Material Selection

Function dictates the choice

Shape restricts the
of material and shape.
choice of material
Function and process.

Material Shape

Process is influenced Process interacts

by material
Process
with shape.

Material selection and process cannot be separated from the shape

and the function of the product, two way interaction.
Ken Youssefi SJSU, ME dept. 1
 Engineering Materials

Materials

Metals Plastics

Ferrous Non-ferrous Thermoplastics Thermosets Elastomers

Steel Aluminum Acrylic Phenolic Rubber

Stainless steel Copper Nylon Polymide Polyurethane
Die & tool steel Zinc ABS Epoxies Silicone
Cast iron Titanium Polyethylene Polyester
Tungsten Polycarbonate
PVC
Ken Youssefi SJSU, ME dept. 2
 Engineering Materials

Materials

Ceramics
Metals Plastics Glass Composites

Carbides Reinforced
plastics
Nitrides
Metal-Matrix
Graphite
Ceramic-Matrix
Diamond
Laminates
Glasses
Glass ceramics
Ken Youssefi SJSU, ME dept. 3
 Most Commonly Used Materials
The following 25 materials are the most commonly used materials in
the design of mechanical products; in themselves they represent the
broad range of other materials.

Steel and Cast Iron

1. 1020 (plain carbon steel, hot-rolled or cold-drawn)
2. 1040 (plain carbon steel, hot-rolled or cold-drawn)
3. 4140 (heat-treated alloy steel, chromium-molybdenum)
4. 4340 (heat-treated alloy steel, nickel-chromium-molybdenum)
5. S30400 (stainless steel)
6. S316 (stainless steel)
7. O1 (tool steel)
8. ASTM20-60 (gray cast iron)

Ken Youssefi SJSU, ME dept. 4

 Most Commonly Used Materials
Aluminum and Copper Alloys
9. 2024 (aluminum, O, T3, T4 or T6)
10. 3003 (aluminum, H12 or H16)
11. 6061 (aluminum, T6)
12. 7075 (aluminum, T6)
13. C268 (copper)

Other metals
14. Titanium 6-4
15. AZ63A (magnesium)

Ken Youssefi SJSU, ME dept. 5

 Most Commonly Used Materials
Plastics
16. ABS
17. Polycarbonate
18. Nylon 6/6
19. Polypropylene
20. Polystyrene
Ceramics
21. Alumina
22. Graphite

Composite materials
23. Douglas fir
24. Fiberglass
25. Graphite/epoxy
Ken Youssefi SJSU, ME dept. 6
 Application of Most Commonly Used Materials
Component Material

Ken Youssefi SJSU, ME dept. 7

 Application of Most Commonly Used Materials
Component Material

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 Application of Most Commonly Used Materials
Component Material

Ken Youssefi SJSU, ME dept. 9

 Properties of Most Commonly Used Materials

Ultimate
Strength in
tension

Ken Youssefi SJSU, ME dept. 10

 Properties of Most Commonly used Materials

Yield
strength

Ken Youssefi SJSU, ME dept. 11

 Properties of Most Commonly used Materials

Fatigue
endurance limit
(strength under
cyclic loading)

Ken Youssefi SJSU, ME dept. 12

 Properties of Most Commonly used Materials

Density

Ken Youssefi SJSU, ME dept. 13

 Cost of Most Commonly used Materials

Ken Youssefi SJSU, ME dept. 14

 Example Materials for table legs
Luigi Tavolino, furniture designer, conceives of a lightweight table of
daring simplicity: a flat sheet of toughened glass supported on slender,
unbraced, cylindrical legs. The legs must be solid and as light as
possible (to make the table easier to move). They must support the table
top and whatever is placed upon it without buckling. What materials
could one recommend.

Ken Youssefi SJSU, ME dept. 15

 Example Materials for table legs
The Model

The leg is a slender column of density and modulus E. The load

P and its length l are determined by design (fixed). The radius r of
the leg is a variable. We wish to minimize the mass m of the leg.

Objective function

Ken Youssefi SJSU, ME dept. 16

 Example Materials for table legs
The constraint is that the legs must support a design load without
buckling.
Eulers buckling equation

where I = r4/4

Solving for the free variable , r, and substituting it into the equation for m
gives,

=
Material properties
The weight is minimized by selecting the subset of materials with the
greatest value of the material index.

Ken Youssefi SJSU, ME dept. 17

 Example Materials for table legs
Solving the Eulers formula for r, gives an equation for the thinnest leg
which will not buckle:

Material properties

The thinnest leg is that made of the material with the largest value of the
material index.

Two material indices,

To minimize the weight, both have to be maximize.

Ken Youssefi SJSU, ME dept. 18
 Procedure for deriving material indices

Ken Youssefi SJSU, ME dept. 19

 Modulus of Elasticity (E) vs. Density () Charts

Constant
guidelines

Ken Youssefi SJSU, ME dept. 20

 Modulus of Elasticity (E) vs. Density () Charts

Ken Youssefi SJSU, ME dept. 21

 Modulus of Elasticity (E) vs. Density () Charts

Ken Youssefi SJSU, ME dept. 22

Ken Youssefi SJSU, ME dept. 23
 Summary of materials for table legs

Ken Youssefi SJSU, ME dept. 24