Length: 7 weeks (3 lectures, interim presentations and final presentation session)
Level: 1st year Sports and Materials Science course
Aims: To demonstrate the application of theoretical concepts in a item of sporting equipment and to encourage students to carry out independent research and study on the topic.
Key skills: Group work, presentation skills, independent research
Assessment: Group report and presentation
This case study involves you working in groups of 5-6 to investigate materials selection and construction windsurfing masts. Windsurfing masts have to fulfil a certain criteria and you must research into the types of material that could be used to meet that criterion.
Session 1 (lecture)
Case study learning and key skill development
Mast Technology
Design Requirements
Materials Selection
Task: Use the Internet to investigate manufacturers websites . Find out what they 'claim' their masts are made from and how they are made.
Produce a list of keywords on mast technology
Session 2 (lecture)
Composite Architecture
Mechanical properties
Calculations of mechanical force and modulus
By the end of this session you should be able to
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Describe the materials used in the construction of a windsurfing mast
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Use the equations that describe the mechanical properties of a uni-directional composite
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Recognise simple fibre architectures
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Specify a mast stiffness and composite modulus for the mast
Session 3 (lecture)
Mast/composite structure production
Filament winding
Curing
Vacuum bag and Autoclave
By the end of this session you should be able to
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Understand how winding pitch affects the modulus of the composite
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Describe the steps involved in the preparation of a composite for curing
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Understand the difference between autoclave and vacuum bag
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Suggest a suitable production method for a mast
Session 4
Mini-presentation of work to date
Session 5
Independent study
Session 6
Presentations
Case Study Tasks
1. Decide on the design requirements for the mast
2. Select a range of materials based on these criteria
3. Refine the selection based on the following cases,
Case 1 (to be considered for a weekend sailor and an infrequent sailor)
· Force 3 wind
· Required Modulus - > 10 GPa
· Required Strength - > 100 MPa
Case 2 (applies to competition masts)
· Force 5 and above
· Required Modulus - > 100 GPa
· Required Strength - > 1 GPa
4. Choose a production process
Assessment
Each group will must submit a single written report (60% of student's marks) summarising the main findings and conclusions drawn. The report is to be 1500 words long (about 4 pages) not including diagrams. The main text should be 12 point text size with 1.5 line spacing. There should also be a 200 word summary with 10 point text size and single line spacing. The report should take the following format:
Introduction - page 1 - background to the mast and the sport
Materials Selection - page 2 - design criteria, ideal materials and their properties
Specification of winding pitch - page 3 - outline steps and working of calculation
Mast production - page 4 - how could the final product be made
Conclusions - page 4 - bullet points
Each group must also give a 10 minute presentation on one aspect of the case study (40% of the case study mark). You must elect 2 or 3 group members to do the presentation. Ensure you introduce who you are and the main areas in your talk. Finish with a slide showing the main conclusions.
Click on the links for tips on presentations and report writing.