engineering-notes
engineering-notes
AREAS OF ENGINEERING
CHEMICAL
- Develop new ways that raw materials can be
made into commercial products/items.
- Researching, designing, developing, and testing
products and solutions related to food, polymers,
pharmaceuticals, minerals, metals, and gas.
BIOMEDICAL
- Design new ways to improve health and medical
services.
- Enhance quality of life for people with disabilities
through research, design and developing and
testing products and solutions related to
prosthesis, diagnostics, equipment and other
medical technology.
CIVIL
- Design, construct, and maintain buildings, dams,
bridges, tunnels, highways, and other structures
while keeping in view time, expenditure,
environmental impact and public health.
- Civil Engineers are responsible for the planning,
design, construction, and/or maintenance of
structures.
HISTORICAL USES
- Stone (Limestone, Granite, Marble) – Used in pyramids, temples, aqueducts; durable but heavy.
- Wood – Used in bridges, ships, buildings; widely available but prone to decay/fire.
- Bronze – Stronger than stone; used for tools, weapons, structures; expensive.
- Iron – Stronger than bronze; used in weapons, tools, early infrastructure; rusts.
- Cast Iron, Wrought Iron – Used in bridges, machinery; stronger than wood but brittle.
- Steel (Bessemer Process, 1856) – Strong, flexible; revolutionized bridges, railways, skyscrapers.
- Rubber & Plastics – Used in insulation, seals, consumer goods; flexible but degrades.
- High-Strength Alloys & Composites – Aerospace, automotive; high performance but costly.
- Nanomaterials & Smart Materials – Self-healing concrete, carbon nanotubes; high-tech but expensive.
HISTORICAL DEVELOPMENTS
- Wheel - 4th millennium BC EFFECT ON INDIVIDUALS
- Bronze - 4th millennium BC
- Iron - 1st millennium BC - Woken up by an alarm, electric toothbrush ready
- Steam engine - 1689 to brush teeth, toasters for bread and bicycle to
- Cast iron - 1707 get to school - all of these created by ‘engineers’
- Steel - 1856 - Engineers make things happen and we reap the
- AC electricity - 1886 benefits.
- Human flight - 1903
- Helicopter - 1920s
- Pacemaker - 1958
Engineering Mechanics
Scalar Possess magnitude but no direction, described fully as a number.
Vector Must have both magnitude and direction. Characteristics include; direction, sense, magnitude and
point of application.
VECTOR MATHEMATICS
Graphical representation of a vector
ADDITION OF VECTORS
Vectors may be added graphically thus determining the
geographical sum or vector sum of the separate vectors.
NOTE - The + sign refers to vector addition
A=B
The equilibrant of (A) and (B) is that vector which
OPPOSITE OF A VECTOR nullifies the effect produced by (A) + (B) and
represented as -(A) and + (B). That is, the equilibrium
The opposite of (A) is a vector, having equal magnitude,
has the same magnitude and direction as the resultant but
same direction but opposite sense and is shown
opposite sense.
symbolically as (-A).
-A = Opposite of A
NOTE - ‘0’ in vector algebra does not mean there are no vectors acting but rather the effect produced by one vector is
nullified (cancelled) by another vector.
NEWTONS LAWS OF MOTION
SIMPLE MACHINES
A machine is a means of overcoming a resistance (load) MECHANICAL ADVANTAGE
by the application of force (effort).
Machines are used for the following purposes: Defined as the ratio of the load to effort.
THE LEVER
L/E
PULLEY
- Allows forces to be applied in different
locations or directions
- Pulleys can be joined together to
produce a block and tackle
- Pulleys can also be used to transfer
torque from one shaft to another.
GEARS
- Like pulleys they can transfer torque
from one shaft to another
- They have the advantage of allowing
drive ratios to be changed.
CLASSIFICATION
- Elements are building blocks of nature, can’t be broken down
- Mixtures are the result of two or more pure substances (elements or compounds) which are mechanically mixed
together.
PROPERTIES
Cementite When austenite transforms, some is left as ferrite and the form cementite which is hard and brittle.
MATERIAL STRUCTURE
CRYSTAL STRUCTURE
A crystal is a homologous solid of definite chemical composition, with internal order, bounded by plane faces. Liquids
have little or no ordered structure, however as a material solidifies the atoms arrange themselves into regular crystal
structure.
Body Centred Cubic (BCC) Face Centred Cubic (FFC) Hexagonal Close Packed (HCP)
FERROUS NON-FERROUS
- Iron is the primary constituent (material) in - Iron is not the primary constituent metal
ferrous metals - Copper and Aluminium are the most commercial
- Mild steels contain low carbon and magnesium non-ferrous metals
- MS can easily be formed (i.e. ductility) machine
and welded.
- Issues are corrosion
- Stainless steel → The chromium reacts with
oxygen to form a chromium oxide layer that
prevents further corrosion.
BRASS ALUMINIUM
- Alloy of Copper & Zinc - Highly used metal → low density and excellent
- Can contain up to 40% zinc, but beyond that is corrosion resistance; low strength and as such
too brittle. is usually used in alloyed form.
- As zinc content increases, alloy becomes - Usually aluminium is alloyed with materials like
harder and brittle. copper, zinc, magnesium, lithium and other
- All brasses are corrosion-resistant and harder metals to gain excellent strength.
than pure copper. - Lightweight, offers strength to weight ratios
- Good wear, conduction and corrosion resistance better than most ferrous alloys.
makes them useful for switchgear and contacts. - Used in motor work due to good casting
- Outdoor taps are cast using 60/40 brass. qualities and high conduction of heat.
BRONZE COPPER
- An ally of copper and tin - The main electrical conductor used due to high
- Strength, good wearing qualities and corrosion electrical conductivity
resistance. - High ductility, malleable and good corrosion
- Leaded Bronze - Addition of 5% lead to resistance
brass improves machining properties. - Used in electrical wiring, electrical contacts,
- Phosphor Bronze - Up to 1% phosphor motor windings
remains after deoxidising the alloy →
increased strength, casting capabilities
and corrosion resistance.
Casting Forming process that involves heating up a material, such as a metal alloy and then placing it in a mold
or cast. Die casting → non-ferrous alloy casting, Sand casting → ferrous alloy casting.
Rolling Rolling may be done at a higher temperature (Hot rolling) which is easier. Cold rolling is harder to do
and the final metal structure will be stressed and deformed, but have a better surface finish and be
dimensionally accurate.
Extruding Extruding is similar to squeezing toothpaste from a tube, Aluminum alloy window frames are
generally made up of extruded sections.
CUTTING PROCESSES
Shearing Achieves cut without removing a waste strip, e.g. ships, often used to cut thin sheet metal.
- Smoother cut, quick action and efficient with little waste.
- Potential for burrs, deformation and difficulty with hard metals.
Sawing Removes a waste section of the materialism blades that are made from tungsten steel for hardest
materials/ high speed.
- Accurate cuts, easier for manual, smaller jobs.
- Generally slower.
Drilling Cutting round holes in metal by rotating and feeding the drill.
- Creates precise holes and is good at handling thicker materials.
- Limited hole shapes and potential heat buildup
Turning Lathe is mainly used for machining circular surfaces, that is cylindrical or conical but can be used for
producing flat surfaces, drill holes, machine slots, etc.
- Precision, versatility and efficiency
- Material waste and potential for defects when not carefully controlled.
Milling Rotating cutting wheel that spins, work is secured to a sliding table and moved to the cutting wheel.
- Very efficient when producing machined slots or flat surfaces.
- Material waste, high cost and operators need to be properly trained.
Grinding A spinning wheel of bonded ceramic is introduced to the work and the surface cuts the chips of
metallic or non-metallic substance from the workpiece.
- Smooth substance, high precision
- Higher cost and potential for heat damage.
Laser Direct output of high-power laser, most commonly through optics, follows CNC or numerical code to
Cutting cut specified shape or image.
- Precise and accurate cuts
- Expensive
Water jet Uses a very high pressure jet of water or mixture of water and abrasive to cut hard materials.
Cutting - Sensitive cuts, uses low temps, precision and versatility
- Slower cutting speeds and higher costs.
Plasma Cuts through electrically conductive materials by means of an accelerated jet of hot plasma.
Cutting - High speed, precision, and low operation costs.
- Noisy, generates excess fumes and aren’t useful for thicker materials.
HEAT TREATMENT PROCESSSES
Annealing Softening materials or to bring about required changes in properties, e.g. machinability,
mechanical, or electrical properties, or dimensional stability.
- Consists of heating steel to or near critical temperature to make it suitable for
fabrication.
Normalising Applicable to ferrous metals only, the purpose is to remove internal stresses induced by heat
treating, welding, casting, forging, forming or machinery.
- Heated to high temperatures and then removed from the furnace/oven for air cooling
Soft Soldering A tin alloy is used to join two metals together at 183℃
Brazing / Silver Using either bronze to fill small gaps or silver at high temperatures to join dissimilar metals.
Soldering
Electric Arc Metal is melted by an electrode, which doubles as the filter metal covered by flux to prevent
Welding oxidation of molten metal. Used to join thick steel sections and small runs.
Oxy-acetylene Metal is melted by flame and filler metal added, used to join steel fan cages.
Welding
MIG Welding Metal inert gas uses a continuous feed wire (electrode) and inert gas (eg argon) preventing rapid
oxidation. Suited for automation.
Bronze Welding A flame heats the parent metal and bronze filler metal which is added to the joint. There is little
or no metal of the parent metal. Applications mainly consist of low strength uses.
TIG Welding Tungsten Inert Gas uses a tungsten electrode (that doesn’t melt) and a manually fed filler rod or
wire. Applications include; Joining aluminium and stainless steel, especially thick sections.
Mechanical Joining Bolts, nuts, screws and solid and pop rivets can be used to fasten materials together, hole
drilling and corrosion pose issues for this form.
Fabricating The process of assembling an item from various components, E.g. mild steel welded together.
POLYMERS
POLYMERISATION
- Process proceeds without the production of a - The process involves the production of a simple
waste. waste product.
POLYMER STRUCTURES
TYPES OF CERAMICS
Porcelain - low porosity (1%) - this is important for plates and cups that hold beverages and food.
- Good electrical and thermal insulator.
- Glaze to improve aesthetics and reduce surface porosity to zero.
- Brittle & heavier than polymers.
Porcelain and china are the two most common seen in homes
Gorilla Glass - Modern smartphones use a capacitive touchscreen that must be strong and resistant to
cracking yet be exposed so a finger can contact it.
- By an ion exchange a compression stress is a set-up in the surface, which makes it more
difficult to introduce tensile failure in the glass
- Higher density
COMPOSITE MATERIALS
NATURAL COMPOSITES
Exist in both plants and animals. Wood / timber is a composite - it is made from long cellulose fibres held together by a
much weaker substance called lignin. Examples of composites:
- Bones → hydroxyapatite + collagen
- Cotton → cellulose + pectin substance + wax + protein.
TIMBER
Advantages: Disadvantages:
- High specific strength (strength-mass - Wood is combustible
ratio) - Strength of wood varies with the species
- Wood is regenerative and if managed and direction of applied force.
professionally can be a permanent
resource
- Easily handled, worked and joined.
EARLY COMPOSITES
Humans have been making composites for many thousands of years.
Examples
- Mud → Can be dried out into a brick form, building materials, having good compressive strength but poor tensile
strength.
- Concrete → Mix of aggregate, cement and sand. Good compressive strength, adding metal rods as eternal
support increases tensile strength.
Composites can be separated into three different categories based on their strengthening mechanisms:
Dispersion Strengthen Fine distribution of secondary particles in the matrix of the material, removing/
disabling deforming mechanisms.
Particle Reinforced Large volume fraction of particles dispersed in the matrix and load is shared by the
particles and matrix.
Fibre Reinforced The fibre is the primary load-bearing component, e.g. fibreglass and carbon fibre.
Communication
DRAWINGS
- Freehand sketching is a style of drawing made without the use of guiding or measuring instruments, as
distinguished from mechanical or geometrical drawing; also, a drawing thus executed.
ENGINEERING REPORT
- Title page
Title of the report, identifies the writer/s, their company or organization and publication date.
- Abstract / Executive Summary
A clear, concise summary of the report, giving the readers a brief explanation on the purpose of the report, to see
if it is relevant for their needs.
- Introduction
Introduction to the report and background information
- Main section / procedure
- Results
- Conclusion
- Acknowledgements
- References / Bibliography
- Appendix
UNIT SUMMARY
Areas of engineering practice Chemical - Raw materials → consumable products;
food, polymers, pharmaceuticals, minerals, metals
- What are some Areas of Engineering
and gases.
Historical and societal influences Throughout history, engineers have selected materials
based on availability, strength, cost and suitability for
- Outline historical uses and appropriateness of
certain tasks:
materials in the design and production of - Stone Age: stone, wood bone → readily
engineering projects available and malleable
- Bronze Age: bronze → stronger weapons
- Demonstrate an understanding of the
- Iron Age: iron and steel → common due to
historical developments of engineering their strength and versatility
- Industrial Revolution: Cast and Wrought
iron → bridges, machines, and buildings
- Modern Era: Advanced materials (steel
alloys, plastics, polymers, composites and
titanium) → high performance in aerospace,
construction and electronics.
Joining Processes:
- Welding: Either using pressure, fusion or an
ally (added metal)
- Soft Soldering: A tin alloy is used to join two
metals together at 183℃
- Brazing / Silver Soldering: Using either
bronze to fill small gaps or silver high
temperatures to join dissimilar metals.
Shaping Processes:
- Casting: pouring a molten metal
- Rolling: Done at both, high and low temps,
metals can be cast in form of ingots or bars.
- Extruding: Squeezing material out of a tube
- Cutting: Removal of unwanted material
Communication Drawing Types
- identify third angle orthogonal projection Orthogonal → front, top and side
Isometric → 3D projection
- draw freehand, orthogonal and three
dimensional pictorial drawings of objects Engineering Report Structure
• Title page
- conduct research using computer technologies Title of the report, identifies the writer or
and other resources writers, their company or organisation
and publication date
- appreciate the value of teamwork • Abstract
- outline the use and basic structure of an A clear, concise summary of the report,
Engineering Report giving the readers a brief explanation on
the purpose of the report, too see if it is
relevant for their needs
• Introduction
Introduction to the report and background
information
• Main section/ procedure
• Results
• Conclusions
• Acknowledgements
• References
• Appendix