University of

Cambridge The CES EduPack

CES EduPack:
A central resource for materials and manufacturing processes

Mike Ashby (University of Cambridge and Granta) and Marc Fry (Granta)
 Introduction

 The CES EduPack is a teaching resource for materials and

manufacturing processes, comprising of CES software and
supporting resources for lecturers and students.

 Widely used: 500+ universities and around 1,500 departments.

 Adaptable, making it attractive to many departments within

one University and through many years of study.

 For these reasons many universities now use it as a central

resource.

© MFA and DC 2005

 The 3 levels of the CES EduPack Software

The CES EduPack

Level 1 Level 2 Level 3

 1st year students:  2nd - 4th year  4th year, masters
Engineering, Materials students of Engineering and research students
Science, Design and Materials Science of Engineering Materials
and Design. and Design.

64 materials, 75 processes 94 materials, 107 processes 2916 materials, 250 processes,

1,881 sections

Materials Polymer Mechanical Aeronautical Architecture

science engineering engineering engineering & civil eng

Environmental Product
+ special editions engineering design
+ special editions
© MFA and DC 2005
 Student friendly records at level 1

Aluminum alloys Injection molding

The material
Rigid
The high-strengthPolymer Foam
aluminum alloys rely (MD) The process
on age-hardening: a sequence of heat No other process has changed product design
treatment
Thesteps that causes the precipitation
material
Acrylonitrile
of a nano-scale butadiene styrene
dispersion of intermetallics (ABS) more than INJECTION MOLDING. Injection molded
that impede
Rigid dislocation motionare
polymer foams andmade
impartstrength.
from polystyrene, products appear in every sector of product design:
Thepolyethylene,
phenolic, material polypropylene or derivatives consumer products, business, industrial, computers,
General properties
Polylactide (PLA)
of polymethylmethacrylate. They are light and stiff, communication, medical and research products,
and have
Density ABSmechanical properties 2500
that make
(Acrylonitrile-butadiene-styrene) them
- 2900is tough,
kg/m^3 toys, cosmetic packaging and sports equipment.
Price attractive The
resilient,
for andmaterial
easilystructural
lightweight
High molded.
performance Ituse.
1.423 is usually
- 2.305 opaque,
concrete
USD/kg (HPC)
although some grades can now be transparent,
Polylactide, PLA, is a biodegradable thermoplastic
General properties
and itderived
can be from
givennatural
vivid colors.
lactic acid from corn, maize or
Physical attributes
Densityproperties
Mechanical milk. ItThe material
resembles 78 - 165
clear polystyrene, provides kg/m^3
good Mass range 1e-3 - 25 kg
Price
Young's modulus aesthetics
High (gloss and68
performance 12.44
clarity), - 24.88
but it(HPC)
- 80
concrete is GPa USD/kg
stiffisand brittle
generally Range of section thickne ss 0.4 - 6.3 mm
Elastic limit
General characterized
propertiesby95the following - 610 properties; ease of
Density and needs modification
placement, compaction
using 1010MPa
plasticizers
without
for most
- 1210
segregation, kg/m^3
early
Surface roughness (A=v. smooth) A
Mechanical
Tensile strength
Price properties
practical applications. 180 - 620
2.511 MPa
- 2.952 USD/kg
Elongation age strength, long-term
1 - mechanical
20 % properties,
Young's modulusGeneral properties
permeability, high
0.08 - 0.2 GPa Economic Attributes
Hardness - Vickers
Elastic limit
Density 60 density,
- 160toughness,
0.4 - 3.5 HV
1210MPa -volume
1250 kg/m^3
Fatigue
TensileMechanical
strength at
strength
Price107
properties
stability
cycles and long-life
57 in
- severe
210
0.65 - 5.1 Economic batch size (units)
environments.
MPa MPa
3.67 - 4.58 USD/kg 1e4 - 1e6
Fracture Young's modulus
toughness
Elongation General properties 21 2- 35 1.1 - 2.9
- 5 MPa.m^1/2 % GPa
Relative tooling costs very high
Elastic
Hardness limit
Density
- Vickers 0.09518.5
- - 51HV
.035 2500MPa
- 2700 kg/m^3Relative equipment cost high
Fatigue
Thermal
Mechanical
Tensile strength
strength
properties at 710
Price properties
cycles 0.45527.6
- 2.8- 55.2
0.083
MPa MPa
- 0.166 USD/kgLabor intensity
Young's
Elongation modulus 1
1.5 3.45
- 100- 3.83
% GPa low
Fracture toughness 6.6e-3
- 0.0486
Thermal conductor or insulator? Good conductor MPa.m^1/2
Elastic
Hardness limit
- Vickers 5.6 48 - 60HV MPa
- 15.3
Thermal conductivity Mechanical
Tensile
Fatigue at 710
strength
strength 118properties
cycles - 174 W/m.K
11.0448 - 60MPa MPa
- 22.08 Process Characteristics
Thermal
Thermal expansionproperties
Young's
Elongation
Fracture toughness 22
modulus - 24 µstrain/°C
5 25
- 7 - 27%
1.186- 4.289 MPa.m^1/2 GPa
Discrete
Specific heat conductor
Thermal Bending
Hardness modulus
890 Good
or insulator?
- Vickers - 1020insulator
J/kg.K
14 25 - 18 - 27HV GPa
True
Melting point conductivity
Thermal Elastic
Fatigue limit,at495
strength 7
10 - 640- 0.038
tension
0.027
cycles °C 6
- 18 - 10MPa MPa Shape
14 W/m.K
Maximum Thermal
service
Thermal properties
temperature
Tensile
expansion
Fracture 120 20
strength
toughness - 170- 70°C 6
- 1.1 - 9 MPa.m^1/2
0.7 µstrain/°C MPa
Thermal
Specific heat conductor
Elongationor insulator?
1120 Good
- 1910 insulator
0
J/kg.K %
Thermal conductivity 0.188 - 0.335 Circular prismatic True
Electrical
Maximumproperties Hardness
service - Vickers
temperature 67 - 157 10 W/m.K
°C - 15 HV
Thermal
Thermal Fat properties
expansion
igue strength 7 84.6
atconductor
10cycles - 2344 µstrain/°C
- 7 MPa Non-circular prismatic True
Electrical conductor or
Thermal insulator?
conductor Good
or insulator?
Specific heat
Fracture toughness 1386Good
- 1919 insulator
0.1 J/kg.K
- 0.4 Solid 3-D
MPa.m^1/2 True
Thermal
Maximum conductivity
service temperature 62 0.12
- 77 - 0.13
°C W/m.K Hollow 3-D
Electrical Thermal
properties
Thermal properties
expansion 126 - 145 µstrain/°C True
ElectricalSpecificThermal
conductor or
heat conductor
insulator? or
Good insulator?
insulator Good insulator
1180 - 1210 J/kg.K
Thermal
Maximum
Electrical
resistivity
service
properties temperature 70 0.77- 80 - 0.9 °C m.K/W Design guidelines
Thermal expansion 7 - 11 µstrain/°C
Electrical Specific
conductor or insulator?
heat 900 - 1000 J/kg.K Injection molding is the best way to mass -produce small, precise, polymer
Good insulator
Maximum service temperature 450 - 500 °C components with complex shapes. The surface finish is good; texture and pattern…
Electrical properties
Emissivity
Electrical conductor or insulator? Good0.63 - 0.97
insulator
Electrical properties
Electrical conductor or insulator?
Poor insulator
© MFA and DC 2005
 Introduces the science behind a property

Age hardening ALUMINUM ALLOYS

 Definition,
The material  Measurement,
The high-strength aluminum alloys rely
on age-hardening: a sequence of heat  Science
treatment steps that causes the precipitation
of a nano-scale dispersion of intermetallics
that impede dislocation motion and impart strength.

General properties
Density 2500 - 2900 kg/m^3 Young’s modulus
Price 1.423 - 2.305 USD/kg

Mechanical properties Definition…………………………………….

Thermal expansion
Young's modulus 68 - 80 GPa …………………………………………………
Elastic limit 95 - 610 MPa
………………….
Tensile strength 180 - 620 MPa Definition…………………………………….
Elongation 1 - 20 % ………………….
Hardness - Vickers 60 - 160 HV …………………………………………………
7
Fatigue strength at 10 cycles 57 - 210 MPa ………………….
Fracture toughness 21 - 35 MPa.m^1/2 Measurement
………………….
…………………
Thermal properties ………………….
Thermal conductor or insulator? Good conductor Measurement
Thermal conductivity 118 - 174 W/m.K ………………….
Thermal expansion 22 - 24 µstrain/°C
…………………
Specific heat 890 - 1020 J/kg.K ………………….
Origins
Melting point 495 - 640 °C
………………….
Maximum service temperature 120 - 170 °C …………………
………………….
Electrical properties Origins
………………….
Electrical conductor or insulator? Good conductor …………………
………………….
………………….

© MFA and DC 2005

Visual communication of information

© MFA and DC 2005

 Possibility to introduce additional science

Why the differences?

• Atom size and weight
• Bonds as (linear) springs
• Spring constant for various
bond types.

Manipulating properties
• Making composites
• Making foams

© MFA and DC 2005

 Students have a tool they can use from day 1

Find materials
that are stiff

Find materials
that are stiff
and light

Find materials
that are light

© MFA and DC 2005

Deriving material indices- a tool for materials selection

© MFA and DC 2005

 A tensile tie rod for an aerospace application

1. Functional requirement: A strong, light tie rod

2. Constraints: Length, L, is specified by the design. The rod must not fail under
load, F. Equation for constraint on A:

F
y ……(1)
A
3. Objective: To minimise mass, m.

m  A L   ……(2)

4. Free variables: Material choice and cross-sectional area, A.

© MFA and DC 2005

5. Derive objective function:
Eliminate A in eqn (2) from eqn (1): From (1):
F
A
y
Substitute into (2):

  
m  FL    ……(3)
 
 y

This is the performance metric, m, which in this case we seek to minimise.


Selection criteria: Choose materials with the smallest value of or the
  y
biggest values of y

y
Thus, the index that we wish to maximise is: M  ……(4)

© MFA and DC 2005
The material index, M, is:
y
M i.e.  y  M


If we plot an ‘Ashby Map’ with log y as the y-axis and log  as the x-axis, then:

log  y  log   log M …..(5)

i.e. on the log-log plot, contours of constant M are lines with a slope of 1

© MFA and DC 2005