Advanced Mechanical Engineering MSc

• Professor Nigel Simms

This module introduces you to the principles of risk and reliability engineering, and associated tools and methods to solve relevant engineering problems in industry.

• Introduction and fundamentals of risk management and reliability engineering,
• Failure distributions: how to analysis and interpret failure data, introduce the most commonly used discrete and continuous failure distributions (e.g. Poisson, Exponential, Weibull and Normal),
• Risk management process: hazard identification, assessment, evaluation and mitigation (risk acceptance, reduction, ignorance, transfer),
• Risk assessment techniques: risk matrix, Pareto analysis, fault tree analysis (FTA), event tree analysis (ETA), failure mode and effects analysis (FMEA), failure mode, effects and criticality analysis (FMECA), hazard and operability study (HAZOP),
• Reliability and availability analysis: system duty cycle, breakdown/shutdown, MTTF/MTBF/MTTR, survival, failure/hazard rate,
• Reliability analysis techniques: reliability block diagram (RBD), minimal cut-set (MCS), series and parallel configurations, k-out-of-n systems, active and passive redundancies,
• Introduction to structural reliability analysis: stress strength interference and limit state function, first-order / second-order reliability method (FORM/SORM), damage accumulation and modelling of time-dependent reliability,
• Identification of the role of inspection and structural health monitoring (SHM) in risk reduction and reliability improvement,
• Introduction to maintainability and its various measures,
• Workshops and case studies: work in groups to determine the risk and reliability of subsea production systems, power distribution networks, wind turbines, gas turbines, etc. 

On successful completion of this module you should be able to:

• Identify and analyse the concepts and principals of risk and reliability engineering and their potential applications to different engineering problems,
• Assess and analyse appropriate approaches to the collection and interpretation of data in the application of risk and reliability engineering methods,
• Evaluate and select appropriate techniques and tools for qualitative and quantitative risk analysis and reliability assessment,
• Analyse and evaluate failure distributions, failure likelihood and potential consequences, and develop solutions for control / mitigation of risks.

This module brings together theoretical and computational stress analysis through finite element simulations, allowing you to appreciate how the two disciplines interact in practice and what their strengths and limitations are. The examination of finite element analysis (FEA) for various practical applications (e.g. engineering components, composite structures, rotating disks, cracked geometries) in conjunction with relevant case studies will allow you to combine theoretical understanding with practical experience, to develop your skills to model and analyse complex engineering problems.

• Stress Analysis: introduction to stress analysis of components and structures, ductile and brittle materials, tensile data analysis, material properties, isotropic/kinematic hardening, dynamic strain aging, complex stress and strain, stress and strain transformation, principal stresses, maximum shear stress, Mohr’s circle, constitutive stress-strain equations, fracture and yield criteria, constraint and triaxiality effects, plane stress and plane strain conditions, thin walled cylinder theory, thick walled cylinder theory (Lame equations), compound cylinders, plastic deformation of cylinders, introduction to computational stress analysis,
• Finite Element Analysis: introduction to FEA, types of elements, integration points, meshing, mesh convergence, visualisation, results interpretation, beam structures under static and dynamic loading, stress concentration in steel and composite plates, tubular assemblies, 2D and 3D modelling of solid structures, axisymmetry and symmetry boundary conditions, CS1: Stress and strain variation in a pressure vessel subjected to different loading conditions, CS2: Prediction and validation of the stress and strain fields ahead of the crack tip. (case studies are indicative).

On successful completion of this module you should be able to:

• Develop a strong foundation on stress analysis and demonstrate the ability to analyse a range of structural problems,
• Explain the fundamentals of Finite Element Analysis, be able to evaluate methodologies applied to the analysis of structural members (beams, plates, shells, struts), and critically evaluate the applicability and limitations of the methods and the ability to make use of original thought and judgement when approaching structural analysis,
• Provide an in-depth explanation of current practice through case studies of engineering problems,
• Use the most widely applied commercial finite element software package (ABAQUS) and some of its advanced functionalities,
• Evaluate the importance of mesh sensitivity in finite element simulations.

This module provides you with an understanding of pertinent issues concerning the use of engineering materials and practical tools for solving structural integrity and structural fitness-for-service problems.

• Introduction & structural design philosophies,
• Fatigue crack initiation,
• Fracture mechanics (1) – derivation of G and K,
• Fracture mechanics (2) – LEFM and EPFM,
• Fracture mechanics (3) – evaluation of fracture mechanics parameters; K and J,
• Fracture toughness testing and analysis; KIC and JIC,
• Creep deformation and crack growth,
• Non destructive testing methods,
• Inspection reliability,
• Defect assessment, fatigue and fracture mechanics of welded components,
• Fracture of composites,
• Corrosion engineering.

On successful completion of this module you should be able to:

• Assess fitness-for-service issues and propose appropriate structural integrity solutions,
• Judge the current component life assessment procedures and distinguish their limitations in aspects of structural integrity,
• Develop a critical and analytical approach towards the engineering aspects of structural integrity,
• Be able to confidently assess the applicability of the tools of structural integrity to new problems and apply them appropriately.

• Dr Liang Yang

This module aims to provide you with a theoretical and applied understanding of fluid mechanics and fluid loading on structures.

Principles of fluid dynamics:

• Properties of fluids: control volumes & fluid elements, continuity, momentum & energy equations, stream function & velocity potential, Bernoulli’s equation,
• Flow structures: boundary layer theory, laminar & turbulent flow, steady & unsteady flow, flow breakdown & separations, vortex formation & stability,
• Lifting flows: circulation theory, Prandtl’s lifting-line theory, sources of drag, aerofoil characteristics,
• Fluid loading on horizontal and vertical axis turbines.

Dynamics of floating bodies: from simple hydrostatics to complex dynamic response in waves.

• Hydrostatics of floating bodies; buoyancy forces and stability, initial stability, the wall sided formula and large angle stability, stability losses, the pressure integration technique,
• Fluid loading on offshore structures and ocean waves theory: the added mass concept, Froude Krylov force, linear wave theory, wave loading (diffraction theory & Morison equation),
• Dynamics response of floating structures in waves: dynamic response analysis, application to floating bodies (buoys, semisub, TLP), effect of moorings.

On successful completion of this module you should be able to:

• Explain how wind, waves and tides are formed, factors that influence their distribution & predictability,
• Review the fundamental equations for fluid behaviour, characterisation of flow structures and forces and moments acting on lifting bodies,
• Evaluate and select the most appropriate model to assess and undertake the simulation of a floating structure static and dynamic stability.

• Dr Joy Sumner

This module provides you with the knowledge and understanding of the corrosion processes that occur on structural materials and the impact on their mechanical performance.

• Mechanical testing - in particular development of stress strain curves,
• Corrosion monitoring:  using electro-chemical methodologies, and electron microscopy,
• Corrosion mechanisms: including effects of underlying material composition and processing, galvanic corrosion, pitting and crevice corrosion, mechanical interactions, microbial corrosion, corrosion of welds, stress corrosion cracking, hydrogen embrittlement and effects of H2S, high temperature corrosion,
• Corrosion control: paints, cathodic protection, corrosion resistant alloys, corrosion monitoring, control by design.

On successful completion of this module you should be able to:

• Evaluate the impact of corrosion on the mechanical responses of structural materials and the impact of inhibition techniques on extending life,
• Critically evaluate analysis and corrosion monitoring techniques to select appropriate methodologies,
• Use an understanding of materials and processing to recommend alternative engineering solutions,
• Discuss the role of codes and standards.

• Dr Patrick Verdin

This module introduces you to the computational fluid dynamics (CFD) techniques and tools for modelling, simulating and analysing practical engineering problems related to renewable energy, with hands on experience using commercial software packages used in industry.

• Introduction to CFD & thermo-fluids: introduction to the physics of thermo-fluids, governing equations (continuity, momentum, energy and species conservation) and state of the art computational fluid dynamics including modelling, grid generation, simulation, and high performance computing, case study of an industrial problem and the physical processes where CFD can be used,
• Computational engineering exercise: specification for a CFD simulation, requirements for accurate analysis and validation for multi scale problems, introduction to turbulence & practical applications of turbulence models, introduction to turbulence and turbulent flows, traditional turbulence modelling,
• Advanced turbulence modelling: introduction to Reynolds-averaged Navier Stokes (RANS) simulations and large-eddy simulation (LES),
• Practical sessions: offshore renewable energy problems (flow around wind and tidal turbines) will be solved employing the widely-used industrial flow solver software FLUENT.  These practical sessions will cover the entire CFD process including grid generation, flow solver, analysis, validation and visualisation.

On successful completion of this module you should be able to:

• Assemble and evaluate the different components of the CFD process,
• Explain the governing equations for fluid flows and how to solve them computationally,
• Compare and contrast various methods for simulating turbulent flows applicable to civil and mechanical engineering, especially offshore renewable energy applications such as wind turbines and tidal turbines,
• Set up simulations and evaluate a practical problem using a commercial CFD package,
• Design CFD modelling studies of renewable energy devices.

• Paul Lighterness

This is a specialised module to advance your technical skills in industry prototyping design processes. This module will also introduce you to the facilities/workshops available at Cranfield.

• Design thinking and creativity,
• Collaborative innovation,
• Understanding the value and use of prototyping for innovation,
• Introduction to technology readiness levels (TRL’s),
• How to identify and write good requirement for design,
• Hands-on use of professional CAD/CAE software,
• Design skills workshops (sketching, CADCAE, mechatronics, 3D printing),
• Knowledge of advanced materials and processes (smart materials, bio-inspiration, nano & micro technologies, additive manufacturing).

On successful completion of this module you should be able to:

• Identify, analyse and evaluate user needs and technical considerations to write good design requirements for a new product, service or system,
• Critically evaluate and apply industrial best practice tools and techniques for converting an idea into commercially viable solutions,
• Develop and build low fidelity proof-of-concept prototypes, using design best practice methods and agile innovation techniques,
• Evaluate knowledge of advanced materials and processes appropriate for a new product, service or system,
• Propose a viable breakthrough innovation proposition through the synthesis of best practice design methods and the application of advanced materials, processes and prototyping.

• Professor Phil Hart

The purpose of this module is to provide you with experience of scoping and designing a project. The module provides sessions on project scoping and planning, including project risk management and resource allocation. A key part of this module is the consideration of ethics, professional conduct and the role of an engineer within the wider industry context.

Project management:

• Project scoping and definition,
• Project planning,
• Project risk assessment and mitigation,
• Resource planning and allocation,
• Team roles and resourcing.

Financial management of projects.

Ethics and the role of the engineer.

• Ethics case study.

Professional code of conduct (in line with the code of conduct defined by the Engineering Council, IMechE, IChemE and Energy Institute).

On successful completion of this module you should be able to:

1. Design and scope a project, including identification of methods, resources required and risk management approaches,
2. Assess the likely financial needs of a new project and pitch for finance,
3. Evaluate ethical dilemmas and the role of the engineer within the context of their chosen industry.