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Design Considerations
1
Chapter 23 -
CHAPTER 22: MATERIALS SELECTION AND
DESIGN CONSIDERATIONS
ISSUES TO ADDRESS...
• Price and availability of materials.
• How do we select materials based on optimal
performance?
• Applications:
-- shafts under torsion
-- bars under tension
-- plates under bending
-- materials for a magnetic coil.
Chapter 23 - 2
PRICE AND AVAILABILITY
• Current Prices on the web: e.g., http://www.metalprices.com
-- Short term trends: fluctuations due to supply/demand.
-- Long term trend: prices will increase as rich deposits
are depleted.
• Materials require energy to process them:
-- Energy to produce -- Cost of energy used in
materials (GJ/ton) processing materials ($/MBtu)
Al 237 (17) elect resistance 25
PET 103 (13) propane 17
Cu 97 (20) oil 13
steel 20 natural gas 11
glass 13
paper 9
Energy using recycled
material indicated in green.
Chapter 23 - 3
RELATIVE COST, c, OF MATERIALS
Graphite/
Metals/ Composites/
Ceramics/ Polymers
Alloys fibers
Semicond
100000
50000 $ / kg
20000
Diamond c=
Pt
Au ($ / kg)ref material
10000
5000
Si wafer • Reference material:
Relative Cost (c)
2000
1000 Si nitride -- Rolled A36 plain
500 carbon steel.
Ag alloys
200
Tungsten
CFRE prepreg • Relative cost, c ,
100 Ti alloys AFRE prepreg
50
Si carbide
Carbon fibers
fluctuates less
Aramid fibers over time than
Cu alloys GFRE prepreg
20
10
Al alloys
Mg alloys Al oxide Nylon 6,6 actual cost.
PC
5 high alloy
Epoxy
E-glass fibers Based on data in Appendix
Glass-soda PVC PET
2 LDPE,HDPE C, Callister, 7e.
Steel Wood
PP AFRE, GFRE, & CFRE = Aramid,
1 pl. carbon PS Glass, & Carbon fiber reinforced
0.5 epoxy composites.
0.1 Chapter 23 - 4
Concrete
0.05
STIFF & LIGHT TENSION MEMBERS
F, δ • Bar must not lengthen by more than δ
under force F; must have initial length L.
-- Stiffness relation: -- Mass of bar:
L F δ
=E (σ = Eε) M = ρLc 2
c2 L
E
• Maximize the Performance Index: P=
(stiff, light tension members) ρ
Chapter 23 - 5
STRONG & LIGHT TENSION MEMBERS
F, δ • Bar must carry a force F without failing;
must have initial length L.
-- Strength relation: -- Mass of bar:
L σf F
= M = ρLc 2
N c2
Chapter 23 - 6
STRONG & LIGHT TORSION MEMBERS
Mt • Bar must carry a moment, Mt ;
must have a length L.
L τ -- Strength relation: -- Mass of bar:
τf 2Mt M = ρπR 2L
τ =
N πR 3
τf2 / 3
• Maximize the Performance Index: P=
(strong, light torsion members) ρ
Chapter 23 - 7
DATA: STRONG & LIGHT
TENSION/TORSION MEMBERS
Increasing P
Strength, σf (MPa) for strong
10 4 Ceramics
torsion members
Cermets
10 3 PMCs
Steels
|| grain Metal
10 2 Adapted from Fig. 22.2,
alloys Callister 7e. (Fig. 22.2 adapted
Ceramics
Cermets
10 3 PMCs
Steels
|| grain Metal
10 2 Adapted from Fig. 6.22,
alloys Callister 6e. (Fig. 6.22 adapted
from M.F. Ashby, Materials
10 Polymers Selection in Mechanical
Design, Butterworth-
grain Heinemann Ltd., 1992.)
1
0.1
0.1 1 10 30
Density, ρ (Mg/m3)
Chapter 23 - 9
DETAILED STUDY I: STRONG, LIGHT
TORSION MEMBERS
τf2 / 3
• Maximize the Performance Index: P=
ρ
• Other factors:
--require σf > 300 MPa.
--Rule out ceramics and glasses: KIc too small.
• Numerical Data:
material ρ (Mg/m3) τf (MPa) P [(MPa)2/3m3/Mg]
CFRE (vf = 0.65) 1.5 1140 73
GFRE (vf = 0.65) 2.0 1060 52
Al alloy (2024-T6) 2.8 300 16
Ti alloy (Ti-6Al-4V) 4.4 525 15
4340 steel (oil 7.8 780 11
quench & temper)
Data from Table 22.1, Callister 7e.
H2 1 σf H ∆t ∆Tmax 1 cv
≤ ≤
$ 2πR 2Lµo N ρd c $ 2πRL ρd c ρe
Chapter 23 - 17
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 18
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 19
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 20
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 21
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 22
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft
Chapter 23 - 23
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 24
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 25
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 26
Chapter 23 -
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 28
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 29
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 30
Case Study 2: Artificial Total Hip Replacement
Chapter 23 - 31
Case Study 3: Chemical Protective Clothing
Chapter 23 - 32
Case Study 3: Chemical Protective Clothing
Chapter 23 - 33
Case Study 3: Chemical Protective Clothing
Chapter 23 - 34
Case Study 3: Chemical Protective Clothing
Chapter 23 - 35
SUMMARY
• Material costs fluctuate but rise over the long
term as:
-- rich deposits are depleted,
-- energy costs increase.
• Recycled materials reduce energy use significantly.
• Materials are selected based on:
-- performance or cost indices.
• Examples:
-- design of minimum mass, maximum strength of:
• shafts under torsion,
• bars under tension,
• plates under bending,
-- selection of materials to optimize more than one
property:
• material for a magnet coil.
• analysis does not include cost of operating the magnet.
Chapter 23 - 36
ANNOUNCEMENTS
Reading:
Core Problems:
Self-help Problems:
Chapter 23 - 37