1
Module 5 : Lecture 24 :Material Selection using Ashby Method.........2
1.1
1.2
1.3
1.4
1.5
Example of Material Attributes........................................................3
Example of Material Attributes........................................................3
Performance Index & Material Index..............................................3
Example: Material Index(M) for a light stiff Tie.............................4
Similar Material Indices..................................................................4
Module 5 : Lecture 25 : Material Selection using Ashby Method Selection
Process
2.1
2.2
2.3
Topics to cover in this lecture:.........................................................4
Case Study: Design of Scanning Probe Microscope........................4
Elastic Deflection of a Telescope Mirror Backing Under its Own Weight
2.4
6
Mirror Backing Material..................................................................6
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1 Module 5 : Lecture 24 :Material Selection using Ashby
Method
Topics to cover in this lecture:
Introduction to Material Selection Process
What are Material attributes?
The Ashby process of Material Selection
We have briefly discussed about the structural materials used in mechanical
design. Once you are aware of all these materials existing around us the
question will be which one to choose and how? There is a systematic way of
selecting material - popularly known as Ashby Process. Following is the
outline of Ashby Process.
Every Material has an array of attributes : density,strength,
stiffness, thermal expansion coefficient, refractive index, cost etc.
Design demands a profile - for example, low density, high
strength, in addition to a design objective of minimization cost,
deflection etc.
To begin with, you have to consider all materials.
Apply property limits - that is maximum allowed limits of a
property and reduce the number of candidate materials: for
example, eliminate materials that can not work in the service
temperature range.
Use Performance Index/ Material Index to further reduce the set
of materials
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1.1 Example of Material Attributes
1.2 Example of Material Attributes
1000 series: Pure Al >99%, Ductile Elect Conductor, Foil
2000 series: Al+Cu(4%), Strong - Aircraft Skin, Rivet
3000 series: Al+Mn(1%), Corrosion Resistant - Roofing Sheet, Cooking
Pan
5000 series: Al+Mg(3%) , Strong - Pressure Vessels
1.3 Performance Index & Material Index
The design of a structural element involves minimization or maximization
of an index given by p=f[F,G,M]
F - Functional Requirement G - Geometric Requirement M - Material
Requirement
For certain designs - variable separation exist :
I E p=f 1 [F] f 2 [G] f 3 [M]
Here M denotes the Material Index
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1.4 Example: Material Index(M) for a light stiff Tie
Performance Index - Minimize the mass of the Tie - m=Al where A is the
area of cross-section of the Tie, l - the length and the density.
Constraint - The deflection of the tie should be within the permissible limit
- Fl/AE<
Eliminating A , we get m>(F / )(l 2 )( /E)
Lightest Element that can carry F is the one which has maximum E/ .
Material Index M= E/
1.5 Similar Material Indices
Light Stiff Beam:
Free area ( no constraint on height and width) - M = E 1/2 /
Free Height - M = E 1/3 /
Free width - M = E/
Light Strong Beam: M= f 3/2 /
Cheap Stiff Coloumn
C=C m Al , F<n 2 EI/l 2
M = E 1/2 / C m
2 Module 5 :
Lecture 25 : Material Selection using Ashby Method
Selection Process
2.1 Topics to cover in this lecture:
Case Study 1: Design of Scanning Probe Microscope
Case Study 2: Design of Mirror-backing plate
2.2 Case Study: Design of Scanning Probe Microscope
In the last lecture, we have discussed about the Ashby process for material selection. In
this lecture, we will try to elaborate this procedure through two examples. We will first
consider the design of a Probe for Scanning Probe Microscope (SPM). Then we will
consider the design of a Telescope Mirror.
Scanning Probe Microscopes (SPM) have contradictory specifications First, the scan
range of an SPM should exceed the size of the largest features on the sample. This
usually implies the use of large and thin walled piezo electric translators.
On the other hand, any SPM is, basically, a system of mechanical resonators. Hence, it
is very important to optimize the design of the SPM for high resonance frequencies.
This usually means to decrease the length of the probe. In this design exercise we will
consider the maximisation of resonating frequency as our design objective.
The eigen-frequency of any single degree of freedom system is given by:
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where k is the spring constant and meff is the effective mass. The spring constant of a
cantilevered beam with uniform cross section is given by
For a rectangular cross section with a width b (perpendicular to the deflection) and a
height h one obtains for I = bh3 /12
Combining the expressions we get the final result for f as :
Now, the effective mass can be calculated using Raleigh's method. If you recall, the
general expression for the kinetic energy T using Raleigh's method is
For uniform beam with a constant cross section and length, the deflection may be
expressed as:
Also, T can be given by:
Hence the effective mass = (9/20)m
Now, in the final form, the resonating frequency may be written as:
It is evident from this equation, that one way to increase the eigen- frequency is to
choose a material with as high a ratio of E/ as possible. In fact the Material Property
index in this case is given by M=(E/ ) 1/2 . The table below shows the E/ values of a
few materials. As per the table both Aluminium and Steel are good candidates for this
purpose.
E(1010 N/m2 )
Material
(103 Kg/m3 )
E/
Al
2.7
2.6
Brass
8.5
1.1
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Steel
20
7.8
2.6
Tungsten
39
19.3
2.0
2.3 Elastic Deflection of a Telescope Mirror Backing Under its Own Weight
Let us consider another example, the design of a backing plate for
telescopic mirror. The objective is to select a suitable material
which will give minimum central deflection of the circular plate
for the same mass of the plate. The thickness of the plate 't' is a
free variable.
2.4 Mirror Backing Material
The material property index in this case is given by ( 3 /E) 0.5 .
Here,
it
is
evident that the material with the lowest
value
of
the
index will be the best for the design;
accordingly,
from the table below, CFRP comes
out as the best choice.
Material
Mg/m3
E GPa
3 /E
Steel
200
7.8
1.54
Concrete
47
2.5
0.56
Al
69
2.7
0.53
Glass
69
2.5
0.48
GFRP
40
2.0
0.45
Wood
12
.6
0.13
PU
.06
.1
0.13
CFRP
270
1.5
0.11
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