Exercise 3 - Computer Exercise

Anas Sayegh

Course: MMTN20 Material and Process

(Computer Exercise)

November 26, 2022

 Exercise 3
A high-performance automotive company called OVLOV has decided to utilize cylinders to
transfer power and replace springs. Their objective is to minimize mass, these cylinders have
different requirements for driveshafts and torsion bars (replacement for springs). Driveshafts
must be able to withstand the torque of the engine whereas torsion bars should replicate a
spring. The cross section of the torsion is the free variable but should stay within a reasonable
range and the material should possess isotropic characteristics. Find suitable materials for both
applications, motivate your answers with at least
• Material indices
• Material limits
• Processing.
You are allowed to use external sources as long as you reference it.
a) Driveshafts: Find optimal materials for the driveshaft application with text and
images motivating the decisions in line with (at least) the bullet points above. Below
is an illustration of a driveshaft for which the main constraint is being able to handle
the load without yielding.

Figure 1

TASK 1
As a driveshaft, it should be able to transmit rotational speed and allows transmission of power
to another part of the system. The material used for the shaft should meet the following detailed
requirements such as capacity of torque transmission, bending natural frequency and capability
of torsion likewise the specific stiffness, elastic limit that is the yield Strength.
However, the tension and compression also need to be satisfied due to the load / force exerted
on the driveshaft, meanwhile the Young’s Modulus is prioritized as one of the main
characteristics that needs to be considered.

Determining the best material,

Material Indices:
The material indices can be reached by either using the performance index finder on Granta or
mathematically analyzing the free variables, limiting constraints, fixed variables and objective
(optimization) of the driveshaft in order to determine the specifications.

Using the Performance index finder, material indices can be determined directly on Granta and
the performance matrix can be achieved by substituting the constraints, free variables and
objectives.

Using the Mathematical Analysis according to Ashby, it can go according to:

Appendix B.2 (Moments of sections) (Material Selection in Mechanical Design Michael F. Ashby)
Using the second moment of Inertia.
𝑚 = 𝐴𝐿ƿ … … … . . 𝑚𝑖𝑛𝑖𝑚𝑖𝑠𝑒 𝑡ℎ𝑒 𝑚𝑎𝑠𝑠 𝑟𝑒𝑙𝑎𝑡𝑒𝑑 𝑜𝑏𝑗𝑒𝑐𝑡𝑖𝑣𝑒
𝐶𝐸𝐼
𝑆 = 𝐿3 ……………..Stiffness of the driveshaft
𝛱𝐷4
𝐼= … … . 𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 𝑜𝑓 𝑎 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑟𝑜𝑑
64
1
64𝐿3 𝑆 4
𝐷= ( ) ;
𝐶𝐸𝛱
𝐸𝑥𝑝𝑟𝑒𝑠𝑠𝑖𝑛𝑔 𝑡ℎ𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑡𝑒𝑟𝑚𝑠 𝑜𝑓 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑠𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠, 𝑙𝑜𝑎𝑑 𝑐𝑜𝑛𝑠𝑡𝑟𝑎𝑖𝑛𝑡𝑠, 𝑦𝑜𝑢𝑛𝑔 𝑚𝑜𝑑𝑢𝑙𝑢𝑠
𝑆 1 ƿ
𝑚 = 8𝐿2 . ( )2 . 1
𝐶𝛱
𝐸2
Performance Matrix (M);
1
𝐸2
𝑀= ; 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝐼𝑛𝑑𝑖𝑐𝑒𝑠
ƿ
Since, we are referencing a driveshaft which will undergo torsion and needs strength, Young’s
modulus E can be related with shear stress G.
1
𝐺2
𝑀= ; 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝐼𝑛𝑑𝑖𝑐𝑒𝑠
ƿ

Figure 2: Shows Granta chart on the material needed for the driveshaft
 TASK 2
Therefore, there can be a limit in the mechanical properties as stated in figure 3. In order to
determine the material with the highest grade for the driveshaft needed to perform the torsion
operation. There must be a minimum limit while the maximum limit is not required due to it’s
transmission of power to another system.

Figure 3: Mechanical Properties limit, with reference to E at 75, S at 60 and σy at 80

TASK 3
As shown in figure 2, the material chosen for the drive shaft is machineable and the process
include hot rolling, thereby finished in size by cold drawing, turning process and grinding.
Figure 4a: Full list of materials present in the chart
Figure 4a: Full list of materials present in the chart
 b) Torsion bars: Find optimal materials for the torsion bar application with text and
images motivating the decisions in line with (at least) the bullet points above. Below
is an illustration of a torsion bar and its difference to a conventional spring. For a
conventional spring the stiffness is dictated by the compression of the spring
whereas a torsion bars stiffness is dictated by the rotation of the cylinder.

TASK 4
Material Indices:
The material indices can be reached by using the performance index finder on Granta. Therefore,
there is need to minimize mass and limiting constraint with the stiffness, because a shaft with
reduced mass and great stiffness is required. However, Figure 5 shows detailed of the material
used for a drive shaft which is machineable and works under in good condition.
Figure 5: Shows Mass per unit of Stiffness with isotropic materials
Figure 6: Shows Mass per unit of Stiffness with isotropic materials in the order of stages
passed
TASK 5
Material Limits:

Figure 7: Shows Beryllium-Aluminum alloy Beralcast 191, cast

The above figure shows the mechanical properties with the limit for the identified material.
Due to the fact that the material needs to resist forces due to compression and torsion,
therefore the alloy of beryllium-aluminum have shown a good stiffness and strength property
with minimized mass.
TASK 6
Processing:

The properties shows the machinability of the material is good and have a good mechanical
property to be casted to a driveshaft.