ASSESSMENT ACTIVITY FRONT SHEET Learner name Course title BTEC HND Diploma in Mechanical...

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ASSESSMENT ACTIVITY FRONT SHEET    Learner name  Course title BTEC HND Diploma in Mechanical Engineering - VT720  Assessor name  Internal Verifier name Date  Unit number and title 21. Materials Engineering – F/601/1626  Assignment title A02: Materials Engineering – understanding the process of suitable materials selection and determining in service life and failure  Group work NO  Outcome number(s) and statement(s) 3. Select suitable materials and processing methods for a specific product  4. Understand the in-service causes of failure of engineering material  Date set  Review dates XXXXXXXXXXLearner declaration  I confirm that the work submitted for this assignment is my own.  Learner signature Date    Introduction  Purpose/aims The aim of this assignment is to provide students with basic background  knowledge and understanding of the mechanical and thermal properties, selection, processing and use of materials.  Background or scenario You want to spend five months of practice as a Mechanical Engineer in  Pluto Company, one of the biggest Engineering Structural Company in Greece. The day of your interview, your potential supervisor asks you to solve the following tasks in order to find out what your level of knowledge is. She gives you a laptop connected to Internet to write your answers and wants back your assignment report showing all intermediate steps to the solution.    Tasks    Task # Task Criteria  covered XXXXXXXXXXThink of a product: XXXXXXXXXXAnalyse its functions in terms of the materials’ constraints    on its design.    P XXXXXXXXXXIdentify the required properties for this product and select    the most appropriate materials and processing methods.    P XXXXXXXXXXIdentify and explain the possible limitations on the product    imposed by the processing and by the need to safeguard the environment and minimise costs    P XXXXXXXXXXExplain the common causes of in-service failure for steel,    porcelain, polyethylene and glass-reinforced plastic by overstressing.  P XXXXXXXXXXIdentify and explain how inappropriate maintenance,    inappropriate use, faults in manufacture and changes in service conditions such as environment, loading and temperature contribute to early failure of carbon steel.      P XXXXXXXXXXExplain two methods for investigating materials failure and for    estimating product service life when a product is subject to creep and fatigue loading.    P XXXXXXXXXXDetermine and make recommendations for remedial/preventive    measures for metals undergoing fatigue stress loads, so that you help improve its service life.    P4.4    The report should be written in formal style. Plagiarism will be penalized and may lead to disciplinary action. The report should also contain a content page indicating the different report chapters and sections. The font letter should be of size 12. Do not forget to write a page containing bibliography and references. You have to submit along with your report’s hard copy one more copy in electronic format in a floppy disk or CD. Do not neglect to put your name, unit title and assignment number on the disk or CD and secure it on the back cover of your report.

Robert · Accepted Answer

Answer 1.1 
1. As per question we consider a product and we will consider the function of that 
product in terms of material constraints 
We will consider the wheel of Electric overhead crane  
Electric overhead travelling crane is used to transfer the goods in workshop or in any 
engineering organization; it uses no. of wheel that runs over the rail track. As per the 
capacity and span of crane manufacturer will decide the no. of wheel should be used for 
that crane
Function of Wheel in terms of material constraints- 
The main purpose of wheel is to move over the rail track and provide the ability to crane 
to move from one location to another with rated load
    Rail tracks are made of High Manganese steel that will be very hard material, hence 
we have to select the material for our wheel that will have  slightly lower  hardness as 
compared to rail track because if there will be any misalignment between the erection of 
crane wheel then it’s collar will touch the rail track and wearied out rapidly.  
So in order to design the wheel we select the material like EN-9 or EN-8 that have 
hardness around 300 BHN and as rail track hardness will be around 350 to 380 BHN , 
In EOT crane wheel, there will be collar on both side of wheel and the width of this collar 
will be around 20 to 25 mm depends on the diameter of wheel. 
Wheel has some important specification  
1. Root diameter 
2. Collar width 
3. Bearing used  
4. Material selection 
5. Process selection
For our safety purpose we used to provide hardness about 340 BHN up to 20 
mm deep in root diameter of wheel  
As wheel runs over the rail track so in order to avoid the rapid wearing of its 
diameter this hardness is provided
Answer 1.2 
Required properties for this product  
There are some properties of crane wheel that we have to mention to the manufacturer  
1. Material EN- 8 or EN-9 
2. Hardness 250-300 BHN 
3. Surface finishing should be good 
4. Root diameter hardness should be 350 BHN up to 25 mm deep  
5. Collar width should be 20 to 25 mm both side 
6. Wheel shaft forged should be made of 300 BHN 
7. There should not be any clearance between shaft and wheel  
8. Self alignment roller bearing should be used 
9. Bearing housing (both side) made of simple mild steel  
10. Self lubrication & good strength
Processing method 
Normally all manufacturer uses forging process to manufacturer the wheel for crane, 
there is some advantage of this process  
1. Good flexibility in design  
2. It provides better strength 
3. Processing time is also short
Answer 1.3 
Possible limitations- 
There is some limitation during the design of the crane wheel and these are as follows 
1. Wheel material should be hard but not more than the hardness of rail track as 
due to wearing action rail track got damage if it has less hardness as compared 
to wheel and it is easy to replace the crane wheel as compared to replacement of 
track 
2. Root-width should be at least 30 mm more than the width of rail track, as during 
the operation there will be shifting in diagonal direction 
3. Root diameter selection depends on the capacity of crane, more capacity crane 
requires larger diameter of wheel 
4. Shaft diameter is also depend on the capacity of crane
Steps to minimize the cost- 
In order to minimize the cost material selection is very important, some manufacturer 
uses EN-24 but it is too much costly and much hard but that much hardness is not 
required for crane wheel, 
Processing method also play crucial role in crane wheel ,

ASSESSMENT ACTIVITY FRONT SHEET Learner name Course title BTEC HND Diploma in Mechanical Engineering - VT720 Assessor name Internal Verifier name Date Unit number and title 21. Materials Engineering –...

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