Summary of processes and experiences.
Project group members: Rownaq Saba Azom [Administrator], Edward Ling [Subject-Matter Expert], Shangrui (Cruz) Wu [Subject-Matter Expert], Izza Hammad [Coordinator], Mohammad Mahdi Mahboob [Manager].
Figure 1. Team Photo.
This project was a materials selection project where my team and I were tasked with selecting the best material to use in a state-of-the-art wind turbine blade for the Swedish Wind and Energy Association. The blade was to be designed for a large-scale system that was both as environmentally conscious as possible and efficient, as it needed to power large populations while remaining conscious about its impact on the Earth. We began by defining a problem statement, from which we drew objective trees and determined the most crucial criteria to evaluate when selecting the material. We used software to then evaluate material sets based on these criteria and selected some of the top-ranking materials as finalists. We then determined additional criteria to consider about the properties of each of the materials; these were used to create a weighted decision matrix, where the finalists were placed and assigned scores based on their ability to meet the criteria. The matrix determined that low alloy steel was the best material to use in this project, and we selected this material since it was also less environmentally-taxing to mass-produce. Finally, we ran deflection calculations and simulations on a design that best fit the material properties of low alloy steel to determine a thickness that made the blade deflect within a specific range. We decided upon a thickness of 28 mm as it gave a deflection within the specified range but also reduced the amount of material removed, thereby creating less waste, which was a critical consideration for our client.
This materials selection project was a unique experience for me. I had previously never done anything related to materials selection before and, throughout the course of these 4 weeks, I learned a lot about the subject and its importance in the engineering field. That being said, material science was not the only exposure this project gave me; I also learned about the engineering design process and how to start form defining correctly the issue at hand, to outlining details that would help to solve the problem, and then using these details to form guidelines for a solution. I believe that this is a crucial skill to have as an engineer, and I know that I will be using these skills in any project that I choose to undertake.
The project also brought me out of my comfort zone: I mainly focused on working with software previously, and dabbled a little bit with electronics and circuits, but I did not like to do work related to material selection and physical design. In fact, I was very skeptical about using Inventor and modeling and testing the physical design of the wind blade; however, as I was doing this project, I realized that these were not as difficult as I perceived them to be. This project gave me exposure to these subjects and I feel more confident going forwards about designing parts and conducting material selection processes.
I have also gained vital teamwork experience during this project. I took on the role of manager, which I am familiar to as I usually took similar roles in projects and programs prior to arriving at McMaster. What I was not familiar with was working with students who were just as, if not more, exceptional as me. This allowed me to divide work more evenly amongst my peers, as well as trust that they could get their work done correctly and on time. I had never previously had the luxury of trusting group members with work, but this skill is crucial in the workplace and I am glad I was able to work as an actual group member, on tasks specifically assigned to me, and minimally helping my peers. This project was a great trust-building experience, and I feel that this aspect of the project will be essential in both future projects in this course and outside of it.