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FAKULTI KEJURUTERAAN MEKANIKAL DAN PEMBUATAN

BDA 20402 / BDA 2042

ENGINEERING MATERIALS SELECTION

2011/2012 Semester 1

CHAPTER 1 :
INTRODUCTION TO MATERIALS SELECTION

Sabda Rasulullah SAW:

“Akan datang kepada manusia suatu zaman,

di mana orang-orang tidak peduli lagi

terhadap apa-apa yang mereka peroleh,

apakah rezeki itu halal atau haram.”

(HR. Bukhary dari Abu Hurairah)

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CONTENTS
Introduction to Materials Selection:

1.1 Methods of Selection

1.2 Materials in Design

1.3 Evolution in Engineering Materials

1.4 Sources of Information

1.1 Methods of Selection

• Classical (Klasik)

• Imitative (Tiruan)

• Comparison
(Perbandingan)

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1.1 Methods of Selection

CLASSICAL SELECTION

• Selection is done through

analysis of function and
properties specification.

• Characteristics:
– function of component
– requirement of component
– materials properties
requirement

1.1 Methods of Selection

IMITATIVE
• Selection is made by
equality or similarity
of function.

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Imitative… some instances

Some metal toilet bolts have a yellowish durable recycled plastic polymer
zinc coating that makes them look like crafted to look and feel like real
brass wood

ceramic with platinum lustre ceramic knife

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1.1 Methods of Selection

COMPARISON
• Assume the component
is made from a normal
& low cost material;
• the material disability is
then evaluated,
• if it is not suitable then
the other material is
selected and evaluated
• the process goes on
until a suitable material
is obtained.
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Comparison… example

1.1 Methods of Selection

Classical method is more

specified, more global, high
cost, required longer time to
complete the selection and
need to do a prototype test.

Imitative and Comparison

method are faster and
involve low cost, however
they are more suitable for
an experienced person or
designer.
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1.2 Materials in Design

Design
a process of translating
new idea or a market need
into the detailed
information from which a
product can be
manufactured.

What is the ROLE of material in design???

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1.2 Materials in Design

FUNCTION
(Fungsi)

MATERIALS SHAPE
(Bahan) (Bentuk)

PROCESS
(proses)

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1.2 Materials in Design

Design problem, almost

always, are open-ended FUNCTION
(Fungsi)

- do not have a unique

MATERIALS SHAPE
or correct solution, (bahan) (Bentuk)

although some solution

PROCESS
will clearly be better than (proses)

others.
Note : Case studies after sub-chapter 1.4

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1.3
EVOL UTION
In
Engineering Materials

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1.4 Sources of Information

An engineer or designer -
should have a sufficient
knowledge and information
about materials and their
properties.

•Standard – ASTM (Am.

Soc. Testing & Materials),
BS (British Standard), DIN,
JIS, MS etc.
•Software - CES, NOVA,
PERITUS etc.
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1.4 Sources of Information

IDEA

Component Housings, covers, gears, bolts,

Complex solid, long, short, hollow
Concentric, non-hollow concentric,
Solid non concentric, cup, dish, cone,
Spirals, repititive, flat, bent, flanged
category Bearings, wear surfaces,
Electrostructural, thermostructural,
Insulators, conductors, large
Shape Mechanical, springs, clips, force
category Absobers, light transmitters

Low temp limit Operational Environment resistance

High temp limit factors Surface coating
Joining method Cost allowance

Process characteristics Materials characteristics

Quantity, Size, Stability, Stiffness,

Candidate materials & processes
Precision, Density, Max. Stress,
Complexity, Finish, Toughness, Cost
Cost Materials data & optimisation

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Case Study 1:
Vacuum Cleaner

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•First successful vacuum cleaner -

Hubert Cecil Booth, 1901, England.

•The machine worked well and was

popular with rich people.

•It was also used in places such as

Westminster Abbey, Buckingam
Palace and windsor castle.

•Booth's cleaner was so large that it

had to be pulled along by a horse, and
six people were needed to operate it.

• The machines were only hired out,

never sold

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It may look like a complicated

machine, but the conventional
vacuum cleaner is actually made up
of only six essential components:
1. An intake port, which may
include a variety of cleaning
accessories
2. An exhaust port
3. An electric motor
4. A fan
5. A porous bag
6. A housing that contains all the
other components

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1905 - 1920

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1920s – 1930s

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1947

1940s – 1960s

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1970s – 1990s

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Beyond 2000…

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21st century –
robotic vacuum
cleaner

Samsung’s Hauzen VC-RE70V is a

robot vacuum cleaner that is smart
enough to know if the given place has
been cleaned by it or not by using a
camera to map rooms which it had
already cleaned.

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Inside a Roomba robotic vacuum cleaner are: (1) five motors, (2) a steering

system, (3) a battery, (4) two motor-driven, and (5) tracked wheels.

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Vacuum cleaner of the future… a “Transformer”…?!?

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CENTRAL-VACUUM-HOUSE
The whole house as a vacuum
cleaner

RIDEABLE VACUUM CLEANER

Lundus University School of Design -
Philips collaboration work for future
vacuum cleaner

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Case Study 2:
CELL PHONE

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From enormous, 80-pound, car-mounted

beasts to tiny terminals in our back
pockets, mobile phones have come a long
way. What once cost thousands, weighed 2
pounds, and packed 60 minutes of battery
life now costs $99, weighs 4 ounces, and
packs 5 to 10 hours of battery life--and also
includes a full-fledged computer, a video
camera, audio/video playback, and high-
speed Internet access. How did we get
from there to here? Let's take a brief tour
through the history of the cell phone. The
http://www.pcworld.com/article/173033/evolution_of_the_cell_phone.html

following phones don't necessarily reflect

the first or best of each type, but instead
represent certain phases in mobile phone
evolution over the last 50 years. 38

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In the days before cellular phone networks,

the world's mobile phones lacked a
unifying standard. Instead, they used
varying communication methods defined
on a company-by-company basis.

The 88 Ibs (~40 kgs) MTA phone, shown

here, is typical in size and weight of early
mobile phone systems from the pre-
integrated-circuit era. Most were so heavy
and power-hungry that they required
permanent installation in a car or other
vehicle. Very few people owned, used, or
SRA/Ericsson MTA even encountered such devices; for
example, the service for the model shown
(Mobile Telephone System A) here existed in only two Swedish cities and
Year: 1956 served a mere 125 subscribers from 1956
to 1967.

Notable qualities: The first automatic

mobile telephone system (no human
operator to manually connect the user to
an outside phone line)

Though Motorola announced the world's first

handheld mobile phone--a prototype of the
DynaTAC 8000X you see above--in 1973, it
took ten years for the DynaTAC to reach the
market. In those ten years, engineers
squeezed more capability into less space,
and Motorola built much-needed
infrastructure--the towers necessary for cell
phone service. Upon its release in 1983,
the DynaTAC 8000X became an instant
Motorola DynaTAC 8000X
cultural icon, both as a status symbol for the
Year: 1983
rich (thanks to the $3995 retail price--$8657
in 2009 dollars) and as an almost miraculous Notable qualities: Small size, light
weight; the first handheld mobile phone
wonder-phone that a person could use
anywhere. With the DynaTAC, the cell phone
revolution had finally begun. 40

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Motorola's handheld DynaTAC was

an amazing breakthrough, but in
reality its size proved limiting due to
the battery technology of the era.
The DynaTAC could manage only 60
minutes of talk time in ideal
conditions, while larger "luggable"
phones equipped with capacious Nokia Mobira Talkman
batteries--such as the Mobira (Year: 1984)
Talkman, shown here--could provide
Notable qualities: Early luggable
many hours of continuous operation. mobile phone; relatively long talk
time

After the success of the DynaTAC,

Motorola followed up with the much
smaller and lighter MicroTAC phone in
1989. The MicroTAC included a novel
space-saving idea: Motorola engineers
placed part of the phone's hardware in
a hinged section that could fold inward
or outward as needed, thus reducing

Motorola MicroTAC the phone's size when it wasn't in use.

Year: 1989 The flip concept lives on in many cell
phones today.
Notable qualities: First flip phone,
first pocket phone; smallest and
lightest cellular phone at the time of its
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debut

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Motorola 2900 Bag Phone
(Year: 1994)
Notable qualities: Long talk times, plus
greater battery life and signal range
Motorola StarTAC
(Year: 1996)
Notable qualities: First fully
"clamshell" mobile phone design;
smallest and lightest mobile phone
at its release
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When many people think of the "car
phones" of the 1980s and 1990s, they
picture bag phones like the Motorola
2900. The bag contained a transceiver
and battery, and the user operated a
much lighter corded handset. Owners
could carry the bag on their shoulder, but
a bag phone's general bulk mostly limited
its usage to cars. Despite the availability
of smaller phones on the market, bag
phones remained popular well into the
late 1990s due to their long talk times
and their superior range. Thanks to
heftier batteries, bag phones could afford
to transmit a cell signal with greater
power, allowing the phone to be used
farther away from a receiving tower. This
was especially important in the days
when cellular coverage wasn't nearly as
widespread as it is now.
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In 1996, Motorola further shrank its line
of pocket cell phones, producing the 3.1-
ounce StarTAC--which immediately
proved popular and influential. The
StarTAC expanded on the partially
collapsible design of its precursor, the
MicroTAC, by allowing users to fold the
phone in half when they weren't talking
on it. We now call this design
"clamshell," for its resemblance to the
way a clam opens and closes. The
StarTAC's general design was widely
imitated, and a large percentage of
mobile phones still use it today.
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Nokia 9000i Communicator
(Year: 1997)
Notable qualities: First Nokia
smartphone; first modern PDA/cell
phone combo; mobile Internet
connectivity
Nokia 8810
(Year: 1998)
Notable qualities: First cell phone
without an external whip or stub
antenna; first "candy bar" phone
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Though the Nokia 9000i wasn't the first-ever
smartphone (many people give that honor to
the IBM Simon), it marked the real beginning of
our modern smartphone era. The 9000i truly
was a pocket computer and a cell phone rolled
into one, with an Intel 386-derivative CPU and
8MB of RAM. The phone's physical configuration
was novel at the time: Users could open the
9000i in a horizontal clamshell fashion to reveal
a wide LCD screen and a full QWERTY
keyboard. When folded, it resembled an ordinary
cell phone.The 9000i could send and receive
faxes, text messages, and e-mail, and it also
had (extremely) limited Web access through
160-character SMS messages. And like any self-
respecting smartphone, it shipped with a full
complement of PDA-like organizer capabilities.
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In the earlier years, all cellular phones
shipped with external antennas that stuck
out in aesthetically unpleasing ways.
Nokia engineers found a way around that
problem by designing a flat, plate-like
antenna that could hide inside the body
of a cell phone. The result was the Nokia
8810, the first true "candy bar" phone in
the modern sense. This small, compact,
non-clamshell design soon became
standard for many Nokia handsets; you
rarely see an external cell phone antenna
these days.
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Not too long ago, WAP (Wireless Application

Protocol) was a huge deal. The mobile
phone industry designed WAP to allow Web
access on simple devices with limited
processing power and displays, like cell
phones circa 1999 to 2002. Instead of a rich
graphical experience, users would see a
stripped-down, typically text-only subset of
the Web. Nokia was the first company to
bring WAP browsing to a mobile phone with Nokia 7110
the 7110, released in 1999. In our present
(Year: 1999)
age of smartphones with full-featured Notable qualities: World's first WAP-
browsers, large screens, and beefy CPUs, capable mobile phone; nifty sliding
keypad cover
WAP has quickly become a relic of the past.
Web browsing has most assuredly not.
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The BlackBerry brand began in 1999 as

a simple two-way pager, but it morphed
into a line of full-fledged smart phones in
2002 with the BlackBerry 5810, the first
of the series to include integrated cell
phone support. Thanks to top-of-the-line
mobile e-mail and text messaging (the
RIM BlackBerry 5810
(Year: 2002) QWERTY keyboard didn't hurt
either), BlackBerry phones soon became
Notable qualities: First BlackBerry
indispensable tools for entrepreneurs
with an integrated voice cell phone;
push e-mail support and other professionals.

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Sanyo SCP-5300
(Year: 2002)
Notable qualities: First U.S. mobile
phone with an integrated camera;
color screen, clamshell camera
phone design
T-Mobile Sidekick /
Danger Hiptop
Year: 2002
Notable qualities: Large, flippable
screen; relatively uncramped and
full-featured QWERTY keyboard
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Who would want a camera in their cell
phone? When news of such combination
devices trickled over from Japan in the early
part of the decade, the idea seemed silly
and excessive. In 2002, Sprint and Sanyo
released the first American cell phone with a
built-in camera, the SCP-5300--and the
public went crazy for it. The camera
phone became a bona fide (genuine)
cultural phenomenon, allowing the average
Joe to quickly and personally share both
mundane and earthshaking events with the
rest of the world. Today, camera phones are
so common that we don't call them "camera
phones" anymore.
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At the time of its release in the US, the T-
Mobile Sidekick (aka Danger Hiptop)
quickly became the text-messaging
addict's dream machine. This innovative
smart phone incorporated a novel design
with a large LCD screen that rotated and
flipped to reveal a generous QWERTY
keyboard. The Sidekick line, with its
distinctive full-reveal keyboard, persists
today, having influenced many similar
hide-and-reveal keyboard designs since
its emergence in 2002. These clever and
attractive designs helped fuel text
messaging's popularity beyond the tie-
and-Frappuccino BlackBerry set,
extending it to the youth of the world.
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At a time when most cell phones were

starting to look the same, Motorola
decided to break the status quo with
the Razr V3, a slim, slab-like clamshell
phone with a large screen, a stylish and
flat keyboard, a built-in camera, and
multimedia capabilities. Impressive
technical features aside, you have to Motorola Razr V3
admit that the Razr simply looks cool
Year: 2004
(especially by 2004 standards), a fact Notable qualities: Stylish
design, slim form, and a full
that contributed significantly to its wide
set of features
popularity.

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Apple iPhone
Year: 2007

Notable qualities: Everything--

but particularly the excellent
software, the large and sharp
screen, the multitouch interface,
visual voicemail, the App Store.

Apple's ability to rock our world through nifty gadgets should not be underestimated.
Between the Apple II, the Macintosh, and the iPod, Apple is responsible for more
trend-setting consumer technology than most companies. In the same vein,
the iPhone goes far beyond being just a mobile telephone: It's a powerful pocket
computer, a game machine, and a multimedia-playback device. Better yet, it gives
you instant, high-speed access to the Web, e-mail, Facebook, Twitter, and YouTube,
wherever you can find mobile phone coverage. In short, it's a revolutionary device,
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and other companies are already coming up with imitators.

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RELATED TIMELINE :
(http://www.futuretimeline.net)

2019 – Computers are expected to break the

exaflop barrier

2020 – Internet use reaches 5 billion

Phoning the future…?!? worldwide

2020 – Texting by thinking

2024 - Petabyte storage devices are available

2026 – The cost per watt of solar PV has

dropped to below $1

2030 – AI is widespread

2032 – Terabit internet speeds are

commonplace

futuristic glass phones 2037 – Quantum computers are widely

available
http://www.atishayjain.info/2011/01/future-mobile-phones-in-india.html
2057 – Computers reach another milestone
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Case Study 3:
PASSENGER CAR

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1769 – Nicolas Cugnot Steam Car 1936 - Toyota Model AA

1972 – Maserati BOOMERANG

2009 – Dodge Viper

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More story at: 57

http://www.autoevolution.com/volkswagen/history/

1932 Volkswagen
Beetle Prototype

1936
Volkswagen
Beetle Prototype

1944 Volkswagen
Beetle

Volkswagen's "Theory of evolution" ad,

showing models from 1949 to 1963, without
http://www.squidoo.com/vwbeetlehistory#module12250758 much change.
http://www.cartype.com/pics/3814/full/evolution-ad.jpg

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VOLKSWAGEN Beetle 1945 - 2003
VOLKSWAGEN Beetle 1998 - 2005
VOLKSWAGEN BEETLE RSI 2001 - 2002
VOLKSWAGEN Beetle Cabrio 2003 - 2005
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The VW Beetle is one of the most popular cars in the
world, being first produced in 1938 and kept in
production until 2003. Although it was first known as
Beetle or Bug, this VW model adopted its name in
August 1967. However, the vehicle never used the
Beetle name in the UK where it was marketed as
Type I, 1100, 1200, 1300 or 1500. The 1945 model of
VW was initially produced for the German army, but
only a few vehicles were produced, especially due to
the lack of gasoline. In 1945, the Beetle production
was stopped due to the attacks of the Allies, but all
the equipment was moved into bunkers in order to
restart the process after the end of the war.
The 1998 version is based on the original Beetle but,
in comparison with the old model of the vehicle, it is
way more spacious and equipped with more
advanced features. The new Beetle comes with a
front-mounted engine, in comparison with the old
one which had the engine mounted in the rear side
of the car. And speaking of engines, the new Beetle
came with a new engine, a 1.9 liter TDI 4-cylinder
engine which could produce 90 horsepower. VW
equipped with 1998 model with air conditioning and
a central locking system as well as side airbags.
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The 2001 VW Beetle RSI was first unveiled at the
Geneva Motor Show in 2000 when the German
automaker presented it as a new car concept.
However, the model was introduced in production
as a limited edition but only 250 units of the car
can be found today. Since it's a special edition of
the vehicle, the Beetle RSI comes with a 3.2 liter,
24-valve V6 engine which could produce 220
horsepower at 6200rpm. Moreover, it has an all-
wheel-drive system with a six-speed transmission
as well as with ABS and electronic brake pressure
distribution system.
The 2003 VW Beetle Cabrio is based on the 1949
Beetle Cabriolet but comes with numerous
improvements and last generation features.
Volkswagen rolled out three European engine
versions of the Beetle Cabrio producing from 75 to
115 horsepower. The five-speed gearbox came as a
standard feature while the Tiptronic six-speed
automatic gearbox was made optional equipment.
The convertible top can be opened or closed in no
less than 13 seconds in case the driver uses the
electro-hydraulic system.
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VOLKSWAGEN Beetle Cabrio 2005 - Present
The 2005 VW Beetle Cabrio is the upgraded
version of the 2003 model which received almost
the same upgrade just like the Coupe edition
launched in 2005. If the German company added
only one new engine, the 103 horsepower 1.9
TDI, the interior received lots of new features
such as the heated seats, the parking sensors and
a six-CD autochanger.

The 2005 version of VW Beetle is the upgraded

VOLKSWAGEN Beetle 2005 - Present
version of the 1998 edition, which obviously came
with a large number of improvements and advanced
features. For example, VW equipped it with an MP3
player, a gadget which was initially an optional
feature, while the turbocharged 1.8 liter four
cylinder version of the Beetle has a six-speed
automatic transmission. Moreover, the 2005 Beetle
provides advanced safety as the side-impact airbags,
the ABS and the daytime running lights are now
standard features.
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VOLKSWAGEN Beetle 2011 - Present

VW showed the first official photos of their new Beetle model a few days before the car hit
the floor of the 2011 New York International Auto Show. The new model comes with a
much more aerodynamic and sporty appearance and comes with a lower stance, while also
having a longer and wider body. The car sports 19-inch wheels and plenty of luxury
equipment as compared to its predecessor, and will be sold (mainly) in the US starting
September 2011.

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1966 - 1st gen. 1970 - 2nd gen.

1974 - 3nd gen. 1979 - 4nd gen.

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1983 - 5th gen. 1987 - 6th gen.

1991 – 7th gen. 1995 – 8th gen.

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2000 – 9th gen. 2006 – 10th gen.

2010 and beyond…?

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Case Study 4 – Space Shuttle

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1977 - Enterprise 1984 - 2010 - Discovery

1981 – 2003* - Columbia 1985 - 2010 - Atlantis

1983 – 1986* - Challenger 1992 - 2010 - Endeavour

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