a load-extension curve. Since the load and extension are functions of specimen size as well as of material properties, the tensile test data are better represented by a stress-strain curve.
Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 5 of 21 STUDENT Assessment requirements 1. You are required to perform the practical tasks below; 2.1, 2.2,2.3 and justify whether the tested material is fit for purpose. 2. Fill out tables 1-5 on pages 8-10 of these practical notes. On separate pages, provide all calculations for the result sheets. This must be word processed using Microsoft equation editor. Attached pictures/photos of hand written calculations are not permitted. 3. Answer the questions as described in section 3 in your report after the discussion section. 4. Adhere to the marking guide and check list as shown at the end of this practical handout 2.0 Procedure 2.1 Part 1. Tensile Test Note: for all steps involving the mounting of specimens in the Instron tensile tester, and the use of the testing software, direct instruction will be provided by your demonstrator. 1. Measure and record the diameter of the parallel reduced section of the sample provided with a vernier calliper. 2. With a centre punch, very lightly punch two marks at the extremes of the parallel reduced section onto the specimen, this will be the gauge length (Fig.2). 3. Measure the distance between the two punch marks with a vernier caliper, noting this distance. 4. Test your sample. 5. Measure the elongation in gauge length by supporting both pieces of the sample in a 'Vee' block and measure the change in diameter at the neck of the break. 6. Save the graph produced by the Instron Tensile testing machine. Fig.2 Typical tensile test samples https://guidebytips.com/tensile-test/
Assessment 2/3 [ Date last updated ] Student practical assessment task © Content is subject to copyright, RMIT University FINAL APPROVED – STUDENT PRACTICAL ASSESSMENT TASK TEMPLATE – June 2019_Version 2.0 Page 6 of 21 STUDENT 2.2 Analysis and Calculations Elastic region : the region OA in which deformation is reversible with respect to loading. Elastic limit or yield strength : The point A, at which permanent deformation first occurs on loading. The measurement of point A depends on the sensitivity of the equipment used since some materials do not show a sharp line deviation from the straight line. Necking : A localised decrease in cross-section, begins at C and because of this, extension continues at lower loads until fracture occurs at D. Note: units for stress ( )= N/m 2 , Pascals {Pa}, Strain ( ) are dimensionless. Percentage Elongation: The percentage increase in gauge length at fracture. (The gauge length over which elongation is measured, assumed here to be the length of the narrowest part of the specimen. A o o = − 100 ( ) I I I Ultimate Tensile Strength, UTS : Obtained by dividing the maximum load (M) reached during the test by the original cross-sectional area (point C). UTS Load A o = max Percentage Reduction of Area: A A A A p = − 100 1 2 1 ( ) where A 1 = original area, A 2 = final area at fracture. Young's Modulus (E) : is defined as
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