MATERIALS SELECTION
Presented by-
Alok Kumar (153651)
Anoop Nath (153652)
Bairy Srinivas (153653)
INTRODUCTION
The designer of any product, other than designing the
product must be involved with material selection.
Selection of materials for manufacturing the design.
1000 Engineering materials
Material selection process is
accomplished by comparing
material properties with the
functional requirements of
the product.
MATERIAL SELECTION- WHY ?
Material cost comprise 60 % (or more) of the total
cost of the product.
Major impact of Material selection
Quality.
Cost (of final product and manufacturing).
Recycling.
Life cycle cost.
Physical Properties.
Mechanical Properties.
Dimension and Tolerances.
RELATION OF MATERIAL SELECTION TO
DESIGN
Fig.1 Interrelations of design, materials and processing to
produce a product
Fig.2 Schematic of the design process.
GENERAL CRITERIA FOR
SELECTION
Performance characteristics ( properties ).
Selection on the basis of impact of the properties of material
on the performance of the product and the design constraints.
Processing (manufacturing) characteristics.
Selection, such that required shape and size is formed with
minimum defect and cost
Environmental Profile.
Impact of environment on product and vice-versa.
Business Considerations
Minimum life cycle cost
OVERVIEW OF MATERIAL SELECTION PROCESS
Analysis of the materials requirements.
Screening of candidate materials.
Analysis of candidate materials in terms of product
performance, cost ,manufacturability etc.
Development of design data for critical systems or
components
PERFORMANCE CHARACTERISTICS OF
MATERIAL
Fig.3 Material Properties- link between structure and performance
CLASSIFICATION OF MATERIALS
Material classification hierarchy.
MATERIAL KINGDOM
FAMILY
CLASS
SUB-CLASS
MEMBER
Fig4. Commonly used engineering
materials
PROPERTIES OF MATERIALS
Structure sensitive materials.
Materials which apart from depending upon atomic binding
energy and arrangement of atoms in solid also strongly
depend upon number, size and distribution of
imperfections (dislocations, line defect, grain
boundaries, inclusions etc) in solid.
Structure insensitive materials.
Materials which dont depend upon structure i.e. imperfections
MECHANICAL PROPERTIES
Ultimate tensile strength.
Modulus of elasticity.
Ductility.
Fracture Toughness.
Damping Capacity.
Creep.
Hardness.
Impact resistance.
Wear Resistance
Fig.5 A typical stress strain curve for a
ductile material
Fig.6 Comparison of hardness of metals, polymers and
elastomers using different tests and scales
ASHBY CHARTS
Charts which were created to compare a large number of
materials during conceptual design stage.
Ashby plot is a scatter plot which displays two or more
properties of a materials
They are adequate for the broad comparisons required
for conceptual design, and, often, for the
rough calculations of embodiment design.
THEY ARE NOT APPROPRIATE FOR
DETAILED DESIGN CALCULATIONS
MATERIALS CLASSES AND CLASS MEMBERS
MATERIAL PROPERTIES
CHART-1 YOUNGS MODULUS (E) AND DENSITY ( )
This chart guides selection of materials for light, stiff,
components.
GUIDELINES
The loci of points will be selected on the basis of
requirements
E/ = C (minimum weight design of stiff ties;
minimum deflection in centrifugal loading)
E^(1/2)/ = C (minimum weight design of stiff
beams, shafts and columns)
E^ (1/3)/ = C (minimum weight design of stiff
plates)
OTHER CHARTS AND THEIR USES
Chart-2 Strength ( f) vrs Density( )
Used for designing light strong structures.
Chart-3- Youngs modulus (E) vrs Strength ( f)
Used for elastic design.
Chart-4-Fracture toughness (Kic) vrs Strength(f)
Used for safe design against fracture
Chart-5- Loss coefficient() vrs Young's modulus,(E)
The chart gives guidance in selecting material for low
damping (springs, vibrating reeds, etc) and for high
damping (vibration-mitigating systems)
There are 20 charts which are used for preliminary
selection of materials on the basis of requirements.
HOW CAN YOU SELECT MATERIAL FOR YOUR
PROJECT?
Objective: Develop a rational method to select the
best material for an application based upon known
material parameters and the requirements of the
application
Use a 5-step method
1.
2.
3.
4.
5.
Select a quantity, Q, to minimize or maximize
Classify the variables
Determine the relationship between the geometry
variable, the requirements, and material properties
Determine Q as a function of requirements and material
properties
Rank candidate materials based upon function f 2
*2.- Based on N.E. Dowling, Mechanical Behavior of
Materials, section 3.8
SAMPLE PROBLEM
We must bridge a gap of L = 8 feet
The bridge must have a width of b = 4
inch
A load P = 300 lb can be applied at any
point
There must be a safety factor X = 1.5 for
strength
The deflection, v, must not exceed 1 inch
Weight (mass) and cost have equal
importance
P
L
Objective: Select the best candidate material from
AISI 1020 steel
AISI 4340 steel
7075-T6 aluminum
Ti-6Al-4V (titanium alloy)
Polycarbonate
Loblolly pine
GFRP (glass fiber reinforced polymer)
CFRP (carbon fiber reinforced polymer)
STEP 1: SELECT A QUANTITY, Q, TO
MINIMIZE
Here, mass and cost have equal importance
Mass, m
Cost, C
Select Q to be the sum of the normalized mass and
cost
Q = m/min(m) + C/min(C)
norm. mass= m/min(m)
norm. cost= C/min(C)
STEP 2: CLASSIFY THE VARIABLES
Requirements: L = 8 feet, b = 4 inch, P = 300
lb, X = 1.5, v = 1 inch
Geometry: Restrict analysis to a rectangular
cross-section, h = height
Material Properties (need step 3 & 4 results
here): = mass density, E = Youngs modulus,
S = strength, Cm = cost index.
STEP 3: DETERMINE THE
RELATIONSHIP BETWEEN THE
GEOMETRY VARIABLE, THE
REQUIREMENTS, AND MATERIAL
PROPERTIES
We have a simply supported beam with a
rectangular cross-section
The worst case occurs when the concentrated
load, P, is applied at the center.
P
L
Design on the basis of :
1. Strength Elastic flexural formula shows the maximum stress
occurs at the extreme fibers of the beam at midspan.
2. Deflection From integration, is found to be maximum
at midspan
STEP 4: DETERMINE Q AS A FUNCTION OF
REQUIREMENTS AND MATERIAL
PROPERTIES STRENGTH BASIS
Try using strength as the basis for material selection
and then check deflection
f2-for mass
f2-for cost
STEP 5: RANK MATERIALS BASED
UPON FUNCTION F2 STRENGTH BASIS
Use spreadsheet to
determine rankings
STEP 4: DETERMINE Q AS A FUNCTION OF
REQUIREMENTS AND MATERIAL
PROPERTIES DEFLECTION BASIS
Try using deflection as the basis for material selection
and then check strength
f2-for mass
f2-for cost
STEP 5B: RANK MATERIALS BASED UPON
FUNCTION F2 DEFLECTION BASIS
Use spreadsheet to
determine rankings
SAMPLE PROBLEM RESULTS
Material selection based only on strength results
in the deflection criterion being violated.
Material selection based only on deflection
results in the strength criterion being satisfied.
We can say that deflection governs this
design.
Pine is best, 1020 steel is second best, CFRP is
worst.
REFERENCENCES
1.
Engineering Design-George E. Dieter and Linda C Schmidt.
2.
N.E. Dowling, Mechanical Behavior of Materials.
3.
http://www-materials.eng.cam.ac.uk/mpsite/DT.html
