Bab 04 - Materials Chart PDF

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CHAP. 4 : MATERIALS SELECTION

CHART (cont.)
4.4 Selection Strategy
4.4.1 Introduction
4.4.2 Materials Attributes
4.4.3 Screening and Ranking
4.4.4 Supporting Information
4.4.5 Local conditions
4.5 Derivation of Property Limits and

Material Indices
4.5.1 Function, Objective & Constraint
4.5.2 Property Limits
4.5.3 Materials Index
4.5.3.1 Light & Strong Tie Rod
4.5.3.2 Light & Stiff Beam
4.5.3.3 Light & Strong Beam
4.5.3.4 Cheap & Stiff Column
4.4 Selection Strategy

4.4.1 Introduction
Basic procedure for selection is establishing the

link between material and function (Figure
4.3).
A material has attributes (density, strength,
cost, resistance to corrosion etc.).
- A design demand certain profile as these: a low density, a high
strength, a modest cost, resistance to sea water, etc.
- Start with full menu of materials in mind; failure to do so may mean a
missed opportunity.
- The task, restated in two lines, is that of:
identifying the desired attribute profile and then
comparing it with those of real engineering materials to find
the best match
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Cont….
Done by:
- examining the design requirement to identify the
constraints that they impose on material choice.
–Screening & Ranking

¤ Screening out the materials that cannot meet the
constraints.
¤ Further narrowing is achieved by ranking the candidates
by their ability to maximize performance.
¤ Criteria for screening and ranking are derived from the
design requirements for a components by an analysis of
function, constraints, objectives, and free variables.
–Supporting Information
–Property Limits
–Material Indices
Figure 4.3: Material selection is determined by function. Shape

sometimes influences the selection. (M.F. Ashby, 1999)
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4.4.2 Materials Attributes

Kingdom Family Class Sub-class Member Attributes
Density
1000 5005-O Modulus
Ceramics Steels 2000 5005-H4 Strength
Glasses Cu-alloys 3000 5005-H6 Toughness
Metals Al alloys 4000 5083-O T-conductivity
Material
Polymers Ti-alloys 5000 5083-H2 T-expansion
Elastomers Ni-alloys 6000 5083-H4 Resistivity
Composites Zn-alloys 7000 5154-O Cost
8000 5154-H2 Corrosion
oxidation
Figure 4.4: taxonomy of the kingdom of materials and

their attributes (M.F. Ashby, 1999)
- Each member is characterized by a set of attributes: its properties. Ex: The
member of sub-class for “5000 series” of Aluminium Alloys is finally the particular
member “Alloy 5083-H2”. It, and every other member of the kingdom, is
characterized by a set of attributes that include its mechanical, thermal, electrical,
optical, and chemical properties, its processing characteristics, its cost and
availability, and the environmental consequences of its use. We call this its
PROPERTY PROFILE
4.4.3 Screening & Ranking
Screening
– elimination of candidates materials which cannot do
the job at all because one or more of their attributes
lies outside the limits imposed by the design.
Ranking
– listing of materials according to their capability to
give the best performance for certain application.
Property limits help to separate the suitable materials.
Materials Index identifies the best materials among a

group of the suitable materials.
Refer Figure 4.5
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All Materials
Translate design requirements, express as

function, constraints, objectives and free variables
Screening: apply property limits

(Eliminates candidates which can‟t do the job)
Ranking: apply material indices
(Find candidates which can do the job well)
Subset of Materials
Supporting Information:
Handbooks, specialized software, expert systems, CD-ROMS,
WWW
(Search “family history” of candidates)
Prime Candidates
Local conditions
(Does the choice match local needs, expertise?)
Final Material Choice
Figure 4.5: The strategy for materials selection. The main steps are enclosed in
bold boxes (M.F. Ashby, 1999)
4.4.4 Supporting Information
The outcome of the screening step is a shortlist of

candidates which satisfy the quantifiable requirements
of the design.
Need details profile for each materials (properties,

graphic, price etc.)
Information can be found in handbooks, supplier‟s data

sheets, CD-based data sources and the worldwide web.
All materials information will be compared in order to be

able to carry out details selection.
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4.4.5 Local Conditions
The final choice between competing candidates will

often depend on local conditions e.g.
- in-house expertise,
- equipment,
- availability of suppliers etc.
There is no specific procedure for this part expect

totally depends on the local conditions.
4.5 Derivation of Property

Limits and Material Indices
Design requirements for a component defines to
prescription of materials through observation on
- function of component
- design constraints
- design objective
which is determined by designer in order to optimize
the component performance.
Function, objective and constraints define the

boundary conditions for selecting a material.
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Modes of Loading (without shape)
(a) Tension : Tie
(b) Bending : Beam
(c) Twisting : Shaft
(d) Compression : Column
4.5.1 Function, Objective &

Constraint (design requirements)
Function What does component do?

Objective What is to be maximized or
minimized?
Constraints * What non-negotiable conditions
must be met?
What negotiable but desirable
conditions?
* It is sometimes useful to distinguish between „hard‟

and „soft‟ constraints. Stiffness and strength might be
absolute requirements (hard constraints); cost might
be negotiable (a soft constraint).
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4.5.2 Property Limits
Involve the certain level of ability need to be fulfill

by material to carry out the required function.
Example:
– If the component must operate at 250ºC, then
all materials with a maximum service
temperature less than this are eliminated.
The screening procedure uses property limits

derived in this way to reduce the kingdom of
materials to an initial shortlist.
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Exercises :
Identify design requirements (function, objective and
constraints) for each product in the stated cases studies.
Case 1 :
A design of cylindrical tie-rod of specified length l,
to carry a tensile force F without failure; it is to be of
minimum mass.
Function Tie-rod
Objective Minimize the mass
Constraints (a) Length, l specified
(b) Support tensile load F without failing
Case 2 :
Think of golf-club shafts. Consider, then, a light
beam of square section b x b and length l loaded in
Bending which must meet a constraint on its stiffness
S, meaning that it must not deflect more than
under a load F . F
b A
b l
Function Beam
(b) Support bending load F without
deflecting too much
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Case 3 :
Consider the selection of a light beam for a strength
limited application. Deflection is acceptable
provided the component does not fail. The
dimensions are the same as the beam in case 2.
Case 4 :
We seek for the cheapest legs of a table (cylindrical
column) of a specified height, l, which will safely
support a load F.
Case 3 :
Function Beam
(b) Support bending load F without
failing by yield or fracture
Case 4 :
Function Column
Objective Minimize the cost
(b) Support compressive load F
without buckling
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Tugasan 3 (1) / Tutorial
Heat sinks for hot microchips

A microchip may only consume milliwatts, but the power is dissipated
in a tiny volume. The power is low but the power-density is high. As
chips shrink and clock-speeds grow, heating becomes a problem. The
Pentium chip of today’s PCs already reaches 85 C, requiring forced
cooling. Multiple-chip modules (MCMs) pack as many as 130 chips on
a single substrate. Heating is kept under control by attaching the chip
to a heat sink Figure 1, taking pains to ensure good thermal contact
between the chip and the sink. The heat sink now become a critical
component, limiting further development of the electronics. How can
its performance be maximized?
To prevent electrical coupling and stray capacitance between chip and
heat sink, the sink must be a good electrical insulator, meaning a
resistivity, e >1019μΩ.cm. But to drain heat away from the chip as fast
as possible, it must also have the highest possible thermal conductivity,
.
Tugasan 3 (2) / Tutorial

Materials for overhead transmission lines
Electrical power, today, is generated centrally and distributed by
overhead and underground cables. Buried line are costly so cheaper
overhead transmission (Fig 2) is widely used. A large span is desirable
because the tower are expensive, but so too is a low electrical
resistance to minimize power loses. The span of cable between two
towers must support the tension needed to limit its sag and to tolerate
wind and ice loads. Consider the tower spacing L is fixed at a distance
that requires a cable with a strength σf of at least 80 MPa and the
objective is to minimizing resistivity losses. From the available charts,
identify two (2) suitable materials for this application?
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CHAP. 4 : MATERIALS SELECTION

CHART (cont.)
4.5 Derivation of Property Limits and
Material Indices
4.5.3.1 Light & Strong Tie Rod
4.5.3.2 Light & Stiff Beam
4.5.3.3 Light & Strong Beam
4.5.3.4 Cheap & Stiff Column
4.6 Selection Procedure

4.6.1 Property Limits: go/no-go conditions
and Geometric Restrictions
4.6.2 Performance Maximizing Criteria
4.7 Structural Index
Material index
- Combination of material properties
which characterizes the performance
of a material in a given application.
Materials Selection
Materials Selection BDA 2042
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Example
Structural Elements – components which

perform physical function (ie. carry load,
transmit heat etc.) or satisfy Functional
Requirements
Functional Requirements – specified by

design (tie must carry load; spring provides
restoring force etc)
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Material Index
Design of structural elements specified by 3

things:
– FUNCTIONAL REQUIREMENTS (F)
– GEOMETRIC PARAMETERS (G)
– MATERIALS PROPERTIES (M)
Description of PERFORMANCE (p)
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PERFORMANCE
Describe by equation: p = f (F,G,M) (i)
Can be separable: p = f1(F) f2(G) f3(M) (ii)
Where f1, f2 & f3 are separated functions which are multiplied

together.
– By maximizing f3(M), performance of F & G is maximized

 efficiency coefficient or MATERIAL INDEX (or merit
index or performance index or material factor)
– f1(F) & f2(G) related to structural coefficient or

structural index OR f1 is the place where the creative
design comes in AND f2 is where geometry can make a
difference.
- f3 is the part we’re most intrested in. When the factors are
separable, the materials selection doesn’t depend on the
details of f1 and f2! This means we don’t have to know that
much about the design to make intelligent materials
choices.
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Material indices when objectives are coupled to constraints

Think for a moment of the simplest of
mechanical components. The loading on a
component can generally be decomposed into
some combination of:
Axial tension
Bending
Torsion
Compression
Almost always, one mode dominates.
The functional name given to the component
describes the way it is loaded: ties carry
tensile loads; beams carry bending moments;
Shafts carry torques; and columns carry compressive
axial loads. The words “tie”, “beam”, “shaft”, and
“columns” each imply a function.
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Examples of Indices (E-ρ chart)
E/ρ = C Minimum weight design of stiff ties;

minimum deflection in centrifugal
loading etc.
E½/ρ = C Minimum weight design for stiff beams,
shafts and columns.
E1/3/ρ = C Minimum weight design of stiff plates
Value of constant, C increases as the lines are

displaced upwards and to the left. Materials offering
the greatest stiffness-to-weight ratio lie towards the
upper left-hand corner.
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4.6.2 Performance
Maximizing Criteria
Modulus = 10 GPa
Density = 3 Mg/m3
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Procedure for deriving material indices

1. Define the design requirements:
a) Function: what does the component do?
b) Objective: what is to be maximized or minimized?
c) Constraints: essential requirements which must be met – stiffness,
strength, corrosion resistance, forming characteristics etc.
2. Develop an equation for the objective in terms of the

functional requirements, the geometry and the material properties
(the objective function)
3. Identify the free (unspecified) variables
4. Develop equations for the constraints (no yield; no fracture;

no buckling etc.)
5. Substitute for the free variables from the constraint equations

into the objective function
6. Group the variables into three groups: functional requirements

(F), geometry (G), and material properties (M), thus
– Performance characteristics f1(F) f2(G) f3(M)
– Performances characteristics f1(F) f2(G) f3(M)
7. Read off the material index, expressed as a quantity M, which

optimizes the performance characteristics.
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CASE STUDY:
4.5.3.1 Material index for a light, strong tie
A cylindrical tie-rod of specific length, L, to carry a

tensile force, F without failure; it is to be of minimum
mass.
Maximizing performance =
minimizing the mass while still
carrying the load, F safely.
Function : Tie rod
Objective : Minimize the mass
Constraints : (a) Support tensile load, F, without failing
(b) Length, L, specified
We first seek an equation describing the quantity to be

maximized or minimized. Here, it is the mass, m of the
tie,
Materials
Materials and it is a minimum BDA
Selection
Selection that
BDA 2042
2042we seek. This equation, 10
called the objective function, is:
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Objective function: m = ALρ

•where:
A - cross section area
L – length
ρ - material density
L& F are specified (fixed); A is free
Mass can be reduced by reducing A, but
with constraint: A must be sufficient to
carry load F.
F/A σf (failure strength);
So :
F/(m/Lρ) σf  m (F)(L)(ρ/σf)
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Material
Performanc index
e
m (F) (L) (ρ/σf)
Geometric
parameter
The lightest tie which will carry F safely is that made of
material with the smallest value of (ρ/σf)
For better performance, p = 1/m,

We, therefore invert the material properties in above
equation and DEFINE THE MATERIAL INDEX M,
M = σf /ρ
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Other example;
The lightest stiff tie-rod which will carry load F
without failing is that with the largest value of
this index (specific strength)
M = E/ρ
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Case 1 :
The cantilever beam (groans) to the right is to be loaded in
torque with an end torque T around its center line. It has a
given length, L, and an unknown square cross section of b x b.
Under the torque load, the end of the beam rotates by THETA
radians.
For this device to function properly, it must be as inexpensive

as possible. It also must not fail with the application of the
torque, and it must be stiff enough to not twist by more than an
angle of THETA max.
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Answer for Case 1 :
(i) Performance, p = 1/cost
(ii) OVERCONSTRAINED, because we have

two constraints (torque and deflection)
and only one free parameter (b- the width
and height of the beam).
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Case 2 :
A local theater effects company has been contracted to provide the stage
effects for the new Broadway Musical production of “Caspar, the
Friendly Ghost”. One of the effects involves an enormous ghost puppet,
which is manipulated through wires attached to a large crosspiece. The
crosspiece must support the substantial load of the puppet at the center of
the main beam (Fcenter), as well as control the puppet motion with wires
attached to the arms of the crosspiece, Frot.The central load problem is
modeled as a simply supported beam, while the puppet control requires a
large torque at the ends of the beam, which leads to a rotational deflection
of the backbone, THETA. Since the puppeteers must manipulate the
crosspiece, its weight is of significant concern.
Because of your immense skill in materials selection, especially when

shape is involved, you have been subcontracted to select the materials for
the crosspiece
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Answer for Case 2 :
(i) Performance, p = 1/m
(ii) OVERCONSTRAINED, because there is one

free parameter (A, or d), and there are
two constraints (ROTATIONAL
DEFLECTION, and STRENGTH IN
BENDING).
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Bacaan Lanjut
M. F. Ashby
p 73 – 77 (Case Study)
Materials Selection
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Light and Stiff Beam
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CHAPTER 4 :
MATERIALS SELCTION CHART
(cont. ..)
4.8 Material Selection Without

Shape
Case study:
Mirrors for large telescope
Mirror as circular disc with specific
diameter, 2R and mean thickness, t,
supported at its periphery. When
horizontal, it will deflect under its own Concave
support for
weight, m; when vertical it will not deflect reflecting surface
significantly. This distortion must be small
enough that it does not interfere with
performance.
In practice, the deflection, δ of the 2R
midpoint of the mirror must be less than t
the wavelength of light.
Additional requirements: no creep and low δ
thermal expansion
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Design requirements
Function
– precision mirror
Objective
– minimize the mass, m
Constraints
a) Radius R specified
b) Must not distort more than δ under its own
weight
c) High dimensional stability: no creep, no
moisture take-up, low thermal expansion
Free variables
- thickness of mirror, t
- Choice of material
The Model
Mirror mass, m = πR2tρ 1
Elastic deformation, δ = (3/4π)(mgR2/Et3) 2
Thickness, t, is a free variable.
Solving for t ( 1 in 2 and
substituting this into the first equation
gives :
m = (3g/4δ)½ πR4(ρ/E⅓)3/2
For better performance, p = 1/m,
We, therefore invert the material properties in
above equation and DEFINE THE MATERIAL
INDEX M,
Index for lightest mirror:M = E⅓/ρ
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The Selection
Suppose:
– Diameter, a = 6m
– Thickness, t = 1m
– Weight, m = 70,000 kg
– Deflection, δ= 10 µm
– Gravity, g = 9.81 ms-2
The Selection
From: m = (3g/4δ)½ πa4(ρ/E⅓)3/2

E⅓/ρ = ( a4/m)2/3 (3g/4δ)1/3 = M
M = E⅓/ρ = **
Refer modulus – density chart
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For example :
M=2
M = E⅓/ρ
At ρ = 1;
E = M3 = (2)3 = 8
At ρ = 0.1
E = (0.2)3 = 0.008
M=2
Reference
line
PROBLEMS :
Today we need to select a material for a diaphragm for a
sensitive vacuum gage. The diaphragm is a thin cylindrical
disk of radius R and thickness t. With a pressure difference
across the diaphragm, the disk deflects, and we will measure
the deflection to find the pressure difference.
Assume the radius, R, and the thickness, t, are free to vary,

and that the design requires as large a deflection as possible.
The constraints are that the mass must be less than mo
kilograms, and it should not fail under the pressure load.
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Use the following information to answer the design

questions below.
Center deflection of the diaphragm:
Maximum stress in the diaphragm:
Mass of the diaphragm:
1) What is the measure of performance, p, for this

design?
p=
2) Is this design OVERCONSTRAINED, FULLY

DETERMINED, or UNDERCONSTRAINED, and why?
FULLY DETERMINED, because there are two

free parameters (R, and t), and there are two
constraints (MASS, and FAILURE STRESS).
Equal numbers of constraints and free
parameters defines a fully determined design.
3) How many M values (materials selection criterion)

should you have for this design?
Because this design is fully determined, there will be

only ONE selection criterion (M-value).
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4) Using the information in problem 1, EXPLAIN how

you would determine the M-value(s) for this
design. (Be explicit without doing the algebra.)
Step 1: Solve the stress equation for the free parameter, t.
Substitute this value into the mass equation to get
an equation for the free parameter R that depends
only on the material properties and design fixed
parameters.
Step 2: Substitute the value for R into the stress equation

to get an equation for t that depends only on the
material properties and design fixed parameters.
Step 3: Substitute both R and t equations into the equation

for the deflection. This results in the equation for
the performance that depends only on the material
properties and design fixed parameters.
Step 4: Separate out the materials property information

from the performance equation to find the
materials selection criterion, M.
5) On the selection chart below I have marked a selection

line for a particular design. What is the VALUE of the M
for which this line is derived? (Be sure to include the
UNITS!)
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Now, to find the value of M for this line position, we only

need to pick off a point on the line and plug the values
for X and Y into the expression for M:
EXERCISE
A) You are asked to select a material for a very

inexpensive socket for a socket wrench set.
The model, shown at the right, is of a thin
walled cylinder of fixed radius, R, and
unknown wall thickness, t. The socket must
not fail under the applied torque, T, and it
should deflect by less than THETA rotational
angle in use. Use the equations below for
the rotational deflection and failure torque to
answer the following questions.
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Rotational deflection of the socket:
Maximum torque on the socket:
Cost of the socket:
1) What is the measure of performance, p, for

this design?___________
2) Is this design OVERCONSTRAINED,

FULLY DETERMINED, or UNDERCONSTRAINED,
and why?
3) Determine the M value(s) you should have

for this design.
Exercise A(i)
On the selection chart below I have marked a

selection line for a particular design. What is the
EQUATION for the M of this line, and what is the
VALUE of the M for which this line is derived? (Be sure
to include your UNITS!)
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B) You have been asked to design a xylophone

to be carried on board the space shuttle to
study gravitational effects on vibrating
structures. The basic design is a simply
supported beam, which is struck (loaded) in
the center with a mallet and the vibration
makes a noise. Because this is to be launched
into space, it must be made as lightweight as
possible. It has an additional constraint that
the fundamental vibration frequency must be
equal to fo.
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Assume the length, L, and the

width, w, are fixed, but the
thickness, t, is free to vary.
Use
the following information to
answer the design questions
below.
Fundamental frequency of
vibration: ,
where K is a constant, E is
the Young's Modulus, and is
the density.
1) What is the measure of 2) Derive the materials

performance, p, for this selection criterion, M,
design?___________ using the frequency
constraint.
3) A particular design asks us to choose a material using

. For a plot of log( ) [X axis] versus log(E)
[Y axis], determine the slope of the selection line.
4) Use the selection chart below to determine the subset

of materials with a thermal conductivity greater than
10 W/m-K AND a performance index less than
. Show your materials with a sketch on the

selection chart.
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C) You have been asked to help a world famous

sculpture artist with a new project. Part of the
design calls for an array of long, slender
cantilever beams extending from the side of a
building. The artist has a fixed length in mind
for each beam, and for esthetic purposes, she
wants the beams to be square cross sections
(b X b) that are as thin as possible (smallest
possible b).
Each beam has a limit on the end deflection,
DELTA, and also it should not break under
load. The only load will be the self weight of
the beam, F = mg.
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Use this information, and the equations for deflection

and failure load, to answer the following questions.
1) What is the measure of performance, p, for this

design?___________
2) Is this design UNDERCONSTRAINED, FULLY

DETERMINED, OR OVERCONSTRAINED, and why?
3) There will be two materials selection criterion

(performance indices). Derive them.
4) Derive the coupling equation that links them.
5) If the artist has a different L and d requirement for each

beam, do you think that all the beams should be made
from the same material? Explain your answer.
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SOLUTIONS :
ASSIGNMENT (A)
(1) p=1/$
(2) OVERCONSTRAINED
- one free parameter (t), two constraint
(rotational deflection and failure torque)
(3) Solve the equation for the free parameter, t.
(3) Solve the torque equation for the free parameter, t.
(4) The equation for the M of this line;
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b
C
for 1, 10
10
C
1
C 10
for 0.01, 1
10
0.01 b
b log 0.01 log10

2b 1
1
b
2
1
log log M log
2
1
log M log - log
2
M 1/2
ASSIGNMENT (B)
(1) p=1/m
(2) Write out the cost constraint equation (for frequency,

fo), solve for the free parameter (t) and substitute
into the performance equation ;
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(3) Take the log of both sides of the M equation and

arrange as Y = A + BX ;
(4)
M1= 10 W/mK
M2= 108 W2s/m4K2
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ASSIGNMENT (C)
1) p=1/b
2) OVERCONSTRAINED
one free parameter (beam cross-section, b), two
constraint (deflection and failure)
3) Failure constraint ;
Deflection constraint ;
4) The coupling equation;
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5) Because the coupling equation depends on the

deflection constraint, DELTA, if the artist wants to
have different deflections for different beams then
the best materials will change. It is interesting
that the materials choice does not depend on the
length of the beams, however.
MATERIALS FOR TABLE LEGS

A furniture designer, conceives of a lightweight table of
daring simplicity : a flat sheet of toughened glass supported
on slender, unbraced, cylindrical legs.
The leg must be solid (to make them thin) 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?
The leg is a slender column of material of density and modulus

Its length, l and the maximum load, P, are determined by the
design they are fixed. The radius r of a leg is a free variable.
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Mass of the legs : m r 2l
Elastic load, Pcrit of a column :

2 3
EI Er 4
Pcrit 2
l 4l 2
For slenderness : p = Pcrit
Design requirements for table legs :
Function Column (supporting compressive load)
Objective (a) Minimize the mass

(b) Maximize the slenderness
Constraint (a) Must not buckle under design loads
Must not fracture if accidentally struck
SOLUTION :
M1 = E1/2/ M2=100GPa
M2 = E
For example;
M1 6
GPa1/2m3/Mg
M2 100GPa
M1=6(GPa)1/2m3/Mg
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Materials for table legs

Material M1 M2 Comment
(GPa m3/Mg)
1/2 (GPa)
Woods 5-8 4 - 20 Outstanding M1; poor M2
CFRP 4-8 30 - Outstanding M1 and M2,

200 but expansive
GFRP 3.5 – 5.5 20 - 90 Cheaper than CRFP, but

lower M1 and M2.
Ceramics 4-8 150 - Outstanding M1 and M2.

1000 Eliminated by brittleness.
19
CHAPTER 4
MATERIALS SELECTION
CHART
4.1 Introduction
4.2 Displaying Materials Properties
4.3 Materials Selection Chart
4.3 MATERIALS SELECTION

CHARTS
1. Modulus – density 10.Thermal expansion – thermal
2. Strength – density conductivity
3. Fracture toughness – density 11.Thermal expansion – modulus
4. Modulus – strength 12.Normalized strength –
5. Specific modulus – specific thermal expansion
strength 13.Strength – temperature
6. Fracture toughness – modulus 14.Modulus – relative cost
7. Fracture toughness – strength 15.Strength – relative cost
8. Loss coefficient – modulus 16.Wear rate / bearing pressure
9. Thermal conductivity – 17.Environment attack chart
thermal diffusivity
1
Modulus
E=Stress/Strain
E Ceramic
E Metal or
Polymer
Strength
2
Fracture Toughness
Hardness
3
Modulus - Density
Guide lines of
constant:
E/ρ
E½/ρ
E1/3/ρ
– allow selection
of materials for
minimum
weight,
deflection-
limited, design
Density of a solid depends on 3 factors:

The atomic weight of its atoms or ions, the
spread of density comes mainly from that of the
atomic weight, ranging from 1 for Hydrogen to
238 for Uranium.
Their size
The way they are packed
4
Metal are dense because they are made of heavy
atoms, packed densely
Polymers have low densities because they are

largely made of carbon (atomic weight; 12) and
H (atomic weigth; 1)
Ceramic, for the most part, have lower densities

than metals because they contain light O, N or C
atoms.
Strength – Density
Guide Lines:
σf/ρ
σf2/3/ρ
σf1/2/ρ
– used in minimum
weight, yield limited
design
5
“Strength”
For Metals and Polymers, it is the yield strength
For brittle ceramics, the strength plotted as the
Modulus of Rupture: the strength of bending
For elastomers, strength means the tensile tear-
strength.
For composites, it is the tensile failure strength
f will be use for all of above “strength”
The vertical of strength-bubble for an individual
material class reflects its wide range, caused by
degree-of-alloying, work hardening, grain size,
porosity etc.
Let’s select a material

Select the best material for a light
and strong pull rod.
F F
Materials : Steel, Aluminium, Nylon,

CRP, Cork, Concrete
6
Material Density Strength Modulus
A 7600 2150 210
B 2800 400 70
C 1450 80 1,8
D 3450 1540 180
E 150 15 0.14
F 2750 20 30
The mass : m = .V= Al

The strength : Ff = A f, A= Ff/ f
m=l.F.( / f)
F/m = l . ( f / )
All materials with same f/ ratio
behave equally well.
The material Index

In the objective function the function
can be split into a geometry index
and a material index, M
For the rod example : M = f /
7
The strong light rod optimisation
M= f /
better
Slope 1
Equal performance
poorer
Material Indices
A method is necessary for translating design
requirements into a prescription for a material
Modulus-Density charts
– Reveal a method of using lines of constant
E1 n n 1,2,3
to allow selection of materials for minimum
weight and deflection-limited design.
Material Index
– Combination of material properties which
characterize performance in a given
application.
8
Characteristic
for selected
material:
1. < 1 Mg/m3
2. f > 10 MPa
3. Minimum
weight
design,
C = f2/3/
= 27 MPa
Selected areas
for potential
materials
Plot
M = T1/2/
= 2 K1/2/MPa
in the chart and

determine the slope
for the line
T1/2/ =2
= T1/2/2
At
T = 400 K, = 10 MPa
T = 1600 K, =20 MPa
Slope :
log M = ½ log T –
log
slope, m = 1/2
9
The material selection for
a light stiff beam
The material giving the lowest

deflection per beam mass ??
Light stiff beam

Mass = V= lbh
Stiffness = F/ = C . E. I / l3 =
= C E A2 / 12 l3
m = (12 S/ C l)1/2 l3 ( / E1/2)
for this case M = E1/2 /

10
Rod versus beam optimisation
Note that relative material performance changes !!!
beam
rod
11
Quiz (10 min)
Determine the slope (m) for

index,
1/ 4
E
CR
List the materials for M ≥ 2

(GPa/Mgm-3)
Characteristic
for selected
material:
1. < 3 (Mg/m3)
2. M = f /
2
M≥20(MPa/Mgm-3)
12

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10/31/2011

CHAP. 4 : MATERIALS SELECTION

4.5 Derivation of Property Limits and

4.4 Selection Strategy

Basic procedure for selection is establishing the

Materials Selection BDA 2042 2

–Screening & Ranking

Materials Selection BDA 2042 3

Figure 4.3: Material selection is determined by function. Shape

Materials Selection BDA 2042 4

4.4.2 Materials Attributes

Figure 4.4: taxonomy of the kingdom of materials and

4.4.3 Screening & Ranking

Property limits help to separate the suitable materials.

Materials Index identifies the best materials among a

Refer Figure 4.5

Materials Selection BDA 2042 6

Translate design requirements, express as

Screening: apply property limits

Final Material Choice

Materials Selection BDA 2042 7

4.4.4 Supporting Information

The outcome of the screening step is a shortlist of

Need details profile for each materials (properties,

Information can be found in handbooks, supplier‟s data

All materials information will be compared in order to be

Materials Selection BDA 2042 8

4.4.5 Local Conditions

The final choice between competing candidates will

There is no specific procedure for this part expect

Materials Selection BDA 2042 9

4.5 Derivation of Property

Function, objective and constraints define the

Materials Selection BDA 2042 10

Modes of Loading (without shape)

(a) Tension : Tie

(b) Bending : Beam

(c) Twisting : Shaft

(d) Compression : Column

Materials Selection BDA 2042 11

4.5.1 Function, Objective &

Function What does component do?

* It is sometimes useful to distinguish between „hard‟

Materials Selection BDA 2042 12

4.5.2 Property Limits

Involve the certain level of ability need to be fulfill

The screening procedure uses property limits

Materials Selection BDA 2042 13

Materials Selection BDA 2042 14

Materials Selection BDA 2042 15

Materials Selection BDA 2042 16

Materials Selection BDA 2042 17

Materials Selection BDA 2042 18

Tugasan 3 (1) / Tutorial

Heat sinks for hot microchips

Materials Selection BDA 2042 19

Tugasan 3 (2) / Tutorial

Materials Selection BDA 2042 20

CHAP. 4 : MATERIALS SELECTION

4.6 Selection Procedure

4.7 Structural Index

4.5.3 Materials Index

Structural Elements – components which