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Introduction To Machine Design: Dr. Shahid Mehmood
Introduction To Machine Design: Dr. Shahid Mehmood
Sy
Tensile Strength, Su
Elastic Limit
Proportional Limit
Stress, s
Modulus of Elasticity
E
Strain, e
Stress Strain Curve for Aluminum
Proportional Limit
Elastic Limit
Sy
Tensile Strength, Su
Yield Strength, Sy
Stress, s
Parallel Lines
Lf Lo
%Elongation x 100%
Lo
Ductile materials - extensive plastic deformation and
energy absorption (toughness) before fracture
Sy
S ys Yield strength in
2 shear
h f ho
LAT
ho
L f Lo
AX
Lo
RANGES
E
G , G
2(1 )
• Valid within the ELASTIC range of the
material
Summary: Key Material Properties:
Percent Elongation:
Yield Strength (psi) = onset of permanent deformation: L f Lo
100 %
Py Lo
y Sy yield strength or use .2% offset Lo = original gauge length
A
Lf = final gauge length
Tensile Strength (psi) = max stress or peak stress sustainable:
• >5% = ductile
Pu
u Su U .T .S • <5% = brittle
A
Percent Reduction of Area :
Modulus of Elasticity or Young’s Modulus (psi) – slope of linear region: Ao A f
100 %
2 1 Ao
E
2 1 Ao = original cross-sectional area
σ2-σ1 = difference in tensile stress between points 1 and 2 Af = final cross-sectional area
ε2-ε1 = difference in tensile strain between points 1 and 2
Modulus of Resilience (psi) = area under stress
G 2 1 Shear Modulus strain curve up to elastic limit or yield strength
2 1
1 2
Poison's Ratio (unit less) = ratio of transverse to longitudinal strain: U R el el el
2 2E
transverse
longitudinal Modulus of Toughness (psi) = total area under stress
strain curve up from 0 to fracture. Related to impact
Strength:
Yield Strength in shear:
Sy U T Area under curve
y Sys yield strength in shear
2
Example: find yield
strength, ultimate strength
and modulus of elasticity:
Example: find yield strength and ultimate
for material that does not exhibit knee
behavior
Example –
DATA
generated
on MTS
machine:
EX:
Su = ultimate
Strength =
47,820 psi Stress-Strain Tensile Curve for Specimen 5 Speed of Loading = 0.1 in/min
Temperature = 23 C
RJM 9/5/05
50000.0
45000.0
40000.0
Sy = Yield
Strength =
44,200 psi
35000.0
30000.0
E = Young’s Modulus = (34,640 –
Stress (psi)
20000.0
15000.0
10000.0
% Elongation = 11.5%
.002 = .2%
5000.0 offset
0.0
0.0000 0.0200 0.0400 0.0600 0.0800 0.1000 0.1200
Strain (in/in)
EX:
45000.0
40000.0
35000.0
30000.0
Modulus of Resilience =
Stress (psi)
0.0
0.0000 0.0200 0.0400 0.0600 0.0800 0.1000 0.1200
Strain (in/in)
Stress-Strain Tensile Curve for Specimen 5 Speed of Loading = 0.1 in/min
Temperature = 23 C
RJM 9/5/05
50000.0
45000.0
40000.0
35000.0
30000.0
Modulus of Toughness =
Stress (psi)
15000.0
10000.0
0.0
0.0000 0.0200 0.0400 0.0600 0.0800 0.1000 0.1200
Strain (in/in)
Hardness
• Resistance of a material to be indented by
an indenter.
– BRINELL 3000 kg load
10 mm ball
of hole = BHN
– ROCKWELL 100 kg load (B Scale)
1/16” Ball (B Scale)
B-Scale for soft materials
C-Scale for harder metals (Heat treated) (Use
150 kg load with diamond cone indenter)
Hardness calculated directly by machine (depth of indentation)
Toughness
• Toughness is the ability of a
material to absorb energy
before failure.
• Parts subjected to impact or
shock loads need to be tough.
• Testing: Charpy and Izod
tests
• Impact energy determined
from the testing is used to
compare materials
Fatigue
• Failure mode of parts experiencing
thousands or millions of repeated loads.
• Endurance Strength - a materials
resistance to fatigue. Determined by
testing.
Creep
• Progressive elongation of a part over time.
• Metals – usually requires a large load
– usually requires high temperature
(> .3Tm)
• Plastic – creep occurs at low temperatures
Mechanical Property Summary
Common or
Property Interpretation
Related Measure
Strength Ability to resist breaking Yield stress
Energy or work
Ability to withstand impact or
Toughness resist breaking
necessary to fracture
material
Ability to resist Scores on hardness
Hardness abrasion/scratching tests
Gradual, continuing
Creep deformation under an Creep strength
applied constant stress
Material Selection
• “The materials selected for a design often will
determine the fabrication processes that can be
used to manufacture the product, its
performance characteristics, and its recyclability
and environmental impact. As a result,
engineers should acquire a robust
understanding of material characteristics and the
criteria that one should use in making material
selections.”
- Voland, Engineering by Design, Addison-Wesley, 1999, pg. 400
Material Categories
• Metals – iron, steel, aluminum, copper, magnesium,
nickel, titanium, zinc
• Polymers – thermoplastics & thermosets
• Ceramics
• Composites – Carbon fiber, Kevlar & fiberglass,
wood and reinforced concrete
Steel
• Widely used for machine elements
– High strength
– High stiffness
– Durable
– Relative ease of fabrication
• Alloy of Iron, Carbon, Manganese & 1 or
more other significant elements. (Sulfur,
Phosphorus, Silicon, Nickel, Chromium, Molydbenum
and Vanadium)
Carbon
• Carbon has huge effect on strength,
hardness and ductility of steel.
Carbon Content
Strength & Hardness
Ductility ↓
All these curves are
steels.
What do they have in
common?
What is different?
Steel Designation Systems
• AISI – American Iron & Steel Institute
• SAE – Society of Automobile Engineers
• ASTM – American Society for Testing
Materials
General Designation
• General Form AISI:
AISI XXXX
Carbon Content in
Hundredths of a percent
Specific alloy in the
group
2350
2550
4140
1060
Plain Carbon Steel
1. Low Carbon (less than 0.3% carbon)
• Low strength, good formability
• If wear is a potential problem, can be carburized
(diffusion hardening)
• Most stampings made from these steels
• AISI 1008, 1010, 1015, 1018, 1020, 1022, 1025
• Full-Annealing: creates
uniform composition of the
material.
– Soft, low-strength material
– No significant internal stress
RT = Room Temperature
LC = Lower Critical Temperature
UC = Upper Critical Temperature
Stress Relief Annealing
• Stress Relief Annealing
– Done after welding,
machining or cold forming to
relieve residual stresses
minimizing distortions
RT = Room Temperature
LC = Lower Critical Temperature
UC = Upper Critical Temperature
Normalizing
• Similar to annealing but
at a higher temperature
(about 1600°F)
• Higher strength
• Machinability and
toughness are improved
over as-rolled state. RT = Room Temperature
LC = Lower Critical Temperature