Professional Documents
Culture Documents
Sans bold
Engineering Studies
Preliminary Course
Stage 6
Bio-engineering
P0021885
Gill
Sans bold
Acknowledgments
This publication is copyright Learning Materials Production, Open Training and
Education Network Distance Education, NSW Department of Education and Training,
however it may contain material from other sources which is not owned by Learning
Materials Production. Learning Materials Production would like to acknowledge the
following people and organisations whose material has been used.
All reasonable efforts have been made to obtain copyright permissions. All claims will be settled in
good faith.
Materials development:John Shirm
Coordination:
Jeff Appleby
Content review:
Stephen Russell
Illustrations:
Tom Brown
DTP:
Carolina Barbieri
Copyright in this material is reserved to the Crown in the right of the State of New South Wales.
Reproduction or transmittal in whole, or in part, other than in accordance with provisions of the
Copyright Act, is prohibited without the written authority of Learning Materials Production.
Learning Materials Production, Open Training and Education Network Distance Education,
NSW Department of Education and Training, 1999. 51 Wentworth Rd. Strathfield NSW 2135.
Revised 2003
Module contents
Icons
............................................................................................... xi
Glossary.............................................................................................xiii
Directive terms.................................................................................xvii
Part 1: Bio-engineering
scope of the profession................................................ 127
Part 2: Bio-engineering
materials ......................................................................... 139
Part 3: Bio-engineering
mechanical ..................................................................... 135
Part 4: Bio-engineering
communication .............................................................. 127
Part 5: Bio-engineering
engineering report......................................................... 119
Bibliography.......................................................................................21
Module evaluation ............................................................................23
ii
Subject overview
iii
iv
vi
Module overview
Module components
Each module contains three components, the preliminary pages, the
teaching/learning section and additional resources.
module contents
subject overview
module overview
icons
glossary
directive terms.
vii
part contents
introduction
exercises
check list.
module appendix
bibliography
module evaluation.
Additionalr
esources
Module outcomes
At the end of this module, you should be working towards being able to:
identify the scope of engineering and recognises current innovations
(P1.1)
describe the types of materials, components and processes and
explains their implications for engineering development (P1.2)
describe the nature of engineering in specific fields and its
importance to society (P2.2)
use mathematical, scientific and graphical methods to solve
problems of engineering practice (P3.1)
develop written, oral and presentation skills and applies these to
engineering reports (P3.2)
apply graphics as a communication tool (P3.3)
viii
Extract from Stage 6 Engineering Studies Syllabus, Board of Studies, NSW, 1999.
Refer to <http://www.boardofstudies.nsw.edu.au> for original and current documents.
Indicative time
The Preliminary course is 120 hours (indicative time) and the HSC
course is 120 hours (indicative time).
The following table shows the approximate amount of time you should
spend on this module.
Preliminary modules
Percentage of time
Approximate
number of hours
Household appliances
20%
24 hr
Landscape products
20%
24 hr
Braking systems
20%
24 hr
Bio-engineering
20%
24 hr
20%
24 hr
HSC modules
Percentage of time
Approximate
number of hours
Civil structures
20%
24 hr
20%
24 hr
Lifting devices
20%
24 hr
Aeronautical engineering
20%
24 hr
Telecommunications engineering
20%
24 hr
ix
There are five parts in Bio-engineering. Each part will require about four
to five hours of work. You should aim to complete the module within 20
to 25 hours.
Resource requirements
To complete this module you will need access to the following material
and equipment:
Icons
As you work through this module you will see symbols known as icons.
The purpose of these icons is to gain your attention and to indicate
particular types of tasks you need to complete in this module.
The list below shows the icons and outlines the types of tasks for Stage 6
Engineering studies.
Computer
This icon indicates tasks such as researching using an
electronic database or calculating using a spreadsheet.
Danger
This icon indicates tasks which may present a danger and
to proceed with care.
Discuss
This icon indicates tasks such as discussing a point or
debating an issue.
Examine
This icon indicates tasks such as reading an article or
watching a video.
Hands on
This icon indicates tasks such as collecting data or
conducting experiments.
Respond
This icon indicates the need to write a response or draw
an object.
Think
This icon indicates tasks such, as reflecting on your
experience or picturing yourself in a situation.
xi
Return
This icon indicates exercises for you to return to your
teacher when you have completed the part. (OTEN OLP
students will need to refer to their Learner's Guide for
instructions on which exercises to return).
xii
Glossary
As you work through the module you will encounter a range of terms that
have specific meanings. The first time a term occurs in the text it will
appear in bold.
The list below explains the terms you will encounter in this module.
abridged
amorphous
amputee
artificial
biological
components
artificial heart
baby boomer
bionic ear
bio-reactor
brazing
cadaver skin
CD-ROM
xiii
Cochlear implant
cryopreserved
effort
electrocardiogram a unit for monitoring heart rates. usually consists of
a screen with a moving point that flashes as it
moves between acceptable levels
ethics
focus engineering
report
flux
fulcrum
hermetic seal
intra-aortic
balloon pump
inter-library loan
Internet
load
xiv
laser beam
myoelectric
impulses
neonatal tissue
ophthalmology
optometry
pathogens
presbyopia
prosthesis
scaffold
search engine
strain
stress
soldering
welding
X-rays
xv
xvi
Directive terms
The list below explains key words you will encounter in assessment tasks
and examination questions.
account
analyse
apply
appreciate
assess
calculate
clarify
classify
compare
construct
contrast
critically
(analyse/evaluate)
deduce
draw conclusions
define
demonstrate
show by example
xvii
describe
discuss
distinguish
evaluate
examine
inquire into
explain
extract
extrapolate
identify
interpret
investigate
justify
outline
predict
propose
recall
recommend
recount
summarise
synthesise
xviii
Bio-engineering
Part 1: Bio-engineering
scope and history of the profession
Part 1 contents
Introduction ......................................................................................... 2
What will you learn? ...................................................................2
Bio-engineering
Introduction
In this part you will explore the development of the field of bioengineering and the associated issues including training, career pathways
as well as ethical and safety considerations.
Extract from Stage 6 Engineering Studies Syllabus, Board of Studies, NSW, 1999.
Refer to <http://www.boardofstudies.nsw.edu.au> for original and current documents.
Bio-engineering
Bio-engineering
Glasses are a bio-engineered article that have been and are being
developed to overcome problems related to vision. Initially, there was a
single eyepiece called a monocle, which was little more than a
magnifying glass in a metal frame.
The development of glasses has occurred at two levels, the frames and
the lenses.
The frames were initially made from metal and were very heavy.
The development of lightweight, strong polymers and metal alloys have
reduced considerably the weight and increased their toughness.
Contact lenses that float on the tear fluid covering the cornea of the eye
can be used to correct refractive errors. This allows a user to be
independent of glasses as well as change the colour of his/her eyes with a
tinted lens.
Laser surgery is being used to alter the shape of the cornea as a way of
correcting refractive errors thereby eliminating the need for glasses and
contact lenses completely.
The design and development of glasses has expanded considerably since
the use of monocles. Research is being undertaken in the development of
silicon chip implants inside the eye that are connected to the optic nerve
and the brain to restore vision to blind people.
Bio-engineering
Biomedical implants
Internal implants need to be surgically placed and can include metal pins,
screws and plates inserted into bones to act as supports. Artificial joints,
such as hip and knee joints are common. The cardiovascular system can
be aided with pacemakers, artificial heart valves and even an artificial
heart.
Cochlear implants
The cochlear implant, also known as the bionic ear, can improve the
ability of a severely impaired person to hear.
An electrode is surgically implanted into the nerve endings of the spiral
cochlear, inside the ear. The electrode is then attached to a receiver
implant, lying just below the skin and behind the ear. Outside the skin,
above the implant, sits a transmitting coil that receives electrical signals
from a speech processor that is connected to a microphone placed behind
the ear.
The microphone collects sounds, which are processed into electrical
signals and sent to the transmitting coil for conversion into radio (FM)
signals. These radio waves then carry a coded signal to the receiver
implant under the skin. The implant sends this signal to the electrode
inside the cochlear, stimulating the nerve endings, which are hopefully
converted into sounds by the brain. Figure 1.2 shows the internal implant
and the external attachments associated with the cochlear implant.
microphone
hook over ear
implant receives radio
waves (and sends signals
through electrode)
electrode stimulates nerve
endings inside cochlear
speech
processor
ear drum
This device is not an amplifier that simply makes noise signals louder,
like many current hearing aids. It relies on the neurological structure of
the hearing nerve.
Dr Graeme Clark pioneered the development of the cochlear implant. He
has subsequently established the Bionic Ear Institute in Melbourne,
which continues development and research into the cochlear implants
and hearing aid innovations.
If you have access to the internet further information on the cochlear
implant can be found at the following websites:
<www.medoto.unimelb.edu.au/info/implant1.htm> (accessed 8.7.03)
<www.medoto.unimelb.edu.au/crc/> (accessed 8.7.03)
<www.phm.gov.au/hsc/cochlear/research.htm> (accessed 8.7.03)
Bio-engineering
10
alter the shape of the body and involved inserting a sealed silicon bag
into the breast by a seemingly simple operation. Over time it has been
found these bags have, in some instances, leaked resulting in dangerous
medical complications.
All implant procedures carry biocompatibility risks but there are further
concerns with the hygiene aspects related to:
The work environment can also cause health problems. This can be
exemplified in the areas where X-rays are used, such as hospitals, dentist
surgery and chiropractic centers. The radiation generated from X-ray
machines has the power to damage body tissue and kill cells.
The effects of short term exposure to high dose radiation can include
nausea, vomiting, fever, haemorrhage, anaemia and in extreme cases
death can result. Long term exposure to radiation can cause bone
degeneration severe burns, sterility, marrow damage, genetic mutation,
malformation of foetuses, leukemia and other forms of cancer.
People working with radiation equipment, such as medical staff in
hospital and dentist surgeries, need to protect themselves where
fluoroscopy, nuclear materials like uranium, radium and radioactive
isotopes are used.
Basic protection that must be observed includes, minimal exposure time,
maximum distance from source and shielding with protective clothing.
There must also be thorough and approved methods of dealing with the
contaminated radioactive waste products that are produced from these
machines.
Another concern is the long-term effect of genetic modification of plants
which is still yet to be determined. This is of particular concern with the
current introduction of genetically modified (GM) foods into the
domestic and commercial food markets.
Turn to the exercise sheet and complete exercise 1.2.
Bio-engineering
11
12
The effects on the community are wide ranging but concentrate on the
development and the enhancement of the individual and the wider
environment.
Ethnics in engineering
Ethics can be described as a system of moral principles, by which human
actions and proposals may be judged.
By its nature ethnics is a particularly difficult area to address and is
emphasised by the absence of ethics units in many of the engineering
courses offered by universities today.
Other professions have established formal guidelines that direct the
practitioner as to their ethical responsibilities. Such examples exist in the
field of medicine (Hippocratic oath) and in the fields of legal ethics and
business ethics. The engineering profession has as yet to formalise their
ethics practices.
To date the engineer has been guided by the legal requirements of the
country within they are working. Australian bio-engineers conduct their
research on animals in accordance with the guideline set down by
Bio-engineering
13
Animal Welfare Acts within each State and Territory. Other aspects of
their research will be guided by community expectations as to the
ethicacy of their work.
Would a bio-engineer working in a highly populated, relatively poor
country face the same ethical considerations as a colleague in Australia?
Turn to the exercise sheet and complete exercise 1.4.
Engineers as managers
It can be the task of an engineer, to initiate a design and then coordinate a
team of experts, such as materials analysts, welders, fabricators,
accountants and advertising agents to see a project through from initial
design concept to a commercially successful venture.
This may involve:
testing prototypes
managing a budget
14
Bio-engineering
15
The wires that run from the pacemaker to the heart delivering the
electrical shock are made from platinum or a similar material. They are
mounted in a ceramic block attached to the top of the pacemaker and are
further sealed by the use of a silicon preparation applied to all seams.
Artificial hearts
Human artificial hearts have been developed to act as auxillary devices to
the heart whilst a transplant organ is being sourced.
There are a variety of types but one successful example is the Intra-aortic
balloon pump (IABP). This system uses a process of counterpulsation
whereby the blood flow to the heart is increased and the hearts workload
is decreased. A devise containing a small balloon is inserted into the
aorta and it is inflated when the heart muscle relaxes, this increases aortic
pressure, pushing the blood from the aorta to the body and minimizes
back flow of the blood. The balloon is deflated just before the next heart
muscle pump, this reduces the pressure against which the heart needs to
pump and results in an improved blood flow and reduced workload on
the heart. The gas used to inflate the balloon is helium, an inert gas that
has a low viscosity, meaning that it will quickly flow into and from the
balloon.
16
Aorta
Balloon catheter
Inserted here
Figure 1.4
A balloon catheter
This procedure has been used in over 100 000 patients per year in the US
and is used before, during and after open heart surgery, during acute
attacks of angina, in emergency situations (heart attack, congestive heart
failure or very low blood pressure due to cardiogenic shock, that is,
inadequate circulation) and through waiting periods as patients are
prepared for a heart transplant. In most instances this process is only
used for a few days or weeks.
There has been further research into mechanical hearts but to date they
have all been used as temporary bridging mechanisms until a suitable
human heart becomes available.
The availability of donor hearts is becoming less and less able to meet
the needs of patients. In the US some 105 000 cardiac patients require
heart transplants but there are only 3 000 hearts becoming available
annually.
Turn to the exercise sheet and complete exercise 1.5.
Bio-engineering
17
18
Exercises
Exercise 1.1
a
ii
iii Explain how the development of eye glasses has improved the
quality of the life of the people who use them.
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
Bio-engineering
19
20
Exercise 1.2
a
ii
Bio-engineering
21
Exercise 1.3
a
Exercise 1.4
a
22
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
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_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
Exercise 1.5
a
ii
ii
Bio-engineering
23
___________________________________________________
___________________________________________________
iv
24
Progress check
Uncertain
Agree
Take a few moments to reflect on your learning then tick the box that best
represents your level of understanding.
I have learnt to
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
In the next part you will examine the materials, components and
processes involved in the field of bio-engineering.
Bio-engineering
25
26
Name: _____________________________
Check!
Have you have completed the following exercises?
Exercise 1.1
Exercise 1.2
Exercise 1.3
Exercise 1.4
Exercise 1.5
If you study Stage 6 Engineering Studies through a Distance Education
Centre / School (DECs) you will need to return the exercise sheets with
your responses as you complete each part of the module. Do not return
all the notes. They should be kept for future reference.
If you study Stage 6 Engineering Studies through the OTEN Open
Learning Program (OLP) refer to the Learners Guide to determine which
exercises you need to return to your teacher along with the Mark Record
Slip.
Bio-engineering
27
Bio-engineering
Part 2: Bio-engineering
materials
Part 2 contents
Introduction ..........................................................................................2
What will you learn?................................................................... 2
Research process.............................................................................27
Exercises ...........................................................................................29
Progress check .................................................................................35
Exercise cover sheet........................................................................37
Bio-engineering
Introduction
In this part you will examined materials used in bio-engineering, their
structure and properties and methods of forming.
forming methods
casting
forging
fabrication
Extract from Stage 6 Engineering Studies Syllabus, Board of Studies, NSW, 1999.
Refer to <http://www.boardofstudies.nsw.edu.au> for original and current documents.
Engineering materials
A range of materials is used in bio-engineering. Each material has its
own unique structure and properties, and forming characteristics.
Forming methods
Like all manufactured products bio-engineered products are constructed
using industrial forming processes which include:
casting
forging
fabrication.
Casting
Casting is the pouring of a molten metal into a mould to form a specific
shape. Generally the shape is as close to the finished product as possible
except when forming ingots. Ingots are usually changed in shape at a
later time by other methods.
Generally casting is a cheaper method of making products when
compared with other methods of forming.
There are a number of physical properties that need to be considered
when producing products by casting. The structure and the physical
properties of the cast product can vary considerably depending on the
material that the mould is made from as the mould materials will affect
the cooling rate of the molten metal.
If heat is extracted quickly a finer grain structure results whereas slowly
cooled metals have a much larger grain structure. The direction that the
heat is removed can also result in the grains having directional properties.
If a molten metal is poured into a mould that is made of sand the initial
crystallisation occurs on the surface of the mould. This is a quick
process and results in the formation of very small grains, known as chill
grains. Once the chill grains have formed the cooling process can slow,
this allows for the formation of larger thin grains, known as columnar
Bio-engineering
grains. These grains grow in the direction that the heat is being drawn
out. This can be seen in figure 2.1 where there is a thin layer of chill
grains on the outside and columnar grains forming on the inside.
Columnar grains
Chill grains
Sand
Sand
Metal
Metal
Figure 2.2 Directional grain growth
Shear planes
In order to strengthen the cast sample it would be best if the central core
of the sample is able to cool at a slower, even rate thus allowing
equi-axed grains to grow. The term equi-axed refers to metallic grains
that have similar axis lengths in all directions and therefore exhibit
similar physical properties in all directions, as shown in figure 2.4.
equal length axes
equi-axed grain
Columnar grains
Bio-engineering
Columnar grains
Equiaxed grains
Chill grains
Secondary pipe
Pipe minimised
or removed after
solidification
Hot top
Types of casting
Sand casting
Sand is combined with clay and small amounts of linseed oil to form a
mix that can be used for casting. The sand needs be fine textured so that
it will accurately reproduce the article that is to be cast and provide an
acceptable level of finish. The finer the sand the better the finish on the
end product.
The first step in making a sand mould is to make a pattern that will be the
shape of the item that is to be moulded. The pattern can be made from
any material and is often made from timber. The pattern becomes the
positive from which a mould or negative is made.
When complex shapes are being made the pattern can be split in half and
then reassembled when it is placed in the casting boxes. This process can
be seen in figure 2.9.
The pattern, is positioned in the
bottom of the casting box.
Casting box
Pattern
Pattern placed on bottom
of casting box
Bio-engineering
Riser plug
Gate plug
Riser
Gate
After the metal has been poured into the mould and then solidified the
sand mould is broken apart to reveal the casting.
Shell moulding
Shell moulding is a specific type of sand casting that uses exceptionally
fine sand bonded with a thermosetting resin to produce a thin walled
shell mould.
Shell moulding is a precision casting process that can create castings
with a superior surface finish and better dimensional accuracy than sand
castings.
The steps used to make a shell mould are described in figure 2.10.
A hot pattern is placed over a
dump box containing a sand
resin mix.
Dump
box
Bio-engineering
Shell
Ejector pins
Molten metal
Flask
Shells
Metal shot
Clamp
The shells are clamped
together and molten
metal is poured in
Figure 2.10 Shell moulding
The cost of producing the shell moulds is greater than sand moulds. Shell
mouldings are used in the production of many engine parts including
crankshafts, camshafts and rocker assemblies.
The moulds that are used in both sand and shell moulding are nonpermanent in nature and are generally destroyed when removing the cast
product.
It is essential that the patterns for the moulds are kept in excellent
condition as any fault in the pattern will be reflected in the
casting.
Investment casting
Investment casting is a very old method of casting metals, and dates
back to Egyptian times. This method requires that a positive, or
model, is made from a material such as wax. Other mould making
materials can include frozen mercury, low melting point metals and
some polymers including foaming resins.
10
Flask is filled
with investment
mould slurry
Bottom plate
Mould material
is broken away
from castings
Casting is trimmed
and polished
Bio-engineering
11
Centrifugal casting
Centrifugal casting relies on centrifugal force to push the casting
material into the mould cavity. It is used to create hollow objects,
such as pipes, as shown in figure 2.12, or it can force the metal to
flow rapidly into mould cavities.
1
Sand or metal lining
Direct drive
or rollers
spin centrifugal
casting machine
Molten metal
is poured in
from basin
2
Casting
Figure 2.12 Cross section of a centrifugal casting machine used for casting
large diameter pipes
12
Die casting
Die casting uses metal dies that are used over and over again. It is
important that the metal that is being cast has a lower melting
temperature than the melting point of the die material, otherwise the die
would be damaged. It is for this reason that aliminium is often used as a
die casting material with the moulds being made from tool steel.
In die casting the metal is forced into the die cavity under significant
pressures. There are two methods of injecting the molten material into
the die:
Fixed
platten
Moving
platten
Fixed
block
Die
Casting
cavity
Ejector
pins
Finished casting
Injection
piston
Casting solidified with
mould ready to open
Molten metal is
forced into the die
by air-injection or
a piston
Gooseneck
Molten metal
Bio-engineering
13
Forging
Forging is the process of shaping metal by the use of localised
compressive forces. The example that might come to mind is that of a
blacksmith shaping a piece of metal with a bellows to heat the metal and
a hammer and anvil to shape it. Articles such as horseshoes are still
fashioned in this way.
An example of a bio-engineering part that is drop forged is the hub on the
wheel of a wheel chair. This is the part on the wheel that has the spokes
connected to it.
14
Recrystallisation
Temperature oC
Melting points o C
Aluminium (Al)
150
660
Copper (Cu)
160
1085
Iron (Fe)
400
1535
Lead (Pb)
Below 20
327
Nickel (Ni)
600
1455
Tungsten (W)
1200
3410
iron
_______________________________________________
tungsten _______________________________________________
lead
_______________________________________________
400 oC
1200 oC
< 20 o C
To hot work iron, the material has to be heated above 400oC, and for
tungsten it is necessary to work the metal above 1200oC, where as lead
can be hot worked at room temperature. Conversely, if tungsten is
deformed by working at a temperature of less than 1200oC it is said to be
cold worked.
The notion of hot and cold working can be confusing unless you know
the recrystallisation temperature of the material.
Why is recrystallisation important?
Bio-engineering
15
Rolling direction
Cold worked structure
The compressed grains are stressed and can provide specific directional
properties. The resultant structure will exhibit high strength. If further
working or deformation occurs the material may fail or break.
When cold working, the grains in the material remain in this stressed
condition. However, if the material is heated to a temperature that is
above its recrystallisation temperature then the stressed grains will
reform into new stress free grains given time. The size of the new stress
free grains will depend on the degree of deformation. If there was a
significant degree of deformation then there will be more grains formed,
therefore a finer grain structure would result. These fine grains can be
enlarged if the metal is held at a temperature above its recrystallisation
temperature. This subsequent growth is known as secondary
recrystallisation.
16
Rolling direction
Original equi-axed
grains
Physical
deformation
Recrystallisation
Primary
Secondary
Types of forging
There are a number of different types of forging techniques. These
include:
blacksmithing
drop forging
press forging
upsetting
swaging.
Blacksmithing
Blacksmithing is accepted as the oldest form of forging and involves
heating the metal to a temperature where it can easily be deformed and
hitting it with a hand hammer. The art of blacksmithing was widely
applied in the past but currently it is generally limited to craft based
industries.
Drop forging
Drop forging is a technique that uses hydraulic pressure to operate a
hammer that shapes the metal. The hammer may operate directly onto
the metal or a press and die may be used to force metal into shape.
Dimensional accuracy is not as good for a drop forged article as it is for a
machined part, however there are other advantages in relation to grain
flow.
Bio-engineering
17
If a machine part was manufactured on a lathe the grain flow in the metal
will not follow the profile of the finished article. This can create localised
weaknesses that can cause the machine part to break under an applied
load. If the same part was hot drop forged with a hammer or a press and
die it will have a grain flow that follows the profile of the part
eliminating the plane of weakness seen in the machined part, as shown in
figure 2.19.
Plane of
weakness
Machined
Forged
18
Force
Punch
Force
Grainflow or fibre in
the upset bolt head
Swaging
Swaging is the specialised forging of cylindrical bars, rods or tubes so as
to increase or decrease their diameter. This can be achieved by forcing
the rod or tube inside a die, thus reducing the cross section of the
material or inserting a mandrel, that is a forming tool, inside a tube. This
will allow an increase in the effective diameter of the tube but will
decrease the wall thickness. Additionally, different shaped mandrels can
be inserted that will allow the inner surface to be a different shape to the
outer surface, for example the outer surface can remain circular with a
hexangular inner profile.
Before
After
Bio-engineering
19
Fabrication
Fabrications involves the construction of an article by assembling a
number of other parts. These individual parts are fixed together by
joining methods such as:
welding
brazing
soldering
bolting.
Welding
Welding involves melting or fusing together to pieces of metal. Welding
is usually carried out on steel or aluminium, but brass and copper can
also be welded.
Brazing
Brazing normally describes the joining together of two pieces of steel
with a brass alloy. The steel, the parent metal is heated to above the
melting point of the brass, it then flows around the pieces of steel to be
joined. When the brass alloy solidifies the steel sections are bonded
together. The steel does not melt or flow.
A wheelchair is an example of a fabricated bio-engineered product. It
consists of a number of parts that are joined together to form the finished
product. The frame is made of tube sections, similar to those on a
bicycle, and are joined together by brazing.
Larger tube
Braze
Smaller tube
Figure 2.22 Tubing brazed into the joins of a wheelchair
20
Soldering
Soldering is a similar process to brazing but the melting point of the
solder is at a lower temperature than brass. Solder is an alloy of lead and
tin.
When soldering it is necessary to ensure that the surfaces to be joined are
physically and chemically clean. Flux is applied to the surfaces of the
metal to complete this cleaning prior to the application of the solder.
Soldered joints are generally not as strong as brazed joints but are
extensively used in electrical circuits.
Bolting
Bolts can be obtained in a range of diameters from about 1 mm to very
large sizes, 300 mm. They consist of a bolt with a threaded shank and a
nut, which is screwed onto the thread.
Turn to the exercise section and complete exercise 2.3.
Appropriate materials
Many materials are used in bio-engineered products. These include
many types of metals including stainless steels, aluminium alloys and
alloys of tungsten. Polymers and ceramics also play an important part in
bio-engineering products, particularly in products that are to be placed
internally into the body.
When inserting prosthesis into the body it is important that they do not
react with the body and remain in an inert state. This ensures the
integrity of the product and the health of the body.
A variety of synthetic material are being used to simulate the action of
the human body in a number of situations. This is particularly apparent
in the use of crash test dummies that have been designed to simulate the
reactions of humans in the testing of cars and other transport vehicles.
Originally crash test dummies were mannequins used by the US Air
Force to evaluate ejection seats for aircraft. They have evolved into
highly sophisticated robotic devices that are able to simulate the human
body in a variety of situations. Specifically they have played an
important role in the development of safety devices and the structural
designs for modern vehicles.
Bio-engineering
21
Stainless steels
Stainless steel is an alloy of steel, which was discovered by a metallurgist
named Brearley in 1913. Its advantage as a bio-compatible material is
that it forms a thin oxide layer on its surface when exposed to the
atmosphere or body fluids. This layer is stable and resists corrosion,
which protects the underlying parent material. Conventional steel, such
as a mild steel or a tool steel, are prone to attack and corrosion by body
fluids. This has the effect of weakening the material and causing
microscopic particles to dislodge from the parent material promoting
infection and rejection by the body.
Stainless steel is used in a range of bio-engineering situations including
surgical pins to join broken bones, artificial hearts and bionic ears.
Titanium
Titanium exists as the ore minerals rutile and ilmenite. Titanium is a
metal that is plentiful on the earths crust (fourth most common)
however, it has been extremely difficult to extract. It was first isolated as
an element in 1887, but was never really considered as a useful material
until the 1950s. Recent technological developments in the extraction
process have lead to a greater availability of titanium.
The material has an excellent strength to weight ratio, high fatigue
strength and forms surface oxide layers that give it resistance to
corrosion. Most importantly, it is not rejected by body fluids and tissue.
It is used as a bio-engineering material in hip joints, bone screws, knee
joints, bone plates, dental implants and pacemaker cases. Titanium is
compatible with medical processes such as magnetic resonance imaging
(RMI) scans and computer tomography (CT) scans.
Titanium is also comparable in machining properties to stainless steel.
Polymers
The use of polymers has developed rapidly with the greater understanding
of the nature of the polymer itself and the interactions that it can have with
the human body.
Polymers, because of their stable and generally inert nature can be used
in bio-engineering. Apart from the application of polymers to physical
devices such as prosthesis, especially artificial limbs and their
accessories, there have been significant advances in implant technologies
that use polymers. Simple applications involve the use of PVC to house
the componentry for the synthetic speech processor in the cochlear
22
Ceramics
Ceramics are far less ductile than metals or polymers and can fracture
when any mechanical force is applied. The application of ceramic
materials through bio-engineering has partly been through the
development of ceramic coatings on metal prosthesis and for dense and
porous bone fillers for orthopaedics, neurosurgery and dentistry.
The use of the ceramic coatings on prosthesis was intended to promote
bone-bonding to the prosthesis. The mechanism by which this occurs is
not clearly understood but there are is evidence that with specific
preparation of the ceramic surface the growth of bone to the prosthesis
can be achieved.
Bio-engineering
23
Technologies in bio-engineering
Bio-engineering is a new and developing area that progresses as
discoveries are made in medicine, materials and computers.
Laser beams
Laser beams work by producing a narrow beam of light energy. Unlike
ordinary light, all the rays in a laser beam are of the same wavelength
and produce a beam of high intensity light. Lasers have been used in a
range of areas including, navigating missiles, writing and reading
information on Compact Discs and reading bar codes at supermarket
checkouts.
As a bio-engineering tool the development of lasers has seen them used
as bloodless scalpels where the intense beam of the laser can be used to
cut tissue and cauterise that is heat seal, the blood vessels as it cuts.
This is useful in delicate operations such as brain surgery where cuts
finer than a human hair need to be made.
Other applications for lasers as a bio-engineering tool are to break up
hard, painful stones that grow in the kidneys, to remove cancer tumors
cleanly without damaging surrounding tissue and to reattach the retina in
an eye by welding it back into position. Dental work is also an area
where lasers are used. Using a beam of ultraviolet light, lasers can be
used to painlessly remove decayed areas of a tooth.
X- rays
A machine that produces X-rays is basically a camera that relies on the
X-rays as opposed to sunlight to expose film. X-rays are electromagnetic
waves of high energy that can penetrate material in vary degrees. When
an X-ray passes through fat, bone, tumors or muscle it is reflected as an
image on film in differing intensities, organs absorb the rays in varying
degrees. By examining these images doctors are able to diagnose healthy
tissue, organs and bones and identify areas of concern. The identification
24
Bio-engineering
25
26
Research process
Bio-engineering is a new and developing field and for this reason it is
often difficult to find information and undertake research work.
Conventional sources of information such as libraries may not have a
section that relates to the topic, particularly if it is a small library in an
isolated area. Much of the information needed for research work in bioengineering is so current it will be found in references such as
magazines, journals and even television documentaries.
Sources of information for research include, the Internet, CD-ROMs and
libraries. Each one of these sources of information for research will be
looked at in the coming parts as we study this module. For this part of
work we will look in detail at the Internet as a tool for research. This is a
particularly good source of information because many bio-engineering
companies, Universities and information data bases use the Internet to
publish.
The Internet can be used to search for topics relating to bio-engineering
through what are known as search engines that scan the Internet for any
topic nominated by the user. Search engines such as Google, Alta Vista,
Answers, Big Pond, are all useful for this purpose. Another form of
search engine that is considered to be more effective in searching for a
topic is a multi-site search engine. Dogpile <www.dogpile.com/> is a
multi-site search engine that searches a number of other sites
simultaneously, therefore giving a far more powerful search for topics.
Another type of search engine is one that clusters the URLs into sub
topics. An example of such a search engine is Vivisimo
www.vivisimo.com. This effective eliminates long lists of URLs that can
be generated by other search engines.
An important area of bio-engineering are the drawings and specifications
of artificial organs and limbs. As well as the design and research
involved in developing these articles, precise drawings need to be
developed that clearly indicate to those who construct them what
materials and sizes are to be used. The accepted form of graphical
communication for this is known as orthogonal projection.
Design and construction in fields such as electrical, mechanical and civil
engineering as well as architecture are governed by different codes or
Bio-engineering
27
standards. The name of the Australian Standard code for the mechanical
drawings is AS 1100.
You will need to begin your research in the bio-engineering area for your
engineering report in Part 5 of this module.
28
Exercises
Exercise 2.1
a
___________________________________________________
___________________________________________________
___________________________________________________
ii
___________________________________________________
___________________________________________________
___________________________________________________
iii ___________________________________________________
___________________________________________________
___________________________________________________
iv
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
Bio-engineering
29
Sand
Sand
Sand
Metal
Sand
Sand
Sand
Metal
Figure 2.23 Grain structure in a sand /sand mould and a sand/metal mould
Sand
Sand
Sand
Sand
Figure 2.24 Grain structure with correct casting temperature
ii
30
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Bio-engineering
31
Exercise 2.2
a
32
___________________________________________________
ii
___________________________________________________
iii
___________________________________________________
iv
___________________________________________________
___________________________________________________
__________________________________________________
ii
__________________________________________________
Exercise 2.3
a
Welding
___________________________________________________
ii
Brazing
___________________________________________________
Exercise 2.4
For a material to be suitable as a bio-engineering material it must be biocompatible.
a
ii
Bio-engineering
33
____________________________________________________
____________________________________________________
c
____________________________________________________
____________________________________________________
____________________________________________________
ii
____________________________________________________
____________________________________________________
Disadvantage
1 ____________________
1 ____________________
2 ____________________
2 ____________________
Exercise 2.5
i
ii
34
Progress check
In this part you examined materials used in bio-engineering, their
structure and properties and methods of forming.
Uncertain
Agree
Take a few moments to reflect on your learning then tick the box that best
represents your level of understanding.
Forming methods
casting
forging
fabrication
I have to learn to
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
Bio-engineering
35
36
Name: _____________________________
Check!
Have you have completed the following exercises?
Exercise 2.1
Exercise 2.2
Exercise 2.3
Exercise 2.4
Exercise 2.5
If you study Stage 6 Engineering Studies through a Distance Education
Centre/School (DEC) you will need to return the exercise sheets with
your responses as you complete each part of the module. Do not return
all the notes. They should be kept for future reference.
A regular return of work is required.
If you study Stage 6 Engineering Studies through the OTEN Open
Learning Program (OLP) refer to the Learners Guide to determine which
exercises you need to return to your teacher along with the Mark Record
Slip.
Bio-engineering
37
Bio-engineering
Part 3: Bio-engineering
mechanics
Part 3 contents
Introduction ..........................................................................................2
What you will learn?................................................................... 2
Bio-engineering
Introduction
In this part you will apply mathematical and graphical methods to solve
problems in bio-engineering.
orders of levers
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
Mechanical analysis
Order of levers
Levers are a very simple mechanism that can be put to great effect in bioengineering products.
Levers are classified into three groups, know as orders first order,
second order and third order.
A lever is a rigid bar that is acted on by a load and an effort and
supported at pivot point called a fulcrum. The positioning of these three
points vary to give the three different orders of levers.
A first order lever is where the fulcrum is between the load and effort.
An example of this is surgical scissors shown in figure 3.1.
effort
load
fulcrum
Figure 3.1 First Order lever surgical scissors
Bio-engineering
A second order lever is where the load and effort are on the same side of
the fulcrum with the load nearest the fulcrum. An example of this is a
cheek retractor shown in figure 3.2.
load
fulcrum
cheek retractor
effort
A third order lever is where the load and effort are on the same side of
the fulcrum with the effort nearest the fulcrum. An example of this is the
tweezers shown in figure 3.3.
effort
fulcrum
load
Figure 3.3 Third order lever surgical tweezers
The distance from the fulcrum to the load is called the load arm and from
the fulcrum to the effort is called the effort arm.
The principle of moments can be used to calculate the forces as required.
SM =
=
0
(Load Load Arm) (Effort Effort Arm)
Mechanical advantage
A machine, or mechanism, is a device for doing work in overcoming a
resistance, or a load, by applying a force known as an effort.
Machines may be used to help do work with less effort, or with greater
speed.
load
effort
L
E
Worked example 1
The clamp shown in the figure 3.4 requires a force of 5 N to achieve a
clamping force of 10 N.
Determine the mechanical advantage.
Effort
Load
Fulcrum
0.1
Figure 3.4
0.1
MA =
=
Load
Effort
10
5
\ MA = 2
Worked example 2
An effort of 50 N is required to lift a load of 24 kg using a lever.
Calculate the MA of the lever.
You will recall that when a mass is given in kg, then you must convert
this to a force (weight). This is done by multiplying the mass (m) by the
gravitational attraction (g).
Bio-engineering
MA =
=
L
E
240
50
= 4.8
Mechanical advantage is a ratio of two forces and has no units, that is, it
is dimensionless.
Name another bio-engineered product that uses the principles of
mechanical advantage in its design.
__________________________________________________________
Did you answer?
Velocity ratio
The trade off in the previous situation was that when we apply a smaller
effort to lift a larger load, we have to move the effort through a greater
distance.
This is expressed as the velocity ratio (VR). As the name implies, it is a
ratio of two velocities. Velocity is found by measuring the distance
moved over a period of time.
VR =
velocity of effort
velocity of load
The velocity ratio is independent of the size of both the applied effort and
the load being lifted.
It is independent of frictional forces in the system. If there is friction in
the system, then the system will be inefficient.
The efficiency (h) of a device is the ratio of mechanical advantage to
velocity ratio.
h =
MA
100%
VR
Bio-engineering
0.005
0.3
0.0166
E
1200
60
1.2
= 50 N
The effort required to lift the load is 50 N.
Pulley systems
There are numerous examples of pulley systems in bio-engineered
products, including lifting apparatus for bed-ridden patients with broken
legs.
Effort
Load
Bio-engineering
50
250
Load
E = 600 N
From this free body diagram, you will notice that it resembles a lever.
The same principles, and calculation techniques, can be applied.
SM = 0
= (F1 d1) + (F2 d2)
= 600 250 L 50
50 L = 150 000
L = 3000
Therefore a load of 3000 N (or mass 300 kg) can be lifted.
load
effort
10
effort
load
Figure 3.9
L
2
F2 =
L
2
Load (L)
Figure 3.10 Analysis of the movable pulley
Bio-engineering
11
The force in the rope has the same magnitude therefore the lifting force is
L
.
2
For example, if the load is 100 kg (1000 N), then the tension in the rope
required to hold the load would be 500 N. If more than 500 N was applied
then the load would be raised.
T2
C
B
T2
T1
T1
effort
load
Figure 3.11 Multiple movable pulleys
For pulley A
2T1 = L
\ T1 =
L
2
For pulley B
2T2 = T1
12
2T2 =
L
2
\ T2 =
L
4
L
4
Thus MA = VR
= 4
Worked example 4
A pulley system similar to that shown in figure 3.11 is used to lift a load
of 100 kg. Determine effort to just lift the load.
100 kg
= 1000 N
from E
then E =
L
4
1000
4
= 250 N
Bio-engineering
13
Determine the velocity ratio and mechanical advantage of the block and
tackle system for the pulley system shown in figure 3.12.
T T
T T
Load
W
Figure 3.12 Block and tackle (T is for tension)
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
Did you answer?
Velocity Ratio
VR
SF
T+T+T+TW = 0
4T
Mechanical Advantage.
For equilibrium:
Since the tension in the rope is assumed to be constant throughout the length of
the rope (frictionless pulleys), then the applied effort will also be equal to the
tension in the rope (T).
14
MA
Load
Effort
4T
T
= 4
In practice, the weight of the pulley block should also be included in the load,
as this weight also needs to be raised.
Inclined plane
The inclined plane is a simple mechanism with no moving parts. It is
commonly found in bio-engineering applications. The most recognisable
inclined plane would be the ramp, which can be used to lift a load from
one level to another level. This can be achieved by sliding the object up
the incline.
Effort
Normal reaction, N
30
Weight, W = mg
Figure 3.13 Example of inclined plane
This is also an application of the three force rule dealt with in earlier.
Worked example 5
Find the force, mechanical advantage and velocity ratio necessary to
move a box with a mass of 30 kg holding a wheelchair that needs to be
lifted from ground level through a vertical height of 2 m up a smooth
inclined surface.
There are three forces acting on the box. These are the effort required to
move the box up the plane, the weight of the box (load), and the normal
reaction of the plane (always at right angles to the surface).
Bio-engineering
15
30
W = mg
= 30 x 10
= 300 N
From the free body diagram, you can draw a force diagram. Remember
this is drawn to scale.
E
W = 300 N
Scale 1mm = 1N
N
Load
Effort
300
150
= 2
VR =
=
16
1
sinq
1
sin 30
1
0.5
= 2
Note that the MA and VR are the same. That is because the incline was
assumed to be smooth (no friction) and thus 100% efficient.
Because the inclined plane has a mechanical advantage, it is classified as
a simple machine.
Turn to the exercise sheets and complete exercise 3.2. and 3.3.
Load
unit is Pa
Area
Bio-engineering
17
CSA
Tensile stress
CSA
Compressive stress
e =
Extension
Originallength
18
CSA
Tensile stress
Figure 3.17 Specimen subjected to a tensile load
Area in tension =
pd 2
4
p(12 10 -3 ) 2
4
p 144 10 -6
4
= 113 10-6 m2
Force = 50 kN
= 50 103 N
Stress (s) =
=
F
A
50 103
113 10 -6
= 442 106 Pa
Worked example 7
A specimen with an original length of 300 mm is subjected to a tensile
load of 40 kN and it was observed that there was an extension of 1.5 mm.
Determine the strain on the specimen.
Strain =
=
extension
Original length
1.5
300
= 0.005
Bio-engineering
19
Strain ( )
Figure 3.18 Stress/strain diagram for a ferrous metal
Yield point the point where the material yields and stress is no
longer proportional to strain. This is the end of what is known as the
elastic range on the graph and where the plastic range begins. Once
the plastic range is reached the material can no longer return to its
original shape because it is permanently distorted.
20
Stress ( )
Strain ( )
0.002
stress
strain
E =
s
e
P
A
e
L
P L
A e
Where L
load
stress
strain
modulus of elasticity
Bio-engineering
21
Worked example 8
Determine the Modulus of elasticity for a specimen that had an original
length of 50 mm and diameter of 3.5 mm that when subjected to a tensile
load of 25 kN extended 6 mm.
Before commencing to use the formulae it is necessary to convert all of
the data into the appropriate units. Remembering that force (F or P) is
measure in N, distance is measured in m and area is m 2.
Data given:
Force = 25 kN
= 25 103 N
Origional length = 50 mm
= 50 10-3 m
extension (e) = 6 mm
= 6 10-3 m
Area =
=
pd 2
4
p( 3.5 10 -3 ) 2
4
= 9.621 10-6 m2
Modulus of elasticity =
E =
=
s
e
P L
A e
( 25 103 ) (50 10 -3 )
( 9.62110 -6 ) (6 10 -3 )
25 50103 10 -3
9.621 10 -6 6 10 -3
1250
57.73 10 -9
= 21 109
= 21 GPa
Turn to the exercise sheets and complete exercise 3.4. and 3.5.
22
Bio-engineering
23
24
Exercises
Exercise 3.1
a
State the order of lever, created by the position of effort, load and
fulcrum, beside each of the following.
_______________________
ii
fulcrum
effort
load
_______________________
ii
fulcrum
load
effort
Figure 3.22 Surgical scissors
fulcrum
_______________________
ii
effort
load
Bio-engineering
25
_______________________
ii
effort
load
fulcrum
effort
load
_______________________
ii
fulcrum
Exercise 3.2
The pulley system shown in figure 3.17 is part of an apparatus attached
to a bed in a hospital to lift the leg of patients.
effort
load
Figure 3.26 Hospital pulley system
26
25
50
75
100
125
Effort
13
22
30
38
47
Effort
Load
Figure 3.27 Load versus effort
Bio-engineering
27
Exercise 3.3
Examine and analyse the function of a screw jack.
350
The screw jack has a pitch (the distance between two consecutive
threads) of 5 mm and is operated by a bar of effective length of 350 mm.
This bar will turn the head on the top end of the threaded section of the
jack.
a
28
Exercise 3.4
a
Bio-engineering
29
30
25
30
20
10
30
Exercise 3.5
a
Nonferrous
Stress (N/m)
Strain
Figure 3.30 Stress/strain diagram for low ductile material
Bio-engineering
31
12
P
Figure 3.31 Pin
32
Progress check
In this part you applied mathematical and graphical methods to solve
problems in bio-engineering.
Uncertain
Agree
Take a few moments to reflect on your learning then tick the box that best
represents your level of understanding.
I have learnt to
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
In the next part you will develop your drawing skills to communicate
bio-engineering ideas.
Bio-engineering
33
34
Name: _____________________________
Check!
Exercise 3.1
Exercise 3.2
Exercise 3.3
Exercise 3.4
Exercise 3.5
Bio-engineering
35
Bio-engineering
Part 4: Bioengineering
communication
Part 4 contents
Introduction ..........................................................................................2
What will you learn?................................................................... 2
Collaborative researching................................................................17
Exercises ...........................................................................................19
Progress check .................................................................................25
Exercise cover sheet........................................................................27
Bio-engineering
Introduction
In this part you will develop your orthogonal drawing skills employed by
engineers in all filed, including bio-engineering, to communicate
information.
dimensioning
collaborative working.
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
Communication
Orthogonal drawing
Bio-engineered products are generally manufactured to the most stringent
standards. This means that sizes must be extremely accurate.
The accuracy of a size is defined by a tolerance the amount of variation
allowable from a stated size. In the case of bio-engineered products, a
tolerance of 1/100th mm would be common.
Explain why accurate sizes are important in bio-products.
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
Did you answer?
Many bio-engineered products need to be custom designed and built for a
particular client. It is important that these components are made to exact
specifications in order that components fit together or operate in the spaces
available.
Bio-engineering
Line types
The type of line used in a drawing can communicate information about
the object to the reader. The following table contains examples of line
styles, examples and common applications.
Line style
Example
Common application
All visible outlines
Continuous
thick
General details
Existing buildings
Landscaping in site
plans
Dimension lines
Projection lines
Continuous thin
Continuous
thin, free-hand
Break lines
Dash thin
Hidden outlines
Chain thin
Chain thick at
ends & at change
of direction
Cutting planes
Bio-engineering
Drawing symbols
The following table contains examples of common drawing symbols
representing specific features that need to be identified.
Symbol
Example
Common application
Diameter of a circle or
cylinder
Placed in front of the
dimension
25
R 10
Radius
Placed in front of the
dimension
10
1:3
Indicates a taper and its
direction
1:6
Indicates a slope and its
direction
SR 15
Indicates the radius of a
spherical surface
Symbol
Example
8
Common Application
16 x 90
Indicates a counter sink
Placed in front of the
dimension
16
Indicates a counterbore
or spotface
Placed in front of the
dimension
10
12
Indicates the depth of a
feature
Bio-engineering
Physical features
The following table define and describe common features found on many
engineered objects. You will be asked to draw several of these features
in the exercise section of this module.
Feature
Explanation
Pictorial
Orthogonal
R 10
Radius
Fillet
Curved edge
on a corner
of a part
A curved
shoulder at
the joining
plane of two
surfaces.
RADIUS
FILLET
R5
Increases
strength
Web
A thin part
that acts as a
support to
increase
strength
Blind hole
A hole drilled
to a
particular
depth
WEB
12
BLIND HOLE
Pitch circle
diameter
(PCD)
The diameter
of a circle on
which holes
or other
features are
placed
Flange
A rim on a
part that is
used for
joining
FLANGE
COUNTERBORE
Counterbore
40
6x 6
EQUISPACED
16
12
An
enlargenent
of a hole
Feature
Explanation
Pictorial
Orthogonal
COUNTERSINK
12 x 60
An
enlargement
of a hole
conically
Spigot
An extended
cylinder or
plug which
fits into a
matching
recess
Boss
A cylindrical
extension on
a casting or
forging
12
BOSS
Countersink
SPIGOT
8
RECESS
Recess
10
A mating
hole in which
a spigot fits
An inclined
plane
Taper
TAPER
TAPER
1:3
A part
conical
section
SHAFT
Shaft
A bar which
transmits
motion or
power
Key
Joins a shaft
to a pulley so
as to
eliminate any
slipping
occurring
between the
two parts.
20
KEYS
Bio-engineering
Dimensioning
Dimensioning was introduced in Landscape products. At this time only
dimensions related to horizontal and vertical surfaces were considered.
Bio-engineering projects include a number of other types of surfaces and
planes.
Radii
R5
R 20 000
R5
R5
R4
R5
R 150
Figure 4.4
Small spaces
Figure 4.5
Spherical shapes
10
20
SR 15
SR
Figure 4.6
Spherical shapes
Squares sections
the Bdenotes a square as shown in figure 4.7.
10
15
Figure 4.7
Square symbol
Tapers
there are several techniques acceptable for indicating a taper, a
diameter might be specified at a particular distance, or an angle
for the taper might be indicated as shown in figure 4.8.
36
20
15
45
15
20
45
Bio-engineering
11
Quality
Application
0.025
0.05
Fine
quality
finish and
costly to
produce
Medium
quality
finishes
0.4
0.8
3.2
6.3
25
12
8.00
7.95
12.00
11.96
Bio-engineering
13
Sectioning
Sections are often used to show hidden detail. A sectioned view shows
the part of an object that remains after a portion has been removed. The
remaining face is usually cross-hatched with continuous, thin lines at an
angle of 45o to the horizontal as shown in figure 4.13. Horizontal or
vertical cross-hatching section lines could cause confusion with other
aspects of the drawing.
If there are two adjoining parts to be sectioned then the section lines for
the second part should be at a different direction or angle as shown in
figure 4.14.
14
SECTION A-A
Figure 4.15 Sectional views
When sectioning a part that contains a fastener (bolt, pin, rivet, key,
washers) shaft, bearing or similar device then no sectioning is shown on
these items; thin elements such as webs, lugs and spokes need not be
sectioned and; holes may be shown even if the cutting plane does not
pass through the center of the hole as shown in figure 4.17.
Bio-engineering
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Collaborativeresearching
Two researchers would undertake research into the topic using CDROMs, the Internet or libraries.
It can be seen that this team would present a far more powerful approach
to solving the problem than an individual working separately on all areas.
Can you think 3 advantages of researching as a team? Can you also think
of one disadvantage?
Turn to the exercise sheets and complete exercise 4.1 to 4.4.
Bio-engineering
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18
Exercises
Exercise 4.1
Identify the following features.
Feature
Name
Bio-engineering
19
Exercise 4.2
Draw a freehand representation of the following physical features
applying AS1100 standards:
20
Bio-engineering
21
Exercise 4.3
Measure and dimension the three following orthogonal views in figure 4.19.
22
Exercise 4.4
Complete the orthogonal view of the pin shown in figure 4.20 by adding
the top view and the major dimensions.
Scale 1 : 1.
Bio-engineering
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Progress check
In this part you developed your orthogonal drawing skills employed by
bio-engineers to communicate information.
Uncertain
Agree
Take a few moments to reflect on your learning then tick the box that best
represents your level of understanding.
dimensioning
research methods.
I have learnt to
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
In the next part you will draw on your knowledge and skills to produce
an engineering report on one aspect of bio-engineering.
Bio-engineering
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26
Name: _____________________________
Check!
Have you have completed the following exercises?
Exercise 4.1
Exercise 4.2
Exercise 4.3
Exercise 4.4
Bio-engineering
27
Bio-engineering
Part 5: Bio-engineering
engineering report
Part 5 contents
Introduction..........................................................................................2
What will you learn?................................................................... 2
Engineering report..............................................................................3
Aims of an engineering report..................................................... 3
Structure of an engineering report............................................... 4
Developing an engineering report ............................................... 6
Sample engineering report ......................................................... 7
Exercises ...........................................................................................17
Progress check .................................................................................19
Exercise cover sheet........................................................................21
Bibliography.......................................................................................23
Module evaluation ............................................................................25
Introduction
communication
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
Lifting devices
Engineering report
title
abstract
introduction
analysis
result summary
conclusions/recommendations
acknowledgments
bibliography
appendices.
Title page
The title page gives the title of the engineering report, identifies the
author and gives the date when the report was completed.
Abstract
The abstract is a concise statement that describes the content of the
engineering report. It covers the scope of the report (what it is about)
and the approaches used to complete the analysis (how the information
was assembled).
The purpose of the abstract is to allow a reader to decide if the
engineering report contains relevant information.
The abstract should be no more than two or three paragraphs shorter if
possible.
Lifting devices
Introduction
The introduction provides an overview of the subject, purpose and scope of the
engineering report. It may contain background information regarding the topic.
It also outlines the sections of the engineering report including why the
investigation was undertaken, what research occurred, how data was collected
and what analysis was conducted.
Analysis
The analysis is the body of the engineering report and should show evidence of
research and experimentation. Information about materials and the mechanics
of products should be collected or calculated for all engineering reports. This
section must contain information required to satisfy the aim and purpose of the
report.
Tables and graphs, used to summarise detailed data in a concise form, are
common features of an engineering report.
Result summary
The result summary should present the results concisely and note any
limitations on the investigation.
The results inform and support the conclusions and recommendations.
Conclusions/recommendations
The conclusions/recommendations summarises major points or issues in earlier
sections of the engineering report.
This section requires the author to draw conclusions or make recommendations
based on data collected. If the purpose of the engineering report was to select
the best.., then the selection should be stated and the reason for the choice
explained.
Acknowledgments
The acknowledgment section provides the opportunity to credit other peoples
work that has contributed to the report.
Bibliography
The bibliography demonstrates that the report is well researched all
references need to be included. Bibliographic entries should follow established
guidelines.
This information allows the reader to source the information for confirmation
of the details or conduct further research.
Appendices
The appendices should contain detail that has been separated from the main
body of the engineering report. The information in this section is not essential
but enhances the other data. Examples could be engineering drawings of
products being compared, where the overall dimensions of the product may not
have been part of the report, but may be relevant to some readers.
During the engineering course this section may contain a technical drawing and
could include information collected from organisations.
Research methods
Research is a critical function for professional engineers. The process
involves:
1
Collecting data
The second step involves collecting data. Sources such as the
Internet, CD-ROM, encyclopedia, texts and journals are all locations
where information can be gathered.
Lifting devices
NOTE:
Take care when gathering information from the Internet. Verify
the accuracy and reliability of the information by checking the
qualifications of the source, it cannot be assumed that the person(s)
placing the information on the Internet is an expert on the subject.
Lifting devices
Bio-engineering
Title:
Bio-fuels
Author/s:
D. Iesel
Date:
January 2000
Abstract
This report will examine the possible role that an environmental
bio-engineer could play in assessing the potential for developing
sustainable alternatives to the current use of fossil based fuels.
Introduction
The realm of the bio-engineer is particularly wide and can cover areas
ranging from cutting edge experimental medical technology, refining
existing medical technologies and practices through to the genetic
modification of plant crops to enhance harvest quality and quantity
and environmental management.
This report, developed by a bio-engineer specialising in environmental
management will show that the continued use of non-renewable fossil
based fuels is environmentally disastrous, and the continued use of
such fuels without modification and exploring alternatives is ethically
irresponsible. It will be shown that the burning of fossil fuels is a
significant contributor to the air pollution levels in major cities and is
responsible for numerous serious medical conditions throughout the
world. As such engineers are ethically bound to explore and find
alternatives that will result in an improved and sustainable living
environment.
Environmental pollution has reached a level that impacts on all living
species on the planet and it is imperative that the sources of pollution
are identified and research be conducted into methods for reducing the
quantities of pollutants being emitted.
Air pollution can be described as the presence in the atmosphere of
any contaminates that may be injurious to the health or welfare of
animal and plant life.
Pollutants can be classified as either natural or human generated.
Analysis
Vehicles, such as cars and trucks, with petrol and diesel engines are
increasing their numbers on the roads of the world today at ever
alarming rates. In the last 50 years their numbers have increased
dramatically and each one of these vehicles will produce significant
quantities of potentially harmful by-products.
Without some form of intervention into their pollution cycle the
quantity of pollutants will choke the cities and render them
uninhabitable.
Data from the US census Bureau indicates that there are currently
in excess of 221 475 000 vehicles on US roads at the moment which
are consuming more than 220 000 000 000 gallons or over
900 000 000 000 litres of fuel annually. These figures only account
for the US and considerable quantities of fuel would be used in
Europe and Asia as well. No matter how these figures are viewed,
this is a lot of fuel.
It has been estimated that for every mile traveled, vehicles emit 3.3
grams of volatile organic compounds, 27.52 grams of carbon
monoxide (CO) and 2 grams of Nitrous oxides (NOx ). This means
that there will be at least 14 520 000 tonnes of volatile organic
compounds, 121 088 000 tonnes of CO and 8 800 000 Tonnes of NO x
released into the atmosphere annually.
The composition of global atmospheric pollution produced by
vehicles includes significant quantities of lead (used in fuel as a
lubricant), solid particulate matter (SPM), sulfur dioxide, nitrogen
oxides and carbon monoxide. Many of these pollutants can be
minimized by improving the efficiency of the fuel burn in the engine
combustion chamber and by modifying the chemical composition of
the fuel.
Alternative fuels
The notion of sustainability resulted in the vehicle manufacturers
developing more efficient motors and experimenting with alternative
fuel supplies liquid petroleum gas (LPG) and compressed natural
gas (CNG). LPG is widely available across most areas of Australia
and has been proven as a reliable and cleaner fuel. Compared to
petrol-powered vehicles LPG produces about 12% less CO2 , 30% less
NOx , CO and hydrocarbons and if compared to diesel vehicles it
produces about 90% less NOx and only 1/50th of the amount of
particles. As a result of the pricing structures it is more cost efficient
too.
CNG has been used in a number of bus fleets and by some councils in
Sydney, but the wide spread uptake has been hindered by the lack of
available purchase points for the public.
Biodiesel
Biodiesel is a clean burning replacement diesel fuel suitable for all
compression ignition engines. Biodiesel can be made from either pure
(new) or recycled vegetable oils, animal fats or restaurant greases.
Biodiesel can be blended with petroleum diesel and used in many nonmodified diesel engines. Commonly 20% biodiesel is mixed with
80% petroleum diesel, this blend is known as B20, whereas pure
biodiesel is designated as B100. Engines using B100 fuel may need to
be modified to take advantage of this type of fuel. The transportation
and storage of this fuel requires no special requirements and in many
instances is safer than petroleum diesel fuel in that the flash point of
biodiesel is 150o C rather than 77o C.
Independent tests have shown that biodiesel produces a significant
reduction in all aspects of emissions and that it does not pose a threat
to human health. In the year 2000, biodiesel was recognised as the
only alternative fuel to successfully satisfy the stringent test
requirements under the US Clean Air Act.
The use of biodiesel significantly decreases the exhaust emissions of
SPM and decreases the CO levels. The CO is converted to CO2
because of a more complete combustion and similar decreases in the
sulfur dioxide emissions are also observed.
The crops used to produce biodiesel absorb large amounts of CO2 as
they grow and as the fuel is non-toxic and biodegradable it is an
excellent fuel for use in fragile environments including estuaries,
lakes, rivers, and national parks.
Electricity
Electricity has been used to power transport networks for many years
trains, trams and trolley busses. But these networks are limited in
that the vehicle must follow specific paths.
To allow for a wider ranging network electricity needs to be stored.
This storage has been through using batteries. Although there has been
significant research into the development of battery storage systems
they are still large and have limited applications.
At present most electric vehicles have a limited range because of the
storage capacity of the batteries and they need to be recharged at very
regular intervals. Development of the hybrid electric vehicle (HEV) is
being carried out and many of the major vehicle manufacturers are
expected to have such vehicles available for personal transport within
the next few years.
There is also significant research currently being undertaken in the
development of the fuel cell. These cells produce electricity by the
electrochemical reaction that takes place between hydrogen and
oxygen in a fuel cell stack. The nonpolluting byproducts of this
reaction are heat and water. This makes it an extremely clean and
efficient fuel but currently this technology is only in its infancy.
Ethanol
The mixing of ethanol with diesel to produce E-diesel is a new
process and the results are not yet conclusive. The mixing of ethanol
with diesel lowers the flash point of the fuel making it more like petrol
to handle. This would necessitate the probable modification of current
diesel motors and would void the manufacturers warranty. As yet this
fuel has not passed the environmental regulations required by the US
Clean Air Act.
Recently in Australia there has been significant controversy over some
fuel distributors adding quantities of ethanol to the fuel supplies.
Vehicle manufacturers have declined to offer warranties for their
vehicles if they are operated with fuels containing significant
percentages of ethanol.
Result summary
Historically there has been significant development of motors and
transport systems based on fossil fuels. Much of the recent activity
has resulted in motors becoming more efficient with their use of fuel
and decreasing the emission of pollutants. But from the shear
numbers of vehicles on the road today there is a need to actively
pursue developments focusing on renewable and nonpolluting energy
sources.
Whilst in the long-term fuel cell and solar technologies may be able to
sustain the fuel requirements it is apparent that short term solutions
need to be developed and implemented as soon as possible. Such an
alternative is the development of biodiesel. It uses existing motor
technology and the fuels are environmentally sustainable.
The results from developing such a fuel would have immediate and
dramatic impacts on the quantities if fossil fuel currently being used
and the pollution profile of vehicles. Whilst diesel motors are
commonly used as truck motors they are becoming more widely used
in passenger vehicles. This trend is particularly apparent in Europe
and is spreading worldwide with the introduction of small highpowered turbo diesel engines for cars.
Conclusions/recommendations
The development of sustainable fuel supplies in both the short and the
long-terms is dependent on the involvement of bio-engineers in the
field of environmental engineering.
Initially the bio-engineer may be involved in developing a crop source
that could be used to supply oil for traditional motors. This may
involve developing better cropping methodology, production
techniques and possible genetic modification of the crop to increase
harvest and quality of the product.
Additionally the bio-engineer may be involved with the development
of recycling methods and reprocessing centers for the repurposing of
various oil products into usable fuels.
Bibliography
The Australian Academy of Technological Sciences and Engineering
<http://www.atse.org.au/publications/reports/urbair3.htm> (accessed
13.08.03)
16
Exercises
Exercises 5.1
Select a bio-engineering development that interests you and report on the
nature of the work done and the related issues.
Describe the project and the technologies that are associated with the
project.
Possible areas could include:
Bio-engineering
17
18
Progress check
In this part of the module you applied your knowledge and skills to
produce an engineering report on bio-engineering the nature of the
work and the ethics related to the profession.
Uncertain
Agree
Take a few moments to reflect on your learning then tick the box that best
represents your level of understanding.
communication
I have learnt to
Extract from Stage 6 Engineering Studies Syllabus Board of Studies NSW, 1999.
Refer to <http//www.boardofstudies.nsw.edu.au> for original and current documents.
Bio-engineering
19
20
Exercises 5.1
Name: _____________________________
Check!
Have you completed the following exercise?
Exercise 5.1
title page
abstract
introduction
analysis
results summary
conclusions/recommendations
acknowledgments
bibliography
appendices.
Bio-engineering
21
22
Bibliography
23
24
Module evaluation
male
female
Study through
DEC
OTEN - OLP
Other
Age group
under 20 years
20 30 years
over 30
Circle the number that best represents your rating of this material.
The number 1 indicates a low rating and the number 5 indicates a high
rating.
There is room to make comment if you would like.
1
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
25
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
____________________________
Finally!
Which were the most challenging parts of the material?
__________________________________________________________
__________________________________________________________
Please return this form to your teacher to forward on to OTEN LMP.
Thank you for this valuable information.
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