Lund University

MMTN20 - Material and Process Selection

Exercise 3

Aamer Siddiqui
Contents
Exercise 3.0 ................................................................................................................................................... 3
Exercise 3.1 ................................................................................................................................................. 10
Exercise 3.2 ................................................................................................................................................. 18

Table of Figures
Figure 1. m1 .................................................................................................................................................. 4
Figure 2. m2 .................................................................................................................................................. 4
Figure 3. M1 vs M2 ( 100 best materials according to M1) ......................................................................... 4
Figure 4. M1 VS M2 (10 best materials according to M2) ........................................................................... 5
Figure 5 M1 vs M2 ( 100 best materials according to M2) .......................................................................... 6
Figure 6. M1 vs M2 ( 10 Best materials according to M1) ........................................................................... 6
Figure 7. M2 vs M1 ...................................................................................................................................... 8
Figure 8. Line C1 & Line C2 ........................................................................................................................ 9
Figure 9. Materials for the lines .................................................................................................................... 9
Figure 10. 100 best materials according to M1 ........................................................................................... 11
Figure 11. 10 Best Materials according to M2............................................................................................ 12
Figure 12. 100 best materials according to M2 ........................................................................................... 12
Figure 13. 10 Best materials according to M1 ............................................................................................ 13
Figure 14. M2 vs M1 .................................................................................................................................. 14
Figure 15. F=10^7 & H=2........................................................................................................................... 15
Figure 16. F=10^6 H=4............................................................................................................................... 16
Figure 17. F=10^8 & L=1 ........................................................................................................................... 17
Figure 18. F=10^5 H=6............................................................................................................................... 17
Figure 19. M1 vs M2 ( 100 best material according to M1) ....................................................................... 19
Figure 20. M1 vs M2 ( 10 best materials according to M2) ....................................................................... 20
Figure 21. M1 vs M2 ( 100 Best Materials according to M2) .................................................................... 20
Figure 22.M1 vs M2 ( 10 Best Materials according to M1) ....................................................................... 21
Figure 23. m/mo vs c/co.............................................................................................................................. 22
Figure 24. 10 best materials ........................................................................................................................ 23
Figure 25.Contour Lines ............................................................................................................................. 24
Exercise 3.0
0. Given that the free variables are the area and the choice of the material. Therefore
a. For the Material index, the following steps are taken to derive it.

𝐹
𝜎𝑦 = 𝑚 = 𝜌𝐴𝐿
𝐴
𝐹𝜌𝐿
𝜎𝑦 =
𝑚
𝝆
𝑴𝟐 = ( ) 𝑭𝑳
𝝈𝒚
𝝆
𝒎𝟐 = ( )
𝝈𝒚

𝐸𝐴 𝐹
Stiffness = S= It is also given that S =
𝐿 𝛿
𝐸𝐴 𝐹
=𝛿
𝐿

𝐸𝑚 𝐹
2
=
𝜌𝐿 𝛿
𝑚 𝐹𝜌𝐿2
=
1 𝛿𝐸

𝝆 𝑭𝑳𝟐
𝑴𝟏 = ( )
𝑬 𝜹

𝝆
𝒎𝟏 = ( )
𝑬

Therefore, both the indices, are available and agree with the Granta software, as shown below.
 Figure 1. m1

Figure 2. m2

b. The 100 best materials were obtained by using the index lines to limit the materials as
follows
i.

Figure 3. M1 vs M2 ( 100 best materials according to M1)

 Figure 4. M1 VS M2 (10 best materials according to M2)

There fore the 10 chosen materials according to the criteria are as follows

• Kevlar 149
• Spectra 1000
• Spectra 900
• Carbon fibers
• Kevlar 46
• SiC
• PEEK/M Carbon Fiber
• Epoxy/HS Carbon Fiber
• Cyanate
• PBO Fiber

ii.
Figure 5 M1 vs M2 ( 100 best materials according to M2)

Figure 6. M1 vs M2 ( 10 Best materials according to M1)

Therefore the 10 best materials are as follows

• PBO
• Carbon Fiber HM (5um)
• Carbon Fiber UHM (10um)
• Carbon Fiber VHM (5um)
• Spectra 1000
• Diamond
• Boron
 • Beryllium (I250)
• Beryllium
• Cyanate

iii. Therefore, comparing the results from the 2 criterion it can be summarized as

According to m1 According to m2
PBO PBO
Cyanate Cyanate
Spectra 1000 Spectra 1000
Beryllium Epoxy/HS Carbon Fiber
Beryllium (I250) PEEK/M Carbon Fiber
Boron SiC
Diamond Kevlar 46
Carbon Fiber VHM (5um) Carbon fibers
Carbon Fiber UHM (10um) Spectra 900
Carbon Fiber HM (5um) Kevlar 146

Both the criteria’s produce different results and it is evident that only 3-4 materials out of the list are
common between them, this is observed as one criteria is given precedence (Stiffness over strength
and vice versa) over the other, and hence effects the entirety of the section when reducing the
materials.

c. Equating M1 & M2 to obtain the coupling constant

𝜌 𝐹𝐿2 𝜌
𝑀1 = 𝑀2 = ( ) = ( ) 𝐹𝐿
𝐸 𝛿 𝜎𝑦

𝐹𝐿2
(𝑚1) = (𝑚2)𝐹𝐿
𝛿
𝐿1
(𝑚1) = (𝑚2)
𝛿
𝑳𝟏
Therefore Cc = 𝜹

𝑳𝟏
𝑳𝒐𝒈(𝒎𝟐) = 𝑳𝒐𝒈(𝒎𝟏) + 𝑳𝒐𝒈 ( 𝜹 )
d. The Plot of M2 vs M2 given below
i. M2 vs M1

Figure 7. M2 vs M1

𝑳𝟏
ii. Since 𝑳𝒐𝒈(𝒎𝟐) = 𝑳𝒐𝒈(𝒎𝟏) + 𝑳𝒐𝒈 ( )
𝜹

𝑳𝟏
Therefore Slope =1 & Y intercept is 𝑳𝒐𝒈 ( 𝜹 )

For plotting the lines, the following table was used

Line Cc x- (Log(m1)) y-(Log(m2)) intercept

C1 10^-2 3 1 -2
C2 10^-3 4 1 -3
Figure 8. Line C1 & Line C2

iii.

Figure 9. Materials for the lines

It is evident that the line C2 is has a lower value (More negative) of Cc and hence has a lower intercept
and hence the materials are as follows.

• SiC
• Ti-Sic
• Alumina
• Mica
 This criterion produces more of Ceramics fibers and hence have higher mass per unit of stiffness
than C2

Where as Line C2 with a higher Cc value provides the following materials.

• Mica
• Mg-B
• Mg-Al203
• Al-SiC
These materials are Metal based composites and possess higher mass per unit of strength than those
produced with C1

Exercise 3.1
1. The following are the steps required for using the formulae from the appendix
𝐸𝐼𝑛2 𝜋2
a. 𝐹 = 𝐿2
(F critical for buckling)

𝐸𝐼𝜋2 𝜋𝑟 4 𝐴𝑟 2
𝐹= 4𝐿2
I= 4
I= 4

𝐶
𝐶𝑚 = 𝑚 𝑚 = 𝜌𝐴𝐿

𝐶 𝐶
𝐶𝑚 = A=
𝜌𝐴𝐿 𝜌𝐿𝐶𝑚

𝐸𝜋 1 𝐴2
𝐹=
16𝐿2

𝐸𝜋 1 𝐴2
𝐹=
16𝐿2

2
𝐸𝜋 1 𝐶
𝐹= ( )
16𝐿2 𝜌𝐿𝐶𝑚

16𝐿4 𝐹𝜌2 𝐶𝑚2

𝐶2 =
𝐸𝜋
 0.5
16𝐿4 𝐹 𝜌1 𝐶𝑚1
𝐶2 = ( ) ( )
𝜋 𝐸 0.5

𝜌1 𝐶𝑚1
𝑀2 = ( )
𝐸 0.5

𝐹 𝐹
𝜎= = 2
𝐴 𝜋𝑟

𝐹𝜌𝐿
𝜎=
𝑚
𝐹𝐿 𝜌𝐶𝑚
𝐶1 = ( )
𝜎

𝝆𝟏 𝑪𝒎𝟏 𝝆𝟏 𝑪𝒎𝟏
𝑴𝟏 = ( 𝝈
) 𝑴𝟐 = ( 𝑬𝟎.𝟓
)

b. Using the Granta Sotware the following plots were obtained

i.

Figure 10. 100 best materials according to M1

 Figure 11. 10 Best Materials according to M2

Therefore the 10 best materials are as follows

• Halite
• Ice
• Mica
• Concrete ( 4 Types)
• Hardboard
• Reactive powered concrete
• High Volume Fly Ash Concrete

ii.

Figure 12. 100 best materials according to M2

 Figure 13. 10 Best materials according to M1

Therefore the 10 best materials are as follows

• Halite
• Ice
• Mica
• Concrete ( 4 Types)
• Hardboard
• Reactive powered concrete
• High Volume Fly Ash Concrete
iii. Therefore, Both the methods provide the same materials and hence for this case
the order of preference does not play a significant role.

c. For H=3m & F=105N, The Following is obtained.

The Previous 10 cheapest materials were taken from Part B, explaining the usage of the
granta software in the same solution. The only values that were obtained were the values
of the density, compressive strength, cost and the modulus of elasticity.
C=Max(C1,C2)
0.5
16𝐿4 𝐹 𝜌1 𝐶𝑚1 𝝆𝟏 𝑪𝒎𝟏
𝐶2 = ( 𝜋
) ( 𝐸 0.5
) = 𝟔𝟒𝟐𝟐. 𝟖𝒙 ( 𝑬𝟎.𝟓
)

𝟑𝒙𝟏𝟎𝟓 𝝆𝑪𝒎
𝐶1 = ( )
𝟏 𝝈
Material Density Cm E Strength C1 C2 C
C. HP 2.20E+03 0.08 3.20E+10 5.33E+07 9.91E-01 6.32E+00 6.3192
C.N 2.20E+03 0.04 1.50E+10 1.33E+07 1.98E+00 4.61E+00 4.614891
C.SL 1.40E+03 0.04 1.10E+10 1.13E+07 1.49E+00 3.43E+00 3.429384
C. SS 2.20E+03 0.04 2.45E+10 2.01E+07 1.31E+00 3.61E+00 3.610971
Halite 2.12E+03 0.01 3.42E+10 4.20E+07 1.51E-01 7.36E-01 0.736287
Hardboard 8.00E+02 0.22 5.00E+11 3.00E+07 1.76E+00 1.60E+00 1.76
High
VLAC 1.80E+03 0.04 3.00E+10 4.50E+07 4.80E-01 2.67E+00 2.669908
Ice 9.10E+02 0.21 9.10E+09 5.80E+08 9.88E-02 1.29E+01 12.86662
Mica 2.60E+03 0.131 1.69E+11 1.86E+08 5.49E-01 5.32E+00 5.321397
RP
Concrete 2.50E+03 0.17 2.80E+10 2.00E+08 6.38E-01 1.63E+01 16.31302
Min C 0.736287

Therefore, its is evident that the best material would be Halite for the following load condition, as
it is the least expensive option.

d. The following is the Graph with the interchanged Index along the axis
i.

Figure 14. M2 vs M1

ii.
0.5
16𝐿4 𝐹 𝜌1 𝐶𝑚1 𝐹𝐿 𝜌𝐶𝑚
𝐶1 = 𝐶2 = ( ) ( 0.5
)= ( )
𝜋 𝐸 𝜎𝑥103
 (𝐹𝜋)0.5
𝑀2 = 𝑀1
4𝐿𝑥103

𝐹 0.5 𝜋 0.5
𝑀2 = ( )( ) 𝑀1
𝐿 4𝑥103
𝐹 0.5
𝑀2 = ( ) (4.43𝑥10−4 )𝑀1
𝐿

𝐹 0.5
𝐿𝑜𝑔(𝑀2) = 𝐿𝑜𝑔(𝑀1) + 𝐿𝑜𝑔 (( ) (4.43𝑥10−4 ))
𝐿

Line 1
For the case of
𝐹 = 107 & 𝐿 = 2

𝐿𝑜𝑔(𝑀2) = 𝐿𝑜𝑔(𝑀1) − 0.1545

Figure 15. F=10^7 & H=2

Therefore, the best materials along the line are as follows

• Concrete
• Vermiculite
• PE-LD Foam
• Mullite Foam
Line 2
For the case of
𝐹 = 106 & 𝐿 = 4
𝐿𝑜𝑔(𝑀2) = 𝐿𝑜𝑔(𝑀1) − 0.955

Figure 16. F=10^6 H=4

Therefore, the best materials along the line are as follows

• Aerated Concrete
• Concrete
• Glass Foam
• Insulation Board

Line 3
For the case of
𝐹 = 108 & 𝐿 = 1
𝐿𝑜𝑔(𝑀2) = 𝐿𝑜𝑔(𝑀1) + 0.6464
 Figure 17. F=10^8 & L=1

Therefore, the best materials along the line are as follows

• PS Foam
• Concrete
• Brick
• Vermiculite

Line 4
For the case of

𝐹 = 105 & 𝐿 = 6
𝐿𝑜𝑔(𝑀2) = 𝐿𝑜𝑔(𝑀1) + 0.447

Figure 18. F=10^5 H=6

 • Al-SiC Foam
• Concrete
• PE-LD Foam
• Glass Foam

Therefore it is evident that the different values of Cc provides different materials, according to the
intercept on the y axis. And hence it can be seen that varying H from 1-6m and F from 10^5-1^8 N, has
given different materials, higher intercept (Line 3 compared with Line 1) is inclining towards M2 criteria .
And a lower intercept means that the emphasis is on the the M1 criteria ( Line 2 compared with Line 1).

Exercise 3.2
2. The question, asks to derive the material index for minimizing mass and cost.

Therefore the following is the derivation of the indices.

𝑃𝑟
𝑚 = 𝜌𝑉 𝜎𝑦 = 𝑡

Finding the Volume of the Tank

Assuming that t is small compared to r, and therefore t
𝑡
𝑟
≈0
4
lim(𝑉)1 = lim((𝜋ℎ(𝑟 2 − (𝑟 − 𝑡)2 ) + 𝜋(𝑟 3 − (𝑟 − 𝑡)3 )
𝑡
→0
𝑡
→0 3
𝑟 𝑟

4
= lim
𝑡
((𝜋ℎ(𝑟 2 − 𝑟 2 −𝑡 2 + 2𝑟𝑡) ) + 3 𝜋(𝑟 3 − 𝑟 3 − 𝑡 3 − 3𝑟 2 𝑡 + 3𝑡 2 𝑟)
→0
𝑟

4
= lim((𝜋ℎ(−𝑡 2 + 2𝑟𝑡) ) + 𝜋(−𝑡 3 − 3𝑟 2 𝑡 + 3𝑡 2 𝑟)
𝑡
→0 3
𝑟

−𝑡 2 2𝑟𝑡 4 𝑡 3 3𝑟 2 𝑡 3𝑡 2 𝑟
= lim((𝜋ℎ𝑟( + ) ) + 𝜋(𝑟 3 (− 3 − 3 + 3 ))
𝑡
→0 𝑟 𝑟 3 𝑟 𝑟 𝑟
𝑟

𝐕 = 𝟐𝒕𝝅𝑳𝒓 + 𝟒 𝝅𝒉𝒓𝟐 𝒕
2𝑟
𝑄=
𝐿
𝐕 = 𝟐𝒕𝝅𝑳𝒓(𝟏 + 𝑸)𝟏

𝐦 = 𝟐𝜌𝒕𝝅𝑳𝒓(𝟏 + 𝑸)𝟏
𝑃𝑟
𝑡=
𝜎𝑦
 𝟏
𝟐𝜌𝑃𝒕𝝅𝑳𝒓𝟐 (𝟏+𝑸) 𝟐𝑃𝒕𝝅𝑳𝒓𝟐 (𝟏+𝑸) 𝜌
M1= 𝐦 = 𝜎𝑦
= 1
(𝜎𝑦)

𝐶
𝐶𝑚 = 𝐶 = 𝐶𝑚. 𝑚
𝑚

𝟐𝑃𝒕𝝅𝑳𝒓𝟐 (𝟏+𝑸) 𝐶𝑚.𝜌

𝑀2 = 𝐶 = 1
( 𝜎𝑦 )

For Low Carbon steel, where ‘o’ denotes the values for Mild steel.

𝜌 𝜌𝑜∙𝐶𝑚𝑜
𝐦𝒐 = (𝜎𝑦𝑜 ) and 𝐜𝒐 = ( 𝜎𝑦𝑜
)
𝑜

Therefore, taking ratios of provides

b.

Figure 19. M1 vs M2 ( 100 best material according to M1)

 Figure 20. M1 vs M2 ( 10 best materials according to M2)

ii.

Figure 21. M1 vs M2 ( 100 Best Materials according to M2)

 Figure 22.M1 vs M2 ( 10 Best Materials according to M1)

iii.
10 Best according to M2 10 Best according to M1
Asbestos W Asbestos W
Asbestos B Asbestos B
Asbestos T Asbestos T
Mica Asbestos A
Basalt Basalt
Banana Banana
Kenaf Kenaf
Sisal Glass E
Steel wire Nylon 6
Jute Fiber Polypropylene

Therefore, it is evident that even though majority of the materials are similar, it depends on the selection
and reduction criteria i.e. if more importance is given to cost or Mass of the desired materials.
It can be seen that choosing 100 items M1 emphasises on mass and choosing 100 items based on M2
emphasizes Cost.

C.

Material Cost Density Yield Strength

Low Alloy steel 1.14 7.79e3 1.52e3
(300M)
 Figure 23. m/mo vs c/co

Therefore the following plot was obtained, theoretically the Low alloy steel is supposed to be located at
the coordinate (1,1). It was observed that this was very close to the (1,1) point but not exactly on it. The
reason for this could be, that the values taken for the material were the lower limit of the properties and
hence it is not exactly on the (1,1) point.
d.
α provides the relative exchange constant, it is basically the translation of weight and cost. A higher α
value would mean that the mass would incur larger cost and a lower cost would mean that the weight
would incur lower cost.
Therefore considering Low alloy steel and its replacements for α=100 & α=10.

Steps
1. Make A m/mo vs c/c0 plot
2. Plot a line with slope 1 and passing through points (1,1)
3. Restrict 10 best materials in the bottom of the graph using the box selection tool
4. Obtain properties of the selected materials
5. Compare and analyze
Figure 24. 10 best materials
 Material Density Cm YS Alpha=1 Alpha=100
300M 7.79E+03 1.14 1.52E+09 2 1.01E+02
Sisal 1.40E+03 0.75 4.95E+08 0.55186 55.54907224
Dacron 1.38E+03 1.32 5.73E+08 0.469928 47.53684748
kenaf 9.80E+02 0.4 1.95E+08 0.980613 98.405363
Glass E 2.55E+03 1.63 1.90E+09 0.261875 26.56185393
Basalt 2.50E+03 2.38 1.43E+09 0.341123 34.82439683
Banana Fiber 1.25E+03 0.77 6.70E+08 0.364034 36.64923138
Asbestos W 2.40E+03 1.66 2.95E+09 0.158744 16.10548073
Asbestos T 3.04E+03 1.66 4.75E+09 0.124878 12.66964484
Asbestos B 3.30E+03 1.66 3.33E+09 0.193364 19.61797484
Asbestos A 3.36E+03 1.66 2.38E+09 0.275467 27.94774598
Silica 2.18E+03 12.4 4.83E+09 0.088068 9.76467326
Coir Fiber 1.15E+03 0.13 1.00E+08 2.243903 224.6461275
PBO 1.54E+03 132 5.68E+09 0.052909 11.4158636

The values of α indicates that at α=1, higher strength material is chosen (PBO), whereas when α=100,
lower weight is prioritized (Silica). The following materials were obtained, and it is evident that α=100,
carries a higher cost premium.
e. & f.

Figure 25.Contour Lines

The following graph shows the trade off surface for the plot, which is represented by the orange line.
The red line represents the contours of Z that are tangent to the tradeoff surface, the first line is alpha 1
and the second is alpha 2.