KU1101

Pengantar Rekayasa dan Desain I

Materials & Manufacturing

1
 Expected outcomes for the 12th week:
 Students know the engineering material’s classification and its
application
 Students know the important aspects in choosing material
 Students understand about mechanical properties of material
 Students understand the importance of manufacturing process in
engineering
 Students able to mention manufacturing process example
Materials
 Failure of a mechanical system is normally caused
by: 1. Blunder in choosing material or 2. Operational
blunder.
 How you choose a material?
 What are the requirements of
material used in component?

3
4
 Material for vacuum cleaner

Dominant Material Power Weight Cost, USD

Hand Powered, 1900 Wood, Canvas, Leather 50 W 10 kg 270
Cylinder, 1950 Mild steel 300 W 6 kg 110
Sphere, 1965 Mild steel 450 W 5.5 kg 100
Cylinder, 1987 Moulded ABS and 800 W 4 kg 60
Polypropylene
5
Material’s classification
 Based on raw material
 Metal
 Ceramic
 Polymer
 Composit
 Based on size
 Nano-material (metal, ceramic, Average material usage in car (USA 1985)
polymer).
 Based on function (Functional Material):
 Structural Material
 Biomaterial
 Electronic material (semi conductor, superconductor)
 Magnetic material (rare earth material for electric motor with very high
efficiency (upto 97%) eg: FeNdB)
 Smart Material

6
 Material Classification (Raw Material)
 Metal:
 Material with the most usage in industry
 Never been used in its pure form because of low strength.
Mostly used in alloy form (paduan)
 High strength, conductive (electrical & thermal), shiny, and
formable (ductile)
 Steel (baja) : iron (Fe) and carbon alloy (C <2.1% weight)
 Bronze (perunggu) : Cu and Sn alloy (< 40%)
 Brass (kuningan) : Cu and Zn alloy (< 35%)
 Anti corrosion steel (stainless steel) : Fe and Cr alloy (min.
11%)
 Anti corrosion because atomic layer Cr2O3 is formed on the surface
(Remember that this atomic layer is still weak against HCl).

7
 Material Classification (Raw Material)
 Ceramic : anorganic material, non-metal
 Isolator (electric & heat), can withstand high temperature, brittle
 Can be divided into two: traditional ceramics and engineering
ceramics
 Traditional ceramics : glass, brick, tile (keramik lantai),
sanitaryware, art product
 Raw material: Silica (SiO2) for glass, Clay (xAl2O3 ySiO2 zH2O) which
consist of several minerals: Kaolinite, Bentonite, Montmorillonite, Illite,
Halloysite.
 Engineering Ceramics : Raw material: Al2O3, SiO2, SiC, Si3N4,
SiAlON (Si3N4 + Al2O3).
 Normally used in machine components, electrical components, or high
strength ceramic application.
 Silicon Carbide for turbo (not yet reliable)
 SiAlON for combustion chamber (not yet reliable)
 SiC for sand paper (ampelas).
 Al2O3 for spark plug isolator.
 WC Tungsten Carbide for lathe machine tools (mata potong mesin bubut).

8
 Material Classification (Raw Material)
 Polymer :
 Organic material which consist of C, H and
O and formed a long molecular chain
(monomer aggregate/ kumpulan monomer)
 Light, flexible, insulator, anti corrosion
 Can be divided into two: plastic and rubber
(elastomer)
 Plastic can be divided into two groups :
 Thermoplastic: can be recycled (heating)
 E.g. : polyvinyl chloride (PVC),
polymethyl metacrylate (PMMA,
flexyglass), polytetrafluoroethylene
(PTFE, Teflon), polyamides (nylon)
 Thermosets : permanent, cannot be
recycled
 E.g. : Epoxy resin, phenolic resin,
melamine-formaldehyde (melamin),
polyester

9
Material Classification (Raw Material)
 Composite Materials
 Combination of two or more materials: Matrix for bonding,
fiber for strengthening
 Exploit the advantages of its component
 Polymer matrix composite (PMC) : glass fiber reinforced
polymer or GFRP
 Metal matrix Composite (MMC)
 Ceramic matrix composite (CMC) : concrete (beton)
 PMC development and usage is way more than MMC and
CMC
 PMC application: Aircraft industry
 Light, anti-corrosion
 Fiber : Glass, carbon, aramid (kevlar) : long or short fiber
 Matrix : polyester resin, epoxy resin

10
11
Classification based on material’s
function
 Structural material:
 Material for constructions and machine components
 Profile steel: low carbon steel (lowalloy steel)
 Low temperature: Austenitic stainless steel
 High temperature (combustion chamber, turbine blade) :
superalloy
 Light construction (aircraft) : aluminum alloy

12
Classification based on material’s
function

BIOCOMPATIBILITY???

13
Material’s Mechanical Properties
 Material’s strength (Load/Cross section area) : the
ability of a material to withstand load
 Tensile Strength (Kekuatan Tarik, σu) [N/mm2]:
 Maximum stress that can be withstand before breaking
 Yield Strength (Batas Luluh, σy) [N/mm2]:
 Maximum stress that can be withstand before plastic
deformation happens
 Elongation (Perpanjangan, e) [%] :
 The ability of a material to elongate before breaking
 Elasticity : Hooke’s Law : σ = eE
 E : Modulus Elasticity [N/mm2]
 Tensile test video

14
Material’s mechanical propertis

Material Yield Strength Ultimate Stregth, density

(typical) (MPa) (MPa) (g/cm3)
Human skin 15 20 2.2
Stainless steel 520 860 8.19
Aluminium alloy
2014-T6 414 483 2.8
Titanium 11 (Ti-
6Al-2Sn-1.5Zr-
1Mo-0.35Bi-
0.1Si) 940 1040 4.5
Carbon fiber N/A 1600 - 4137 1.75
Diamond 1600 2800 3.5
15
Carbon nanotube N/A 11000-63000 0.037-1.34
Comparing Material’s Mechanical Properties
 www-materials.eng.cam.ac.uk

16
Nanomaterial
 Can be: metal, ceramic, polymer, or composite
 Grain size < 0.1 µm (100 nm)
 Changes that might happen after reducing the grain
size from micro to nano:
 Strength and ductility increased by 6x
 Opaque (tidak tembus cahaya) become transparent
(tembus cahaya)
 Isolator become conductor
 Material will be easier to burn
 Better biocompatibility because smaller porosity

17
Manufacturing
 Manufacturing is the process of converting (either by
manual labor or by machines) raw materials into
finished products, especially in large quantities.
(Kosky et al)
Needs and Effort in Needs Fulfillment

EFFORT IN NEEDS FULFILLMENT

Idea

NEEDS DESIGN PRODUCTION Product Using The Product

Detail Drawing

Assembly Drawing

Geometry

Dimensions

Tolerance

Material

Special Case
Casting Process
 Net shape process
 occurs when the output
is at or near its final
shape, such as
stamping, forging,
casting, injection
molding, blow molding,
and thermoforming.
 Casting
 manufacturing process
by which a liquid material
is poured into a mold
containing a cavity of the
desired shape, and then
allowed to solidify
Bulk Deformation Process
 Extrusion is a
continuous process of
manufacture used to
create objects of a fixed
cross-sectional profile
by pushing or drawing
material through a die of
the desired cross
section.
Sheet Metal Process
 Stamping is a
metalworking process in
which sheet metal is
formed into a desired
shape by pressing or
punching it on a machine
press.
Machining Process
 Subtractive process
 The subtractive
process involves
material removal via
machining (turning,
drilling, milling)
Polymer Processing
 Injection molding is a
manufacturing process
used to make parts by
injecting molten plastic at
high pressure into a mold.
 Blow molding is a
manufacturing process in
which hollow plastic parts
are formed
 Thermoforming is a
manufacturing process
used with plastic sheets.
Plastic sheets or film is
converted into a finished
part by heating it in an oven
to its forming temperature,
then stretching it on a mold
and cooled
Joining Process
 Additive process
 add material to a
base object to
create complex
shapes. This is far
less expensive
than cutting an
intricate product
from a solid block
of material by the
subtractive
process.
Modern Manufacturing
 Four elements for good manufacturing process
 Movement of materials (efficient material handling, small transportation times,
and short queues)
 Time (setup time plus process time from order to shipping)
 Cost (Material, labor, tooling, and equipment costs)
 Quality (high quality products, minimum deviations from design specifications)

 Just in Time Manufacturing

 Minimize inventory of raw material, parts and finished product
 Flexible manufacturing system (FMS)
 contains enough flexibility to allow the system to rapidly react to production
changes.
 Lean Manufacturing
 The main principles are zero waiting time, zero inventory, internal customer pull
instead of push, reduced batch sizes, and reduced process times.
 Life Cycle Manufacturing
 Consider environmental impact of manufacturing process (from design of the
product to recycle/disposal of the product)