A successful product One that perform well, is good

value for money and gives pleasure to the user. Uses the
best materials for the job and fully exploits their potential
and characteristics.
Families of materials - metals, polymers, ceramics and
composites.
Profile of properties.
Family likeness need to know to decide which family to
choose /decide to be used for a given design.
Choosing material is only half the story . The other half is
the choice of a process route to shape, join and finish it.
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Materials and processes
1
The materials tree :
The menu of engineering materials
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2
Steel
Cast iron
Metal
Cu Alloy
Zn Alloy
Ti Alloy
Alumina
Silicon Carbide
Ceramics
Silicon Nitride
Zirconia
Composite
Sandwiches
Hybrids
Segmented structures
Lattices
forms
PE, PP, PET,PC,PEEK
Polymers
Polyester
Phenolics
Epoxies
Isoprene
Neoprene
Butyl rubber
Elastomers
Natural rubber
Silicon
Soda glass
Borosilicate glass
Glasses
Silica glass
Glass ceramic
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Raw materials
Casting
Methods
Sand
Die
investment
Molding
methods
Injection
Compression
Blow moulding
Deformation
Methods
Rolling
Forging
Drawing
Powder
Methods
Sintering
HIPing
Slip casting
Composite
forming
Hand lay up
Filament wind
RTM
Special
Methods
Rapid prototype
Lay up
Electro form
Primary shaping
Secondary processes
Machining
Cut, turn, plane
Drill, grind
Heat treat
Quench, temper,
Age harden
ORGANIZING PROCESSES
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Finished Products
4
Joining
Surface treatment
Fastening
Riveting
Welding
Heat bonding
Adhesives
Cements
Snap fits
Friction bonds
Polishing
Texturing
Painting
Printing
Plating
Metallizing
Anodize
Chromizing
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5
Kingdom Family Class Member Attributes
Process
Joining
Shaping
Surface
Treatment
Casting
Deformation
Molding
Composite
Powder
Prototype
Compression
Rotation
Transfer
Injection
Form
Extrusion
Resin Casting
Thermoforming
Blow molding
Material
Shape
Size range
Minimum section
Tolerence
Roughness
Minimum batch size
Cost model
Documentation
A Process record
The taxonomy of the kingdom of process with part of the shaping family expanded
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Process property Interaction
Processing can change properties.
e.g forging
(harder to annealing)
Stretching
Polyethylene fibre
Rubber vulcanizing
Composites
Resin and fibre reinforced
Joining
Welding
Surface treatment
Electroplating
Carburizing
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Computer aided information management
for materials and processes
1. Classification
Records of every member for materials and processes
Software
Materials and properties
Physical attributes
Economic attributes
Typical uses
The process
2. Documentation
Content of records
Structured data.
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Matching material to design - Strategic thinking
The design flow chart
Material data Needs
Choice of material
Family
Metal, ceramics..
Choice of material
Class
Steel, al alloy etc..
Choice of single
Material
6061 Al,
304 Stainless steel
Process data
Needs
Choice of process
family
Casting, moulding
Choice of process
Class
Die cast, sand cast
Choice of single
Process
Pressure die cast
Concept
Explore working
Principles
Embodiment
Define general
Layout and scale
Detail
Optimize form
Manufacture and assembly
Market Need
Problem definition
Product specifications
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The interaction between design requirements
Materials, shape and process.
Design Requirement
Required shape
Cost
Required property
profile
Material
Process
Eco-impact
Final Choice
Requirement
Constraints
choice
Consequences
Decision
The design process
Original design
Original design starts from scratch.
Involved new idea or working principle.
Can be stimulated by new materials.
The starting point may be market need or new idea.
A need must be established before it can be met.
At the conceptual design stage all options are open.
Alternative concept
Sizing
Operation
Materials
Processes.
Redesign
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The strategy applied to materials
All materials
Translate design for requirements
Express as function , constraints, objectives and free variables
Screen using constraint
Eliminate materials cannot do the job
Rank using objective
Find the screened materials that do the job best
Seek Documentation
Research the family history of top ranked candidates
Final material choice
Function, Constraints, Objectives and free variables
Function
What does the component do ?
Constraints
What non negotiable conditions must be met ?
Objectives
What is to be maximized or minimized ?
Free variable
What parameters of the problem is the designer free to change
Common constraints Common objectives
Meet a target value of Minimize
Stiffness Cost
Strength Mass
Fracture toughness Volume
Thermal conductivity Impact on the environment
Electrical resistivity Heat loss
Magnetic remanence
Optical transparency Maximize
Cost Energy storage
Mass Heat flow
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Common constraints and objectives
Translation for the Redesigned CD case
Function
Contain and Protect a CD
Constraints
Optically clear
Able to be injection moulded
Recyclable
Tougher than polystyrene
Dimensions identical with PS case
Objective
Minimum cost
Free variable
Choice of Material
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Investment casting
Casting Work
Powder Metallurgy
Howrah Bridge Kolkata West Bengal (1943)
Corroded by Saliva mixed with betel and lime- Reuters
Air Bags problem in Honda
Toyota Pedal Assembly