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OVERVIEW
Important aspect of design for aerospace, mechanical, electrical, thermal, chemical or other applications is selection of best materials Systematic selection of best material for a given application usually depends on 2 aspects: 1. Properties 2. Cost
A few examples: Thermal blanket must have poor thermal conductivity in order to minimize heat transfer for a given temperature difference Large amounts of copper in superconducting magnets: copper needed for low resistance path for large currents in case superconductivity lost Samarium-Cobalt Permanent Magnets on DS-1 SR-71 structure: 85% titanium and 15% composite Hummer armor should it be stiff or deflect against a bomb blast
Example 1: Rod Design a rod that is stiff and light-weight Requires a material with high Young's modulus and low density If rod pulled in tension, specific modulus, or modulus divided by density E/, will determine best material Example 2: Plate Design a plate that is stiff and light-weight Plate's bending stiffness scales with thickness cubed Best material for a stiff and light plate is determined by cube root of stiffness divided density E/r
ASHBY PLOTS
Ashby plot is a scatter plot which displays two or more properties of a materials Example of stiff, light part would have Young's modulus on one axis and density on other axis, with one data point on graph for each candidate material On such a plot, it is easy to find not only material with highest stiffness or lowest density, but that with best ratio E/. Ashby plot on next slide shows density versus Young's modulus
Metals are represented by blue squares, ceramics by green, and polymers by red
Using a log scale on both axes facilitates selection of material with best plate stiffness E/r. Second plot shows same materials attributes for a database of approx 100 materials
Materials families (polymers, foams, metals, etc.) are identified by the larger colored bubbles
http://www.matweb.com/index.aspx http://www.matweb.com/tools/contents.aspx
Probably the most comprehensive materials database ever created Worth spending a few hours sifting and surfing this site in preparation for selecting materials for your project
COST ISSUES
Cost of materials plays a very significant role in their selection Most straightforward way to weight cost against properties is to develop a monetary metric for properties of parts For example, life cycle assessment can show that reducing weight of a car by 1 kg averages around $5, so material substitution which reduces weight of a car can cost up to $5 per kilogram of weight reduction more than original material For commercial aircraft: $450/kg Spacecraft: $20,000/kg However, geography- and time-dependence of energy, maintenance and other operating costs, and variation in discount rates and usage patterns (distance driven per year in this example) between individuals, means that there is no single correct number for this
COST ISSUES
As energy prices increase and technology improved, automobiles have substituted increasing amounts of light weight magnesium and aluminum alloys for steel Aircraft are substituting carbon fiber reinforced plastic and titanium alloys for aluminum Satellites have long been made out of exotic composite materials. Cost per kg is not only important factor in material selection An important concept is 'cost per unit of function'. For example, if key design objective was stiffness of a plate of material, then designer would need a material with optimal combination of density, Young's modulus, and price Optimizing complex combinations of technical and price properties is a hard process to achieve manually, so rational material selection software is an important tool but lets see what we can do by hand
The 787 features lighter-weight construction. Its materials (by weight) are: 50% composite, 20% aluminum, 15% titanium, 10% steel, 5% other.[75] Composite materials are significantly lighter and stronger than traditional aircraft materials, making the 787 a very light aircraft for its capabilities.[76] By volume, the 787 will be 80% composite. Each 787 contains approximately 35 tonnes of carbon fiber reinforced plastic, made with 23 tonnes of carbon fiber.[77] Composites are used on fuselage, wings, tail, doors, and interior. Aluminum is used on wing and tail leading edges, titanium used mainly on engines with steel used in various places Higher humidity in the passenger cabin is possible because of the use of composites (which do not corrode). http://en.wikipedia.org/wiki/Boeing_787
Options:
Injection molding Cast aluminum/die or mold Wrought aluminum/stamping Wrought steel/stamping
Large parametric investigation of multiple designs: Structural integrity Rigidity Weight Manufacturability Modularity Portable Flexibility of design for future enhancements
Novel calibration and testing plan Quadra-axial feature (torque) presents unique design challenges
FINAL DESIGN
Next generation design considered a tubular elements for enhanced rigidity Triangular cross section Feasible and practical design, but easier to implement current design
CONCEPTUAL DESIGN
KEY FEATURES
Horizontal and vertical capabilities Factor of safety of 15 on structural design, factor of safety of 5 on sensors on nominal maximum thrust conditions Accommodate wide range of rocket sizes and thrusts Low friction, free rotation orthogonal force measurement system No residual orthogonal force due to mounting on forward array Corrosion resistant
LITERATURE REVIEW
Review of numerous thrust stands Review of wide range of commercial hobby, amateur, and high-powered rocketry solid and hybrid rocket motor classes Review of university / small corporation rocketry needs Materials, instrumentation, and manufacturability options
Rocket Motor Loki Research: H or I class Diameter 1.14 inches Thrust 51 lbf Burn Time ~ 2 sec
2.12 inches
5.98 inches 4.5 inches 3 inches 4 inches
284 lbf
1,873 lbf 336 lbf 2,030 lbf 5,520 lbf
~ 3 sec
~ 6 sec 29 seconds 1.9 seconds 2.1 seconds
weight (lb)
1500
SS 316L - 2x2 1000 Al 6061 T6 - 3x3 500 Al 6061 T6 - 2.5x2.5 Al 6061 T6 - 2x2
STRUCTURAL FRAME
Made from 316L 3x3 inch square tube stock with 0.25 inch wall thickness Frame includes several cross members for rigidity Gusset plates for rigidity/stiffness Numerous mounting holes to allow for location of forward and aft mounting braces to accommodate rockets of any size Versatile and adjustable anchoring system
Total Deformation
Materials selection slides included in next design presentation Materials selection section included in final report
COPPER PRICES
GOLD PRICES
October 22, 2008: Gold futures tumbled 4.3% Wednesday to the lowest level in one year, while copper futures were set for their worst year since 1988 in a broad sell-off that was sending stocks and commodities sharply lower. Gold for December delivery fell $32.80, or 4.3%, to end $735.20 an ounce on the Comex division of the New York Mercantile Exchange, the lowest closing level since October, 2007. Gold has fallen nine out of the past 10 trading sessions. Meanwhile, December copper slumped 14.15 cents, or 7.1%, to $1.8655 a pound. The metal has dropped 39% so far this year, heading for the biggest yearly percentage drop since 1988, when trading data first became available on the Nymex.
MID-TERM QUESTIONS/ANSWERS
Examine all questions and answers for each team from the Mid-Term presentations
Regarding the questions:
How good were the questions themselves? Could the questions have been more poignant?
Come up with 3-4 questions for each team that you think should be answered at this point in the semester
Dont repeat questions blindly but re-phrase them so they are more specific and directly ask what you feel should be answered/addressed Write-up questions and submit by 10 am on October 27, 2008 In lecture on October 27, 2008 I will submit collated questions to each team *before* the final presentations no team caught off guard During the week of October 27 October 31, we meet to together and decide which questions need to be answered/addressed Interweave answers to questions in final presentation Audience re-assesses how well these questions have now been answered