Beruflich Dokumente
Kultur Dokumente
Outline
Historical development of engineering materials Properties of engineering materials Interaction between part material and function, process, and shape General practice of material selection
Objectives
Students will be able to Recall knowledge from their previous engineering curriculums Understand the interaction between different product design elements
Ashby (2005)
Engineering materials
Metals
Steels, cast irons, al-alloys, cu-alloys, zn-alloys, tialloys PE, PP, PET, PC, PS, PEEK, PA (nylons), polysters, phenolics, epoxies Aluminas, silicon carbides, silicon nitrides, zirconias Soda glass, borosilicate glass, silica glass, glassceramics
Glasses Elastomer Metal
Polymers
Ceramics
Ceramic Hybrid
Polymer
Glasses Elastomers
Isoprene, neoprene, butyl rubber, natural rubber, silicones, EVA Composites, sandwishes, segmented structures, lattices, weaves 6
Hybrids
Material properties
General
Density, price
Mechanical
Elastic moduli (Youngs, shear, bulk), yield strength, ultimate strength, compressive strength, failure strength, hardness, elongation, fatigue endurance limit, fracture toughness, loss coefficient (damping capacity)
Material properties
Thermal
Melting point, glass temperature, maximum/minimum service temperature, thermal conductivity, specific heat, thermal expansion coefficient, thermal shock resistance
Electrical
Electrical resistivity, dielectric constant, breakdown potential, power factor
Material properties
Optical
Optical (transparent, translucent, opaque), Refractive index
Eco-properties
Energy/kg to extract material, CO2/kg to extract material
Environmental resistance
Oxidation rates, corrosion rates, wear rate constant
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Interaction in-between
The central problem of materials selection in mechanical design the interaction between four elements: function, material, process, and shape (Ashby, 2005)
Function: Dictates the choice of both material and shape Material: Influence the manufacturing process (its formability, machinability, weldability, heat-treatability, etc.) Process: Interacts with shape (size, precision, and cost) Shape (macro-shape): Depends on the materials and combination of processes
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Constraint-driven design
Design parameters can be either design objectives (especially for engineering optimization) or design constraints (limitations) A product design might have multiple objectives and multiple constraints. Conflicting constraints can be employed as penalty functions. (We might want to insert an example or examples here.) To identify feasible solutions, either the analytical methods or the graphical methods can be applied. More detail can be found in the problem identification and problem solving PowerPoint file.
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Material selection
Major factor: Function Minor factor: Shape
Function
Material
Material families, classes, sub-classes, and members Material attributes Material limits and indices
Shape
Process
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Se e k supporting information
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The maximum pressure is carried most safely by the K12C M2 = material: f The thinnest wall of a material is that with the largest yield strength: M3 = f
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Selection of materials
M2
M1
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M3
Ranking of materials
Material M1 M3 (MPa) Stainless steel Low alloy steels 0.35 0.2 300 800 Nuclear pressure vessels are made of grade 316 stainless steel These are standard in this application Hard drawn copper is used for small boilers and pressure vessels Comment
Copper
0.5
200
0.15 0.13
200 800
Pressure tanks of rockets are aluminum Good for light pressure vessels, but expansive
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Selection of processes
Each process is characterized by a set of attributes: The materials it can handle, the shapes it can make and their precision, complexity, and size. Process selection is to find the best match between process attributes and design requirements.
Function
M aterial
Shape
Process
Attributes: Material, shape and size Minimum section thickness, tolerance and roughness Minim um section, batch size, captal cost
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Classifying processes
Shaping
Primary: Casting, molding, deformation, powder, and special methods Secondary: machining, heat treatment
Joining
Adhesives, welding, fasteners
Finishing
Polish, coating, paint/print, texture
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Classes of process
(Ashby 2005, Fig 7.11)
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Se e k supporting information
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Selection of shape
Major factor: Function, process Minor factor: Material
Function Shape
Shape factors for bending and tw isting
Material
Process
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Shape consideration
Shape factors
Spatial limitation Load consideration: Axial tension, bending, torsion, axial compression
Limitations
Empirical limitation Local bulking limitation
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Process-shape matrix
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Reference
Ashby, M. F. (2005). Materials selection in mechanical design. (3rd ed.). Burlington, MA: Elsevier Thompson, B. S. (1998). Creative engineering design. (3rd ed.). Okemos, MI: Okemos Press Juvinall, R. C., and Marshek, K. M. (2006). Fundamentals of machine component design. (4th ed.). Hoboken, NJ: John Wiley & Sons
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Additional Reading
NAP (1995). Computer-aided materials selection during structural design. Ashby, M. F. (1999). Materials selection in mechanical design. (2nd ed.). CES Materials & Process Selectors (computer-aided material and process selection) by Granta Material Intelligence
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Acknowledgments
The author wishes to acknowledge the support from the Society for Manufacturing Engineers Education Foundation, SME-EF Grant #5004 for Curriculum Modules in Product Lifecycle Management.
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