Materials and processes

A successful product One that perform well, is good value for money
and gives pleasure to the user. Uses the best materials for the job and
fully exploits their potential and characteristics.
Families of materials - metals, polymers, ceramics and composites.
Profile of properties.
Family likeness need to know to decide which family to choose
/decide to be used for a given design.
Choosing material is only half the story . The other half is the choice
of a process route to shape, join and finish it.

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 The materials tree
The menu of engineering materials.
Steel
Cast iron

Metal
Cu Alloy
Alumina Zn Alloy
Silicon Carbide Ti Alloy
Ceramics
Silicon Nitride
Zirconia PE, PP, PET,PC,PEEK
Composite
Sandwiches Polymers
Hybrids Polyester
Phenolics
Segmented structures Epoxies
Lattices
forms
Soda glass
Borosilicate glass
Isoprene
Glasses Neoprene
Butyl rubber
Silica glass
Glass ceramic
Elastomers
Natural rubber
Silicon
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 ORGANIZING PROCESSES
Raw materials

Primary shaping
Deformation
Casting Molding Powder Composite Special
Methods
Methods methods Methods forming Methods
Rolling
Sand Injection Sintering Hand lay up Rapid prototype
Forging
Die Compression HIPing Filament wind Lay up
Drawing
investment Blow moulding Slip casting RTM Electro form

Secondary processes

Machining Heat treat

Cut, turn, plane Quench, temper,
Drill, grind Age harden

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 Joining
Surface treatment

Fastening Welding Polishing Plating

Riveting Heat bonding Texturing Metallizing

Snap fits Adhesives Anodize Painting

Friction bonds Cements Chromizing Printing

Finished Products

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Kingdom Family Class Member Attributes

Compression
Casting Material
Joining
Rotation Shape
Process Deformation Size range
Transfer Minimum section
Shaping
Molding Tolerence
Injection Roughness
Composite Minimum batch size
Surface
Form Cost model
Treatment
Powder Documentation
Extrusion
Prototype
Resin Casting
A Process record
Thermoforming

Blow molding

The taxonomy of the kingdom of process with part of the shaping family expanded
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 Process property Interaction
Processing can change properties.
e.g forging
(harder to annealing)
Stretching
polyethylene fibre
rubber vulcanizing
Composites
Resin and fibre reinforced
Joining
Welding
Surface treatment
electroplating
Carburizing
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 Process property Interaction
Processing can change properties.
e.g forging
(harder to annealing)
Stretching
polyethylene fibre
rubber vulcanizing
Composites
Resin and fibre reinforced
Joining
Welding
Surface treatment
electroplating
Carburizing
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 Computer aided information management
for materials and processes

1. Classification
Records of every member for materials and processes
Software
Materials and properties
Physical attributes
Economic attributes
Typical uses.
The process
2. Documentation
content of records
Structured data.
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 Matching material to design - Strategic thinking
The design flow chart
Market Need
Problem definition

Material data Needs

Concept Process data
Choice of material Explore working Needs
Principles
Family
Metal, ceramics.. Choice of process
Embodiment
Define general
family
Choice of material Layout and scale Casting, moulding
Class Choice of process
Steel, al alloy etc.. Detail Class
Optimize form Die cast, sand cast
Manufacture and assembly Choice of single
Choice of single
Material Process
6061 Al, Pressure die cast
304 Stainless steel
Product specifications
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 The interaction between design requirements
Materials, shape and process.

Design Requirement Requirement

Required property
profile Required shape Constraints

Material Process choice

Cost Consequences
Eco-impact
Decision
Final Choice
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 The design process

Original design
Original design starts from scratch.
Involved new idea or working principle.
Can be stimulated by new materials.
The starting point may be market need or new idea.
A need must be established before it can be met.
At the conceptual design stage all options are open.
Alternative concept
Sizing
Operation
Materials
Processes.
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Redesign
 The Strategy applied to materials

All materials

Translate design for requirements

Express as function , constraints, objectives and free variables

Screen using constraint

Eliminate materials cannot do the job

Rank using objective

Find the screened materials that do the job best

Seek Documentation
Research the family history of top ranked candidates

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Final material choice
Function, Constraints, Objectives and free variables

Function
What does the component do ?
Constraints
What non negotiable conditions must be met ?
Objectives
What is to be maximized or minimized ?
Free variable
What parameters of the problem is the designer free to change
 Common constraints and objectives

Common constraints Common objectives

Meet a target value of Minimize
Stiffness Cost
Strength Mass
Fracture toughness Volume
Thermal conductivity Impact on the environment
Electrical resistivity Heat loss
Magnetic remanence
Optical transparency Maximize
Cost Energy storage
Mass Heat flow

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Translation for the Redesigned CD case
Function
Contain and Protect a CD
Constraints
Optically clear
Able to be injection moulded
Recyclable
Tougher than polystyrene
Dimensions identical with PS case
Objective
Minimum cost
Free variable
Choice of Material

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Investment casting
Casting Work
Powder Metallurgy
 Howrah Bridge Kolkata West Bengal (1943)

Corroded by Saliva mixed with betel and lime- Reuters

n

04/11/17 21
Air Bags problem in Honda

Toyota Pedal Assembly