Q1: You are tasked with selecting a material for a foundry tool used for

moving metal around during the casting process. It is basically a

long pole of fixed length and unknown circular cross section that is
used in two ways.
First, it is used as a prod, during which there may be a large end load
(see figure A) that could lead to buckling failure.
Second, it is used as a pry-bar, during which it is loaded in bending (see figure B)
that could lead to a yielding failure.
Finally, because the tool is used to move molten metal around, the heat conduction
up the pole must be below a given value, q 0, to avoid burning the technician.
The foundry needs to reduce costs, and so would like the tool to be as inexpensive
as possible. Use this information and the equations below to answer the following
questions.
𝜋 3 𝐸𝑟 4 𝜋𝑟 3 𝜎𝑓
𝐵𝑢𝑐𝑘𝑙𝑖𝑛𝑔 𝐹𝑒𝑛𝑑 = 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝐹𝑝𝑟𝑦 =
4𝐿2 𝐿
𝜋𝑟 2𝜆Δ𝑇
𝐻𝑒𝑎𝑡 𝐸𝑛𝑒𝑟𝑔𝑦 𝑞𝑜 =
𝐿
 Is this design underconstrained, fully determined, or overconstrained, and
why?
 What is the performance metric for this design?
 Derive the merit indices, M, for this design.
 Derive the coupling equations required for this design.
Sol:
This design is overconstrained because of C>F
1 1 1 1
𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑀𝑒𝑡𝑟𝑖𝑐 𝑃𝑀𝑎𝑥 = = = =
𝐶 𝑐𝑚 𝑐𝜌𝑉 𝑐𝜌𝜋𝑟 2𝐿
Merit Indices
1
3 4 2 4
𝜋 𝐸𝑟 4𝐿 𝐹𝑒𝑛𝑑
𝐹𝑜𝑟 𝑏𝑢𝑐𝑘𝑙𝑖𝑛𝑔 𝑐𝑜𝑠𝑛𝑡𝑟𝑎𝑖𝑛𝑒𝑑 𝐹𝑒𝑛𝑑 = ⟹ 𝑟 = ( )
4𝐿2 𝜋3𝐸
1 1 1
1 1 𝜋 2𝐸 2 𝐸2
𝑃𝑀𝑎𝑥1 = = 1 = 1 ∴ 𝑀1 =
𝑐𝜌𝜋𝑟 2𝐿 𝑐𝜌
4𝐿2 𝐹 2 2𝑐𝜌𝐿2 𝐹𝑒𝑛𝑑 2
𝑐𝜌𝜋𝐿 ( 3 𝑒𝑛𝑑 )
𝜋 𝐸
1
3
𝜋𝑟 𝜎𝑓 𝐿𝐹𝑝𝑟𝑦 3
𝐹𝑜𝑟 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑐𝑜𝑠𝑛𝑡𝑟𝑎𝑖𝑛𝑒𝑑 𝐹𝑝𝑟𝑦 = ⟹𝑟=( )
𝐿 𝜋𝜎𝑓
2 2
1 1 𝜎𝑓 3 𝜎𝑓 3
𝑃𝑀𝑎𝑥2 = = 2 = 1 5 2 ∴ 𝑀2 =
𝑐𝜌𝜋𝑟 2𝐿 𝑐𝜌
𝐿𝐹𝑝𝑟𝑦 3 𝑐𝜌𝜋 3 𝐿3 𝐹𝑝𝑟𝑦 3
𝑐𝜌𝜋𝐿 ( )
𝜋𝜎𝑓
1
𝜋𝑟 2𝜆Δ𝑇 𝐿𝑞𝑜 2
𝐹𝑜𝑟 ℎ𝑒𝑎𝑡 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑠𝑛𝑡𝑟𝑎𝑖𝑛𝑒𝑑 𝑞𝑜 = ⟹𝑟=( )
𝐿 𝜋𝜆Δ𝑇
1 1 1
1 1 Δ𝑇 2𝜆2 𝜆2
𝑃𝑀𝑎𝑥3 = = 1 = 1 1 ∴ 𝑀3 =
𝑐𝜌𝜋𝑟 2𝐿 𝑐𝜌
𝐿𝑞 2 𝑐𝜌𝜋 2𝐿2 𝑞𝑜 2
𝑐𝜌𝜋𝐿 ( 𝑜 )
𝜋𝜆Δ𝑇
Coupling equations:
1 1 2
𝜋 2𝐸 2 𝜎𝑓 3
𝑃𝑀𝑎𝑥1 = 1 = 𝑃𝑀𝑎𝑥2 = 1 5 2
2𝑐𝜌𝐿2 𝐹𝑒𝑛𝑑 2 𝑐𝜌𝜋 3 𝐿3 𝐹𝑝𝑟𝑦 3
 1 1 1
𝜋2 1 2𝐿3 𝐹𝑒𝑛𝑑 2
⟹ 1 𝑀1 = 1 5 2 𝑀2 ⟹ 𝑀1 = ( 5 2 ) 𝑀2
2𝐿2 𝐹𝑒𝑛𝑑 2 𝜋 3 𝐿3 𝐹𝑝𝑟𝑦 3 𝜋 6 𝐹𝑝𝑟𝑦 3
1 1 1 1
𝜋 2 𝐸2 Δ𝑇 2𝜆2
𝑃𝑀𝑎𝑥1 = 1 = 𝑃𝑀𝑎𝑥3 = 1 1
2𝑐𝜌𝐿2 𝐹𝑒𝑛𝑑 2 𝑐𝜌𝜋 2𝐿2 𝑞𝑜 2
1 1 1 1
𝜋2 Δ𝑇 2 2𝐹𝑒𝑛𝑑 2 Δ𝑇 2
⟹ 1 𝑀1 = 1 1 𝑀3 ⟹ 𝑀1 = ( 1 ) 𝑀3
2𝐿2 𝐹𝑒𝑛𝑑 2 𝜋 2𝐿2 𝑞𝑜 2 𝜋𝑞𝑜 2

2 1 1
𝜎𝑓 3 Δ𝑇 2𝜆2
𝑃𝑀𝑎𝑥2 = 1 5 2 = 𝑃𝑀𝑎𝑥3 = 1 1
𝑐𝜌𝜋 3 𝐿3 𝐹𝑝𝑟𝑦 3 𝑐𝜌𝜋 2𝐿2 𝑞𝑜 2
1 1 2 1
1 Δ𝑇 2 𝐿3𝐹𝑝𝑟𝑦 3Δ𝑇 2
⟹ 1 5 2 𝑀2 = 1 1 𝑀3 ⟹ 𝑀2 = ( 1 1 ) 𝑀3
𝜋 3 𝐿3 𝐹𝑝𝑟𝑦 3 𝜋 2𝐿2 𝑞𝑜 2 𝜋 6 𝑞𝑜 2

Q2 The Flying Bonzoni Brothers, want to design a new spring board as they prepare
to take their acrobatic act on the road to fame and fortune. There are two objectives
about the board the one is that it stores as much elastic energy as possible as and the
second is have the min cost as possible. They know that the cost and energy stored
in this spring board are given by:
𝐶 = 𝑐𝜌𝐿𝐴 = 𝑐𝜌𝐿𝑏ℎ
1 𝜎2 1 𝜎2
𝐾= 𝐿𝐴 = 𝐿𝑏ℎ
2𝐸 2𝐸
Where K is the stored energy, E is the elastic modulus, A is the
cross sectional area, L, b, and h are the dimensions of the spring board, and 𝜎 is the
failure stress of the board. The length, L, and width, b, are fixed, but the thickness,
h, is free to vary.
The one constraints on the design are that the board should not fail under the load of
Marco and Luigi. This constraint can be written as:

𝐹𝑚𝑎𝑥 𝐿 3𝐹𝑚𝑎𝑥 𝐿
𝜎= =
4𝑍 2𝑏ℎ2
 Derive the penalty function expression for this problem.
 Derive the minimizing objective functions Pmin for this problem and calculate
the value of the constants in the (minimizing) objective equations using the
values given below:
L = 3.6 [m], b = 30 [cm], F = 1500 [N], and mo = 36 [kg].
Sol:
1
𝑃𝑀𝑖𝑛1 = , 𝑃𝑀𝑖𝑛2 = 𝐶
𝑘
𝑃𝑒𝑛𝑎𝑙𝑡𝑦 𝐹𝑢𝑛𝑐𝑡𝑖𝑜𝑛 𝑍 = 𝛼1𝑃1 + 𝛼2𝑃2
1
𝑍 = 𝛼1 + 𝐶
𝑘
Constant for objective equation
1 2𝐸
𝑃𝑀𝑖𝑛1 = = 2
𝑘 𝜎 𝐿𝑏ℎ
1
3𝐹𝑚𝑎𝑥 𝐿 3𝐹𝑚𝑎𝑥 𝐿 2
𝜎= ⟹ ℎ = ( ) ⟹
2𝑏ℎ2 2𝑏𝜎
 2𝐸 2.83 𝐸
∴ 𝑃𝑀𝑖𝑛1 = 1 = 1⁄2
( 3⁄2
)
3𝐹 𝐿 2 31⁄2 𝐿3⁄2𝑏 1⁄2𝐹𝑚𝑎𝑥 𝜎
𝜎 2 𝐿𝑏 ( 𝑚𝑎𝑥 )
2𝑏𝜎
2.83 𝐸 𝐸
⟹ 𝑃𝑀𝑖𝑛1 = 1⁄2 3⁄2 1⁄2 ( ) = 0.0112 ( )
3 3.6 0.3 1500 1⁄2 𝜎 3⁄2 𝜎 3⁄2
1 ⁄
1 2
3𝐹𝑚𝑎𝑥 𝐿 31⁄2 𝐿3⁄2 𝑏1⁄2 𝐹𝑚𝑎𝑥
2 𝑐𝜌
𝑃𝑀𝑖𝑛2 = 𝐶 = 𝑐𝜌𝐿𝑏ℎ = 𝑐𝜌𝐿𝑏 ( ) = ⁄ ( )
2𝑏𝜎 21 2 𝜎 1⁄2
31⁄23.63⁄2 0.31⁄2 15001⁄2 𝑐𝜌 𝑐𝜌
⟹ 𝑃𝑀𝑖𝑛2 = ⁄ ( ⁄ ) = 177.64 ( )
21 2 𝜎1 2 𝜎 1⁄2