IPE 3104

Product Design and Development

Sessional
( Spring 2019)

Dr. M. Azizur Rahman

Assistant Professor
Dept. of Mechanical and Production Engineering
Ahsanullah University of Science and Technology (AUST)
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Product Design and Development Sessional

All the students must complete all the three

formalities i.e.
 product design and development,
 presentation, and
 report.

Failing at least any of this formalities will cause

 achieving grade ‘F’.

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 Topics Covered

SUNDAY (A) / 3.30 pm – 6.00 pm

WEDNESDAY (B) / 3.30 pm – 6.00 pm

1. Market analysis
2. Quality Function Deployment
3. Functional Structure Development
4. Specification and Design Analysis
5. Materials Selection
6. Manufacturing Process Selection
7. Cost Analysis

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 MATERIAL SELECTION

Methods of Material Selection

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 MATERIALS SELECTION

Selection Properties?
 Mechanical –
Strength, modulus, Yield strength, Hardness, etc.
 Physical –
Density, melting point.
 Electrical, Thermal, Optical and Magnetic –
Conductivity, resistivity,
 Aesthetic –
Appearance, texture, colour
 Processability –
Ductility, mouldability
 Ease of Manufacturing, joining etc.
 Corrosion, Friction, Abrasion and Wear
 Cost and Availability

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 MATERIALS SELECTION
Where do I find the data?

 Textbooks
 Databooks
 Manufacturer’s literature
 Internet Sites

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 MATERIALS SELECTION
Materials Selection Charts

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 MATERIALS SELECTION

Modulus - Density Chart

 Modulus spans 5 orders of magnitude

 0.01 GPa for foams to 1000 GPa for diamond
 The charts therefore use logarithmic scales,
where twice the distance means ten times.
 This makes it possible to show the full
range on one chart

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 MATERIALS SELECTION

Materials Selection Charts

 Allow easy visualization of properties

 Show lots of different materials

 Can be ‘drilled down’ to specifics

 Show balances of properties. e.g. strength v cost

 Ideal for a first ‘rough cut’ selection

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 MATERIALS SELECTION

Quantitative Methods
 Having Specified the performance requirements of the different
parts, the requires materials properties can be established for
each of them.
 These properties may be quantitative or qualitative, essential or
desirable.
 The essential materials property may be tensile and fatigue
strengths, while the desirable properties that should be
maximized are process ability, weight, reliability, and resistance
to service conditions.
 All these properties should be meet at a reasonable cost.
 The selection process involves the search for the material or
materials that would best meet those requirements.

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 MATERIALS SELECTION

Analysis of material performance

requirements
The material performance requirements can be divided into
5 broad categories:

 Functional requirements
 Process ability requirements
 Cost
 Reliability requirements
 Resistance to service conditions

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 MATERIALS SELECTION
Weighted Properties Method
 In most applications, the selected material should satisfy more than one
functional requirements

 In this method each material requirement (or property) is assigned a certain

weight (which depends on its importance to the performance of the design)

 This method attempts to:

Quantify how important each desired requirement is by determining a
weighting factor (α)

Quantify how well a candidate material satisfies each requirement

by determining a scaling factor (β)

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 MATERIALS SELECTION

Weighted Properties Method

Find weighting factors Convert properties of

of properties of different materials into
candidate materials scaled properties

Find the Performance

Index (γ)
γ= ∑α β

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 MATERIALS SELECTION

Selection Importance Mild Steel Steel 1030 Wood

Criteria Rating Weight Rating Weight Rating Weight
Corrosion 20% 2 .4 5 1 3 .6
Resistance
Surface 20% 2 .4 5 1 3 .6
Finish
Low Cost 10% 4 .4 2 .2 3 .3
Durability 20% 3 .6 4 .8 5 1
Machinability 10% 4 .4 3 .3 5 .5
Wastage 5% 1 .05 1 .05 3 .15
Low Weight 15% 5 .75 4 .6 2 .3
Total 100% 3.45 3.95 3.35

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 MATERIALS SELECTION

• We can also use the Digital Logic Method

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 MATERIALS SELECTION

• The number of attributes that should be listed vary between 5 - 10

• This method combine properties with different units. This limitation is

overcome by the use of a “scaling factor”

• The relative merit of each property of the candidate material may be

incorporated by assigning the value of 100 (%) to the best material in
that property category

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 MATERIALS SELECTION
• For a given property, the scaling factor (β) for a given candidate
material is:
• For properties that should have maximum values (strength, toughness…)

numerical valueof property

β= ×100
maxvaluein the list

• For properties that should have low values (density, cost, corrosion …)

lowest value in the list

β= ×100
numerical value of property

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 MATERIALS SELECTION
• The best material may either have the largest value of the given
property or the smallest
• For example;
■ High Strength is given 100
■ Low density or low corrosion rate are given 100

Performance Index
• The material performance index (γ) is calculated:

γ = ∑ αβ

• The material with the highest γ is considered to be the best

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 Case study: Selecting the optimum material for
a cryogenic storage tank
Materials requirements:
• used in cryogenic applications for liquefied nitrogen gas
must not suffer ductile-brittle transition at -196oC
• Using stronger material gives thinner walls, which means a
lighter tank, lower cool down losses, and easier to weld.
• Lower specific gravity gives lighter tank.
• Lower specific heat reduces cool down losses.
• Lower thermal expansion coefficient reduces thermal
stresse.
• Lower thermal conductivity reduces heat losses.
• The cost of material and processing

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 Application of digital logic method to
cryogenic tank problem

Property Decision number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Toughness 1 1 1 1 1 1
Yield strength 0 1 0 0 1 1

Young’s 0 0 0 0 0 1
modulus
Density 0 1 1 1 1 1
Expansion 0 1 1 0 1 1
Conductivity 0 0 1 0 0 0
Specific heat 0 0 0 0 0 1

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 Weighting factors for cryogenic tank
Property Positive decisions Weighting
factor (α )

Toughness 6 0.28

Yield strength 3 0.14

Young’s modulus 1 0.05

Density 5 0.24

Expansion 4 0.19

Conductivity 1 0.05

Specific heat 1 0.05

Total 21 1.00

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 P r o p e r t i e s of c a n d i d a t e m a t e r i a l s f o r
cryogenic tank
Material 1 2 3 4 5 6 7

T o u g ha n e s s Yield Young’s Specific Thermal Thermal Specific

index strength modulus gravity expansion conductivity heat d
b c
(GPa)
(MPa)
Al 2014-T6 75.5 420 74.2 2.8 21.4 0.37 0.16

Al 5052-O 95 91 70 2.68 22.1 0.33 0.16

SS 301-FH 770 1365 189 7.9 16.9 0.04 0.08

SS 310- 187 1120 210 7.9 14.4 0.03 0.08

3/4H

Ti-6Al-4V 179 875 112 4.43 9.4 0.016 0.09

Inconel 718 239 1190 217 8.51 11.5 0.31 0.07

70Cu-30Zn 273 200 112 8.53 19.9 0.29 0.06

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 Scaled values of properties and
performance index
Material Scaled properties (β ) Performance
∑
index (γ) = α β
1 2 3 4 5 6 7

Al 2014-T6 10 30 34 96 44 4.3 38 42.2

Al 5052-O 12 6 32 100 43 4.8 38 40.1

SS 301-FH 100 100 87 34 56 40 75 70.9

SS 310-3/4H 24 82 97 34 65 53 75 50.0

Ti-6Al-4V 23 64 52 60 100 100 67 59.8

Inconel 718 31 87 100 30 82 5.2 86 53.3

70Cu-30Zn 35 15 52 30 47 5.5 100 35.9

From the above calculations the value of performance index has shown
we can choose SS 301-FH for cryogenic tank 23
 MATERIALS SELECTION PROCESSES

 First, the parts those need to be manufactured should

be listed, then the materials requirements for every
part should be described briefly. It should be described
how the materials requirements are converted to
materials properties.

 Then, the candidate materials should be listed for every

part (description is necessary); finally, by using the
Digital Logic Method it must be explained why the
materials are selected for every part.

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