Design for Manufacture and Assembly

Materials Selection Property Maps

Reference
MF Ashby, Materials Selection in Mechanical
Design 3rd Edition, Elsevier, 2005

Materials Selection
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Design for Manufacture and Assembly

Design

Materials

Processes

Market Need
Concept

All Materials
Low precision data

All Processes
Low Resolution

Embodiment

Subset of Materials
Higher Precision

Subset of Processes
Higher Resolution

Detail

One Material
Highest Precision

One Process
Highest Resolution

Product
Materials Selection
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Design for Manufacture and Assembly

Comparison of Properties of Materials

Property

Metals

Ceramics

Polymers

Density, gcm-3

2 - 22

2-19

1-2

Melting Point

low[ Ga 29.8 C]
High [ W, 3410 C]
Medium

High
[ up to 4000 C]
High

Low

Good

Poor

Good

Youngs Modulus

15 400 GPa

150 450 GPa

0.001 10 GPa

Tensile Strength

up to 2500 MPa

up to 400 MPa

up to 140 MPa

Compressive
Strength

up to 2500 MPa

up to 5000 MPa

up to 350 MPa

Hardness

Machinability

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Low

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Comparison of Properties of Materials (contd.)

Property

Metals

Ceramics

Polymers

High Temperature
Creep Resistance
Thermal
Expansion
Thermal
Conductivity
Thermal Shock
Resistance
Electrical
Characteristics

Poor - Medium

Excellent

Medium to High

Low to Medium

Very High

Medium to High

Very Low

Good

Medium to Low at
high temperature
Poor

Conductors

Insulators

Low to Meduim

Excellent

Insulators
[some conductors]
Good

Generally Poor

Oxides-excellent
Carbides, Nitrides
- good

Chemical
Resistance
Oxidation
Resistance
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Material Property Maps

Materials Selection
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Example Maps

Strength Density
Modulus Density
Fracture Toughness - Density
Strength Relative Cost
Modulus Relative Cost

Relative Cost

Materials Selection
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Cost per kg of the material

CR
Cost per kg of mild steel rod

Design for Manufacture and Assembly

Modulus Density
Map

Ref:MF Ashby, Materials Selection in Mechanical Design , Pergammon Press, 1992

Materials Selection
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Strength-Density
Map

Ref:MF Ashby, Materials Selection in Mechanical Design , Pergammon Press, 1992

Materials Selection
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Fracture Toughness
- Density Map

Ref:MF Ashby, Materials Selection in Mechanical Design , Pergammon Press, 1992

Materials Selection
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Modulus - Relative
Cost Map

Ref:MF Ashby, Materials Selection in Mechanical Design , Pergammon Press, 1992

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Strength Relative
Cost Map

Ref:MF Ashby, Materials Selection in Mechanical Design , Pergammon Press, 1992

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Relationships Between Failure Modes and Material Properties

Failure Mode

Material Property

Gross Yielding

Yield Strength, Shear Yield Strength

Buckling

Compressive Yield Strength, Modulus of

Elasticity

Creep

Creep rate

Brittle Fracture

Impact energy, Transition temperature, K1C

Fatigue, Low cycle

Fatigue Properties, Ductility

Fatigue, High cycle

Fatigue Properties

Contact Fatigue

Compressive Yield Strength

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Relationships Between Failure Modes and Material Properties

Failure Mode

Material Property

Fretting

Compressive Yield Strength, Electrochemical

potential

Corrosion

Electrochemical potential

Stress-Corrosion
Cracking

Ultimate Tensile Strength, K1SSC ,

Electrochemical potential

Galvanic Corrosion

Electrochemical potential

Hydrogen
Embrittlement

Ultimate Tensile Strength

Wear

Hardness

Thermal Fatigue

Creep rate, Coefficient of Thermal Expansion

Corrosion Fatigue

Fatigue Properties, Electrochemical potential

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Design for Manufacture and Assembly

Design

Materials

Processes

Market Need
Concept

All Materials
Low precision data

All Processes
Low Resolution

Embodiment

Subset of Materials
Higher Precision

Subset of Processes
Higher Resolution

Detail

One Material
Highest Precision

One Process
Highest Resolution

Product
Materials Selection
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Design for Manufacture and Assembly

Selection Methodologies-Concept Design

Make use of Materials Desirability factors or Performance
Indices
The aim is to find a material which maximises the
performance index

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Design for Manufacture and Assembly

Beam in Bending

b
d

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Example Materials Desirability Factor

Consider a beam in bending. Irrespective of precise nature of
loading the maximum stress, max, in the beam will be given
by

max

M max 12 d M max 12 d

3
1
I
12 bd

(1)

where I = second moment of area

M = bending moment
b = depth
d = width
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Assuming that we are comparing different materials on the basis

that length, width and loading are fixed but beam depth is a design
variable then

b1

(2)

where b1= constant

But the mass, m, of the beam is given by

m rbdL

(3)

where r = material density

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Substituting for d from 2 into 3 gives

b2r
m

where b2 is the same constant for all materials

is a materials selection criterion but is more usually expressed as

which is the Materials Desirability Factor where and r are yield

strength and density values for the materials being compared
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Design for Manufacture and Assembly

If we want a beam of minimum mass but maximum

strength we will look for materials with high values of the
Desirability Factor

Desirability Factors for other loading situations

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Example Desirability Factors

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Example Desirability Factors

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Example Desirability Factors

Ref: MF Ashby, Materials Science and Technology, 1989, Vol5, , 517-526

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Design for Manufacture and Assembly

Use of Desirability Factors with Property Maps

Strength-Density Map

Consider a Beam in Bending,

Lightest beam to carry a given load
is one where the condition below is
a Maximum

1 2
C , C constant
r
or
log 2 log r C1 , C1 constant

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Lines of Slope = 2 can be drawn on

the map and used to identify
materials which are optimal for the
loading condition

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Materials Selection

A Simple but relevant example

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Ashbys Approach
Primary Constraints
Any design imposes any non-negotiable constraints on
the material(s) of which it is MADE
E.g., Temperature
Components which carry load at 300cC cannot be made
from Polymers

Primary Constraints take the form

P > Pcrit
or P < Pcrit
where P = Property set by the design
Primary Constraints appear as vertical or horizontal lines
on a property chart

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Primary Constraints

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Performance Maximising Criteria 1

Stiff Lightweight Design

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Performance Maximising Criteria 2

Stiff Lightweight Design

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Design for Manufacture and Assembly

Bicycle Forks

Fork = Tube which should resist bending

Desirability factor to maximise is

2/3/r

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Design for Manufacture and Assembly

Bicycles Forks
Strength is not the only criterion
Cost
Manufacturability
Resistance to fracture
Stiffness
Are also important

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Design for Manufacture and Assembly

Other Criteria Strength vs Relative cost

2f / 3
C
CR r

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Design for Manufacture and Assembly

Fork Materials
Material

Comments

Aluminium Alloy (7075)

Popular choice for Racing and

Mountain Bikes

Titanium alloy

Expensive no advantage over Al

alloys

Magnesium alloy

Difficult to shape

Steel (Reynolds 531)

Standard for cheaper bicycles

CRFP (with some glass or kevlar)

Outstanding but expensive, used on

racing and up-market mountain
bikes

Wood

Material properties good but cannot

be easily shaped, bio-degradeable!

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