Beruflich Dokumente
Kultur Dokumente
Outline
Resources:
M. F. Ashby, Materials Selection in Mechanical Design Butterworth Heinemann, 1999
The Cambridge Material Selector (CES) software -- Granta Design, Cambridge
(www.grantadesign.com)
Metals
Cu-alloys
Ni-alloys
Ti-alloys
PE, PP, PC
PA (Nylon)
Alumina
Si-Carbide
Polymers,
elastomers
Ceramics,
glasses
GFRP
CFRP
Soda-glass
Pyrex
Composites
Butyl rubber
Neoprene
KFRP
Plyw ood
Polymer foams
Metal foams
Foams
Ceramic foams
Glass foams
Woods
Natural
materials
Natural fibres:
Hemp, Flax,
Cotton
Thermal expansion
General
Density , Mg/m3
Cost/kg Cm, $/kg
Mechanical
Elastic limit,y
Youngs modulus, E
Stress
Strain
Stiffness:
Strength:
Thermal conduction
Thermal
Brittle materials
(fracture)
Tensile
strength,
Youngs
modulus, E
Electrical
Expansion
coefficient,
Temperature, T
ts
T1
To
Area A
Q joules/sec
Stress
Ductile materials
lo
Thermal strain
Weight:
Expense:
Thermal
conductivity,
Conductor? Insulator?
(T1 -T 0)/x
Strain
All OK !
Statistical
analysis
Data
capture
Selection of
material and process
Economic analysis
and business case
Mechanical Properties
B ulk M odulus
Com pressiv e Strength
Ductility
E las tic Limit
E ndurance Lim it
Fracture Toughness
Hardness
Loss Coefficient
M odulus of Rupture
P ois son's Ratio
S hear Modulus
Tensile S trength
Y oung' s Modulus
Test
Test data
4.6 GPa
60 MP a
0.07
45 MP a
27 MP a
2.6 MP a.m1/2
140 MP a
0.026
55 MP a
0.42
0.95 GPa
48 MP a
2.8 GPa
Design data
$
Real
applications
Potential
applications
Characterisation
Numeric
modulus,
density.
Rankings
eg corrosion resistance
in sea water? A,B,C,D,E
Boolean
Design guide-line
Standards
Case studies
Codes
eg can be blow-moulded?
Yes/No
Descriptive info.
Specific documentation
Experience with the material
Applications
Help
lines
Failure analysis
Supply
chain
FE
modules
Consultants
Non-specific documentation
Kingdom
Family
Class &
member
Ceramics
MATERIAL
Glasses
Polymers
Metals
Elastomers
Composites
Natural
Steels
Cu-alloys
Al-alloys
Ti-alloys
Ni-alloys
Zn-alloys
1000
2000
3000
4000
5000
6000
7000
8000
Attributes
Density
Mechanical props.
Thermal props.
Electrical props.
Optical props.
Corrosion props.
Supporting information
Processes
Shapes
A material record
General Properties
Density
Price
1.05 2.1 -
1.07 Mg/m^3
2.3 USD/kg
Mechanical Properties
Bulk Modulus
Compressive Strength
Ductility
Elastic Limit
Endurance Limit
Fracture Toughness
Hardness
Loss Coefficient
Modulus of Rupture
Poisson's Ratio
Shear Modulus
Tensile Strength
Young's Modulus
4.6 GPa
60 MPa
0.07
45 MPa
27 MPa
2.6 MPa.m 1/2
140 MPa
0.026
55 MPa
0.42
0.95 GPa
48 MPa
2.8 GPa
Glass Temperature
Ma x Service Temp
Min Service Temp
Specific Heat
Thermal Conductivity
Thermal Expansion
350
350
150
1500
0.17
70
360
370
200
1510
0.24
75
K
K
K
J/kg.K
W/m.K
10-6/K
15
MV/m
3.3
1.6x1022 ohm.cm
0.009
Electrical Properties
Breakdown Potential
Dielectric Constant
Resistivity
Power Factor
14
2.8
6.3x1021
0.008
Average
Good
Average
Very Poor
Good
Good
Good
Good
Poor
Good
Good
Design Notes. The acrylonitrile gives thermal and chemical resistance, rubber-like
butadiene gives ductility and strength, the styrene gives a glossy surface, ease of machining
and a lower cost. ABS can be welded to ABS/PC, acrylic and itself, and it can be bonded
with polyester, epoxy, alpha-cyanoacylate or nitrile-phenolic adhesives. Ultrasonic welding
can reduce the strength of the material to 95% of the original; hot plate welding can reduce
the strength to 80%. ABS can be extruded or formed to sheet. Thin (extruded) gauges of
ABS can be easily processed on all types of forming equipment. A co-extrusion process or a
special film overlay is recommended to extend the life of ABS for outdoor applications.
Compression moulded heavy gauge ABS is often used for prototype model making. ABS has
the highest impact resistance of all polymers. It allows many colour options and has
attractive aesthetic qualities. Integral metallics can be easily added (as in GE Plastics'
M agix.) ABS is UV resistant for outdoor application if stabilisers are added.
Shaping. ABS is distributed as pellets for moulding or extrusion. The material is normally available a rod or sheet in a range of colours.
Highlights. ABS is FDA compliant. It is readily available, easily machined, bonds well, product versatility, easily formed, good
mechanical properties, cost, good impact strength (also at low temperatures), satisfactory stiffness, satisfactory dimensional stability, glossy
surface, easy to machine, resistant to some bases and alcohol
Warnings. ABS is hygroscopic (may need to be oven dried before thermoforming), and damaged by petroleum-based machining oils. It
has only limited chemical resistance, with poor resistance to solvents.
Typical Uses. Cabinets and cases for domestic goods, TV boxes, telephones, food mixers, vacuum cleaners, baths, showers trays, pipes.
Other typical applications include luggage shells, RV parts, business machine housings and parts, shower stalls and cassette holders;
automotive parts, housing for tools and appliances, luggage and safety hard hats. Lego, computer mice, razors, handles, shavers, chairs.
Kingdom
PROCESS
Family
Deformation
Moulding
Powder
Casting
Machining
Composite
Molecular
Special
Class &
member
Investment
Full mould
Sand 1
Shell
Sand 2
Sand
Die
Sand 3
Squeeze Sand 4
Ceramic Sand 5
mould
Permanent
mould
Attributes
Size Range
Shape/complexity
Min. section
Tolerance
Roughness
Economic batch
Materials
Shapes
25 - 100 kg
5 - 999 mm
1.2 - 3
mm
12 - 25 mm
1 - 20
1 - 5
30 - 300 mm
5 - 50 mm
100 - 3000mm
1 -4
Economic attributes
Economic batch size
Capital cost
Tooling cost
Lead time
Production rate
Tool life
Material utilisation fraction
1 1000100 2
0.1 10 0.5 -
1000
units
5000
2000
4
weeks
1
Units/hr
1000 Units
0.7
Class attributes
Material class
Process class
Shape class
Typical Uses.
Sources of data.
Bralla, J.G. (1986) Handbook of Product Design, McGraw Hill, NY.
Schey, J.A. (1977) Introduction to Manufacturing Processes, McGraw Hill, NY.
Clegg, A.J. (1991) Precision Casting Processes, Pergamon Press, Oxford U.K.
Metals Hanbook - Vol 15, Casting, (1988) 9th Ed. ASM Int Ohio, USA
Finding data
Library searches
Use the SEARCH facility to find all records contain candidate name, or
trade-name, or application
The Worldwide Web, using WEBLINKS to find web sites containing data
(e.g. www.matweb.com)
Diamond
ee
CFRP
1000.
Silicon Nitride
Acetal
100.
PolyUrethane
Silica
Fibreboard
Copper
10.
Lead
MDF
Butadiene
1.
Aerated Concrete
Ceramics
Metals
Polymers
Materi al s:\Cerami c
Materi al s:\Metal
Material Class
Composites
Materi al s:\Composi te
Youngs
Young'smodulus
Modulus (GPa)(GPa)
WC
BC
S iC
1 000
Alumina
Ti-alloys
1 00
Cu-alloys
Zn-alloys
Al-alloys
Mg-alloys
10
CFR P
Glass Ceramic
Acetal, POM
Polyester, rigid
PS ABS
Silica glass
KFRP
Soda-Lim e glass
GFRP
P UR
PE
PC
PP
Al-SiC C omposite
Plywood
P TFE
Ionomer
0 .1
EVA
0 .01
Polyurethane
Natural R ubber (NR)
1 e-0 03
Neoprene
Metals
1 e-0 04
Polyme rs
Ma ter ials: \POLY MER S
Compos ites
Ma te rial s:\COM POSIT E S
Untitled
Explore relationships
100 0
Silicon C arbide
Alumina
Modulus - Density
Boro n C arbide
Silicon
Tungsten Carbides
Steels
N ickel alloys
Al alloys
C FRP
GFR P
B amboo
Youngs
modulus
(GPa)
Young's Modulus
(typical)
(GPa)
Copper alloys
M g alloys
100
Zinc alloys
T itanium
Wood
10
Lead alloys
C oncrete
Plywood
PET
PVC
PUR
PP
1
PE
PT FE
EVA
Silicone
Cork
0.01
Polyisopren e
Polyurethane
B utyl R ubber
1e-0 03
Neopr ene
1e-0 04
0.01
0.1
10
Density (Mg/m3)
E
=
Need
Design phase
(Material needs)
Concept
Embodiment
Detail
Life phase
Production
Redesign
Use
Tools for
life-cycle
analysis
Disposal
Design requirements
Translation
material specification
Design concept
Analyse: Function
What does the component do ?
Objective(s) What is to be maximised or minimised ?
Constraints What essential conditions must be met ?
Free variables Which design variables are free ?
From which we obtain
Screening criteria expressed as numerical limits on
material property-values
Or expressed as requirements for processing,
corrosion, .
Ranking criteria based on material indices that
characterise performance
Screen on attributes
Requirements: must
operate at 100oC
be electrical insulator
conduct heat well
Screen on links
Requirements: must
be extrudable
Property value
Diamond
Steel
CFRP
Silica
GFRP
Copper
Polyethylene
PP
Cement
Lead
Ceramics
Fibreboard
Metals
PTFE
Polymers
Composites
Diamond
ee
CFRP
1000.
Silicon Nitride
Acetal
100.
PolyUrethane
Silica
Fibreboard
Copper
10.
Lead
MDF
Butadiene
1.
Aerated Concrete
Ceramics
Metals
Polymers
Materi als:\Cerami c
Materi als:\Metal
Composites
Materi als:\Composite
Material Class
Ranking by performance
Objective -- a metric of performance, to be maximised or minimised.
Examples: Mass, volume, eco-impact, cost .per unit of function
Convention: express in form to be minimised.
C
P m
y
Mass per unit bending stiffness
1/ 2
1
yD
Many more
Performance metric
Performance metrics:
Minimise -Value range of metric
for selected materials
Material indices
Strong tie of length L and minimum mass
F
Area A
L
Length L is specified
Must not fail under load F
Function
Tie-rod
Constraints
Objective
Minimise mass m
m = AL
(1)
F/A < y
(2)
Materials indices
Each combination of
FUNCTION
Tie
Function
Objective
Constraint
Free variable
Has a
characterising
material index
OBJECTIVE
Beam
Minimum cost
Shaft
Minimum
weight
Column
Maximum energy
storage
Mechanical,
Thermal,
Electrical...
Minimum
environ. impact
CONSTRAINTS
Stiffness
specified
Strength
specified
Fatigue limit
Geometry
specified
INDEX
M=
y
Minimise
this!
Cm
Density,
Modulus,
Strength,
Endurance limit,
Thermal conductivity,
T- expansion coefficient,
Stiffness
Strength
Tension (tie)
/E
/ y
Bending (beam)
/E1/2
/ 2/3
Bending (panel)
/E1/3
/1/2
y
Minimise these!
Many more: see Appendix B of the Text
y = / C
Log y = Log() Log(C)
=C
y
Contours of constant
C are lines of slope 1
on an y- chart
Search
region
Steps of selection
All materials (processes.)
Structured
data
Further Information :
search family history of candidates
Shortlist of candidates
Local conditions:
does the choice match the local needs, expertise ?
Deformation
Moulding
Powder methods
Casting
Machining
Composite forming
Molecular methods
MATERIALS
Ceramics
Glasses
Polymers
Metals
Elastomers
Composites
Natural materials
PROCESSES
SHAPES
Axisymmetric
Prismatic
Flat sheet
Dished sheet
3-D solid
3-D hollow
Enter
(Density, )
Attribute 2 > C2
(Modulus, E)
Attribute 3 > C3
(Strength, )
Attribute 4 = C4
(Poisson, )
MATERIALS
Multiple
constraints
Material 1
Material 2
Material 3
..
PROCESSES
Process 1
Process 2
Process 3
..
PRODUCTS
Product1
Product 2
Product 3
..
Selection by association
Select on processability and material properties
Enter
and has
Attribute 1 > C1
Attribute 2 > C2
Attribute 3 < C3
MATERIALS
Material 1
Material 2
Material 3
..
PROCESSES
Multiple
constraints
Process 1
Process 2
Process 3
..
Attribute 4 < C4
PRODUCTS
Product1
Product 2
Product 3
..
Selection by analogy
Select on similarity (and innovative substitution)
Find material that is like
Material X, or like that of
MATERIALS
Material 1
Material 2
Material 3
..
Product Z
but has
Attribute 1 > C1
Attribute 4 < C4
PROCESSES
Additional
constraints
Process 1
Process 2
Process 3
..
PRODUCTS
and is of type
SAND-CASTABLE
Enter
Product1
Product 2
Product 3
..
Conflicting
objectives
A Dominated
solution
Cost C
Performance, P
Cost, C
B Non-dominated
solution
Trade-off surface
Cheap
Expensive
Performance metric P
High
Low
solution
Cost C
A Dominated
B Non-dominated
solution
Trade-off surface
Cheap
Expensive
High
Performance metric P
The trade-off surface (or Pareto front) is the surface on which the nondominated solutions lie
Use intuition to select
Form a value function: a composite objective
Low
Cost of insulation
(1000$/m3 )
Co st/kgC
xD
mensity
R efrigerator insulation
Trade-off
surface
10
Ba lsa (0 .1)
C o rk
PS fo a ml (0.050)
P S fo a m (0.020)
PP fo a ml (0.02)
PP foa m (0 .03)
0.0 1
0 .01
0.1
10