5 THEUNIVERSITYOF MELBOURNE Department of Mechanical Engineering MCEN90012 Design for Manufacture Material Selection Design Project: DP1 MATERIAL SELECTION IN MECHANICAL DESIGN and COMPUTERISED MATERIAL SELECTION TOOLS A. MATERIAL SELECTION IN MECHANICAL DESIGN 60% 1. AIMS 1. To derive performance indices appropriate for material selection of engineering components, 2. Apply performance indices to material selection charts, identifying the optimal material, and 3. Understand the modifying influence of shape factor on material selection. 2. YOUR TASKS Task 2.1 S marks With reference to the relevant material selection chart, locate the titanium alloy “bound region” and confirm that the Young’s (elastic) modulus, £ and density, are consistent with values sourced from another reference. Are any materials available on the material selection chart that have at least the same Young’s modulus, £ as titanium that could also float on water? Are there any engineering alloys with a similar stiffness to titanium? Answers must use the appropriate material selection chart (i.e. graphical solution is required). PI (2020) page 1/7Task 2.2 S marks Consider the cross-section of a molybdenumm beam with a rectangular section with proportions height, f= 4.78 x rand base, b =r Find the shape factor of this selected shape and clearly show the effect of this section, compared to a solid-circular section, when designing a stiffness limited, minimum weight component. When molybdenumm of average stiffness and lowest possible mass is formed into this rectangular shape, are there any materials that are comparable when formed into a solid circular section? What is the diameter of a solid-circular section with same area as the rectangular section? Your answer must be based around the appropriate material selection chart (1. graphical solution is required). Task 2.3 5 marks When considering a strong, light tie-rod, is there an obvious best candidate material from the available engineering polymers? Your answer must be based around the appropriate material selection chart (i. graphical solution is required). Task 24 S marks In units of MJ/m’, nominate an estimated embodied energy per cubic meter for stainless steel Nominate alternative materials to stainless stee! that have a lower estimated embodied energy per cubic meter while having stiffness similar to that of stainless steel Your answer must be based around the appropriate material selection chart (i. graphical solution is required). DPI (2020) page 2/7Task 2.5 — Knife-edges and Pivots 40 marks Watches with a mechanical mechanism sometimes have “sapphire” (Al,Os) printed on the watch face. The sapphires were used as “knife-edges” or “pivots” (figure 1). More expensive watches used diamonds. In more common language, bearings, where two members are loaded together in nominal line or point contact, and can tilt relative to one another, or rotate freely around the load axis (figure 2). The essential material properties, arising directly from the design requirements (table 1) are high hardness (to accommodate the contact pressures) and high modulus of elasticity (to offer positional precision and to minimize frictional losses). ‘The engineering designer must consider materials that can best accommodate these (and other) design requirements. Figure 1. Photograph of a mechanical watch movement showing shaft “pivot” bearings. Motion <> Motion —- TS Load, P| Load, P| GD Knife edge Pivot Block n or fracture) and a high modulus of elasticity (to minimize unwanted elastic flattening in the contact zone that will result in frictional losses). Table 1, Design requirements [ Funetion Knife-edges and pivots Objective Maximise positional precision for given load | Maximize load capacity for a given geometry | Constraints Contact stress must not damage either surface High toughness (especially for pivots exposed to shock loading) Low thermal expansion (for high precision pivots) DPI (2020) page 3/7The designer must consider the combination of hardness and modulus. ‘The best solution depends on the objective: maximum precision or maximum load-carrying capacity. Designers seek to maximize the load, P, that the contact can support, subject to the constraint that both faces of the bearing remain elastic. ‘The contact pressure, p, at an elastic, non-conforming, contact (one that appears to touch at a knife-edge or along a line) is proportional to: (| where P is the load, £ is the modulus of elasticity (Young’s modulus) and 2 is the radius of the knife-edge or pivot. ‘The modulus of elasticity is on the numerator because the elastic contact area decreases if £ is large, and this increases the associated contact pressure. ‘The knife or pivot will indent the block, or deform itself, if the contact pressure exceeds a limit associated with the material hardness, H; where H is proportional to the general strength, oj For this problem, regard gj as being associated with maximum normal (bending) stress, o This constraint is described as: (22) ec, imate value, C = 3.2). As such, for a given geometry, the where C; is a constant (of appros maximum bending load is: a) ‘Nominate a suitable material selection index, M,, associated with stiffness and strength, 10 marks The second constraint that the designer should consider is that of low total contact area, The contact area, A, of any non-conforming contact has the form: 2/3 A=C, (2) where C) is another constant (of approximate value, C) = 1). For any acceptable value of P with reference to equation (1), the second constraint can be satisfied by a second material selection index, Me Nominate a suitable material selection index, Mz, associated with low total contact area, 5 marks Complete a series of analyses using manual Material Selection charts and Cambridge Engineering Selector (CES) as required to investigate candidate materials for this application. Labeled material selection chart (or charts) will be an essential feature of your report. 5 marks ‘Your resulting table of candidate materials will include the following candidate materials: quartz, high-carbon steel, tool steel, silicon, sapphire, silicon carbide, silicon nitride, tungsten carbide, diamond. DPI (2020) page 4/710 marks. Ofer a brief discussion about recommended materials, based on the application. For example, sensitive force balances and other measuring equipment require extremely low friction, whereas high load-capacity devices (e.g. vehicle weigh bridges, mechanical testing equipment), an ability to absorb overloads is an advantage. Environment (benign or hostile) and cost also assist the designer completing a final selection from a list of candidate materials. 5 marks Students seeking excellent marks are encouraged to investigate * how temperature changes will influence positional accuracy of a pivot; * how rough handling impacts on pivot survival (i.e. toughness, or ‘fracture toughness’); and, * hardness directly via material selection charts rather than indirectly (je. as previously mentioned, H is proportional to the general strength, 7); and, + relative cost of candidate materials. 5 marks PLUS ‘No more than 5 bonus marks for outstanding investigation and reporting DP1 (2020) page 5/7B. COMPUTERISED MATERIAL SELECTION TOOLS, 30% 3. AIMS 1, To apply the material selection concepts developed in lectures to a database of potential materials, and 2. To provide experience in computerized material selection for engineering design using the Cambridge Engineering Selector (CES) software. 4. YOUR TASKS Task 4.1 Constraint-limited material property selection 10 marks Apply a “limit stage” selection to find the material(s) with both + Young’s Modulus, £ < 30 GPa, and * Density, p> 10,000 kg/m’, Graphically identify the associated subset of materials and save for inclusion in your report. Is there a highly stiff material with density, 0 > 10,000 kg/m’ ? Task 4.2 Graphic material property search 10 marks Graphically compare the specific yield strength’ (Sy /p) of titanium (Ti) alloys, zine (Zn) alloys and tungsten (W) alloys. Hint: Initially, plot the specific strength as a combined property on the y-axis and leave the x-axis blank. Applying a limit stage to include only Ti, Zn and W alloys will make the resulting material selection chart more readable. Use the CES “search” tool to find specific materials Task 4.3 Multiple stage, graphic material property search 10 marks Graphically identify the subset of materials with fracture toughness, Kie> 10 MPa m'?. Identify the subset of materials with with fracture toughness, Kic > 10 MPa m' and both: + Young’s Modulus, £ > 90 GPa, and * M=E'?/p>2.35 (GPa)'? (Mg/m’)'. Graphically identify the intersection of materials that satisfy both above conditions. Hint: ‘The performance use of a material selection guideline on a material sele: ndex constraint, IM, may be satisfied by a combined property axis, or by ion chart of E versus p. ' CES uses the symbol, oj as a general failure strength. Here, or = DPI (2020) page 6/7REPORT PRESENTATION 10% Itis expected that all reports will be of a professional standard ‘A mark out of 10% is associated with the presentation of your submitted report, Refer to your MCEN90012 Subject Outline document and revisit your Technical Report writing seminar for advice about how to prepare a report of acceptable quality For DPI, it is recommended that the main body of your final report (excluding cover sheet) be no longer than twenty (20) A4 single-sided pages (12pt font, single-line spaced). Long reports that delve deeply (and correctly) into tasks are acceptable if not laudable, especially if the report is essentially concise and easily read. Overly long, rambling, non-cohesive, poorly structured reports will incur significant presentation penalties. All details (ie. full name, correct student ID, correct unimelb email address) of both team members ‘must be clearly and correctly stated on the cover sheet and within the brief Introduction on the first page of your report. A report presentation penalty will be applied if this is not done.” Correet name for your Turnitin submission: DPI .pdf e.g. DPI 123456 654321.pdf Of course, remove the *<° and >" symbols PROJECT SUBMISSION Submit your DP1 material selection assignment as a single report, with headings that match those used in this document, ‘One report per team. The correct Melbourne Schoo! of Engineering COVER SHEET must be used. Workshop sessions for DP 1 are yet to be finalized. Workshop locations: Week-2 workshop sessions: MSE Design Office, room D207 Week-2 workshop sessions: MSE Computer Lab, room B102 > Week-3 workshop sessions: MSE Design Office, room D207 Week-3 workshop sessions: MSE Computer Lab, room B102 Submission deadline: 11pm Sunday 22 March 2020 Submission location: Electronic submission via the subject Canvas website This requirement is highlighted in 2020 as DP reports will be submited electronically We seek to ensure non-submitting student teammates receive their deserved mark > Postgraduate Computer Centre - room B102 (Building 175, Block B) is often used by MCEN90012 students to complete assignment DPI. Software “Cambridge Engineering Selector” is installed on 8102 computers. Enter via external stirs between Blocks B (bldg. 175) and C (bldg. 174) and “tum right’ DPI (2020) page 7/7