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Product Development Using New Material Concepts

Module name (EN): Product Development Using New Material Concepts
Degree programme: Engineering and Management, Master, ASPO 01.10.2019
Module code: MAM_19_PE_2.06.PEW
Hours per semester week / Teaching method: 4V+2S (6 hours per week)
ECTS credits: 8
Semester: 2
Mandatory course: yes
Language of instruction:
German
Assessment:
Project with documentation and final presentation


[updated 04.11.2020]
Applicability / Curricular relevance:
DFMME-2b3 Mechanical Engineering, Master, ASPO 01.10.2019, semester 2, mandatory course, Specialization Product Development
MAM_19_PE_2.06.PEW Engineering and Management, Master, ASPO 01.10.2019, semester 2, mandatory course, Specialization Product Development
Workload:
90 class hours (= 67.5 clock hours) over a 15-week period.
The total student study time is 240 hours (equivalent to 8 ECTS credits).
There are therefore 172.5 hours available for class preparation and follow-up work and exam preparation.
Recommended prerequisites (modules):
None.
Recommended as prerequisite for:
MAM2.1.3.24


[updated 23.08.2021]
Module coordinator:
Prof. Dr. Bernd Heidemann
Lecturer:
Prof. Dr. Walter Calles
Prof. Dr.-Ing. habil. Andreas Fricke
Prof. Dr. Bernd Heidemann
Daniel Kelkel, M.Sc.
M.Eng. Oliver Müller


[updated 29.07.2020]
Learning outcomes:
After successfully completing this module, students will be familiar with new material concepts, their technological properties and development potential and will be able to develop and use them.
They will be able to implement product functions with these properties by applying specific design methods.
Students will be able to analyze and optimize their product in terms of safety.
They will be able to assess whether a product falls under the Machinery Directive and determine its hazards.
Students will be able to classify safety engineering terms in the overall context of the Machinery Directive.
They will be able to apply the Machinery Directive and know the scope of a conformity procedure.
They will be familiar with the 3-step method for reducing hazards and will be able to select or develop measures to reduce hazards.
Student will be able to carry out a risk assessment of simple machines and products using harmonized standards.
They will be familiar with the Sistema calculation and can interpret an existing calculation.
 
 
 


[updated 04.11.2020]
Module content:
Material concept - Plastics:
technological properties, design and production relevant properties, ecological properties, sustainability.
 
Selecting materials:
Integration of databases for plastics and metallic and ceramic materials in product development and calculation.
 
Material concepts created in additive manufacturing processes: technological properties, design and production relevant properties, ecological properties, sustainability.
 
 
Material concept - "Other materials"  (fibre composites, graphene, current developments in materials technology):
technological properties, design and production relevant properties, ecological properties, sustainability.
 
 
Product development and component design with regard to material-specific properties: The principles of integral design methods and the integration of functions versus differential design methods and the separation of functions.
 
Explanation of terms and delimitations pertaining to product safety and the Machinery Directive.
Legal foundation of the Machinery Directive
Types of hazards
The 3-step method of risk reduction
Risk assessment procedure (risk assessment, evaluation and risk reduction)
The importance of harmonized standards and their application
Documenting a risk assessment
Examples of inherently safe product design
Protective devices: mechanical, control, organizational
Basics of Sistema calculation
 


[updated 04.11.2020]
Teaching methods/Media:
Seminaristic, interactive instruction.
 
The project will be carried out according to an annually updated guideline (specification sheet), that will be available at the beginning of the course. The project will be monitored in regular meetings.
 
The project should be carried out in teams in order to use and master group dynamic processes and procedures.

[updated 04.11.2020]
Recommended or required reading:
Gunter Erhard: Konstruieren mit Kunststoffen. Hanser-Verlag.
Gottfried Wilhelm Ehrenstein Mit Kunststoffen konstruieren: Eine Einführung. Hanser-Verlag.
Schürmann, Helmut: Konstruieren mit Faser-Kunststoff-Verbunden. Springer-Verlag.
Kurt Moser: Faser-Kunststoff-Verbund. Entwurfs- und Berechnungsgrundlagen. Springer-Verlag.
Andreas Gebhardt: Generative Fertigungsverfahren: Additive Manufacturing und 3D Drucken für Prototyping - Tooling _ Produktion. Hanser-Verlag.
Ian Gibson, David Rosen, Brent Stucker: Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer-Verlag.
John O. Milewski: Additive Manufacturing of Metals: From Fundamental Technology to Rocket Nozzles, Medical Implants, and Custom Jewelry. Springer-Verlag.
Tarek I. Zohdi: Modeling and Simulation of Functionalized Materials for Additive Manufacturing and 3D Printing: Continuous and Discrete Media. Springer-Verlag.
Gries, Thomas, Klopp, Kai (Hrsg.): Füge- und Oberflächentechnologien für Textilien - Verfahren und Anwendungen. Springer-Verlag.
Safety engineering:
 
 
Alfred Neudörfer: Konstruieren sicherheitsgerechter Produkte. Springer Berlin Heidelberg.
Marco Einhaus, Florian Lugauer, Christina Häußinger: Arbeitsschutz und Sicherheitstechnik. Hanser Verlag.
Maschinenrichtlinie Richtlinie 2006/42/EG
Volker Krey, Arun Kapoor: Praxisleitfaden Produktsicherheitsrecht. Hanser Verlag.
Bernd Bertsche, Gisbert Lechner: Zuverlässigkeit im Fahrzeug und Maschinenbau. Springer Verlag.


[updated 04.11.2020]
[Wed Dec  1 18:55:24 CET 2021, CKEY=mpmnw, BKEY=mm2, CID=MAM_19_PE_2.06.PEW, LANGUAGE=en, DATE=01.12.2021]