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  • 7/30/2019 Most Commonly Used Materials and Selection

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    Ken Youssefi SJSU, ME dept. 1

    Material Selection

    Function

    Material Shape

    Process

    Material selection and process cannot be separated from the shape

    and the function of the product, two way interaction.

    Function dictates the choice

    of material and shape.

    Process interacts

    with shape.

    Process is influenced

    by material

    Shape restricts thechoice of material

    and process.

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    Ken Youssefi SJSU, ME dept. 2

    Engineering Materials

    Materials

    Metals Plastics

    Steel

    Stainless steel

    Die & tool steel

    Cast iron

    Ferrous Non-ferrous

    Aluminum

    Copper

    Zinc

    Titanium

    Tungsten

    Thermoplastics

    Acrylic

    Nylon

    ABS

    Polyethylene

    Polycarbonate

    PVC

    Thermosets

    Phenolic

    Polymide

    Epoxies

    Polyester

    Elastomers

    Rubber

    Polyurethane

    Silicone

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    Ken Youssefi SJSU, ME dept. 3

    Engineering Materials

    Materials

    Metals PlasticsCeramics

    Glass

    Carbides

    Nitrides

    Graphite

    Diamond

    Glasses

    Glass ceramics

    Composites

    Reinforced

    plasticsMetal-Matrix

    Ceramic-Matrix

    Laminates

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    Ken Youssefi SJSU, ME dept. 4

    Most Commonly Used Materials

    The following 25 materials are the most commonly used materials in the

    design of mechanical products; in themselves they represent the broad

    range of other materials.

    Steel and Cast Iron

    1. 1020 (plain carbon steel, hot-rolled or cold-drawn)

    2. 1040 (plain carbon steel, hot-rolled or cold-drawn)

    3. 4140 (heat-treated alloy steel, chromium-molybdenum)

    4. 4340 (heat-treated alloy steel, nickel-chromium-molybdenum)

    5. S30400 (stainless steel)

    6. S316 (stainless steel)

    7. O1 (tool steel)

    8. ASTM20-60 (gray cast iron)

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    Ken Youssefi SJSU, ME dept. 5

    Most Commonly Used Materials

    Aluminum and Copper Alloys

    9. 2024 (aluminum, O, T3, T4 or T6)

    10. 3003 (aluminum, H12 or H16)

    11. 6061 (aluminum, T6)

    12. 7075 (aluminum, T6)

    13. C268 (copper)

    Other metals

    14. Titanium 6-415. AZ63A (magnesium)

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    Ken Youssefi SJSU, ME dept. 6

    Most Commonly Used Materials

    Plastics

    16. ABS17. Polycarbonate

    18. Nylon 6/6

    19. Polypropylene

    20. Polystyrene

    Ceramics

    21. Alumina

    22. Graphite

    Composite materials

    23. Douglas fir

    24. Fiberglass

    25. Graphite/epoxy

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    Ken Youssefi SJSU, ME dept. 7

    Application of Most Commonly Used Materials

    Component Material

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    Ken Youssefi SJSU, ME dept. 8

    Application of Most Commonly Used Materials

    Component Material

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    Ken Youssefi SJSU, ME dept. 9

    Application of Most Commonly Used Materials

    Component Material

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    Ken Youssefi SJSU, ME dept. 10

    Properties of Most Commonly Used Materials

    Ultimate

    Strength in

    tension

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    Ken Youssefi SJSU, ME dept. 11

    Properties of Most Commonly used Materials

    Yieldstrength

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    Ken Youssefi SJSU, ME dept. 12

    Properties of Most Commonly used Materials

    Fatigue

    endurance limit

    (strength under

    cyclic loading)

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    Ken Youssefi SJSU, ME dept. 13

    Properties of Most Commonly used Materials

    Density

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    Ken Youssefi SJSU, ME dept. 14

    Cost of Most Commonly used Materials

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    Ken Youssefi SJSU, ME dept. 15

    ExampleMaterials for table legs

    Luigi Tavolino, furniture designer, conceives of a lightweight table of

    daring simplicity: a flat sheet of toughened glass supported on slender,

    unbraced, cylindrical legs. The legs must be solid and as light as

    possible (to make the table easier to move). They must support the table

    top and whatever is placed upon it without buckling.What materials

    could one recommend.

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    Ken Youssefi SJSU, ME dept. 16

    ExampleMaterials for table legs

    The Model

    The leg is a slender column of density and modulusE. The load

    P and its length l are determined by design (fixed). The radius r ofthe leg is a variable. We wish to minimize the mass m of the leg.

    Objective function

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    Ken Youssefi SJSU, ME dept. 17

    ExampleMaterials for table legs

    The constraint is that the legs must support a design load without buckling.

    Eulers buckling equation

    The weight is minimized by selecting the subset of materials with the

    greatest value of the material index.

    where I= r4/4

    Solving for the free variable , r, and substituting it into the equation for m

    gives,

    Material properties

    =

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    Ken Youssefi SJSU, ME dept. 18

    ExampleMaterials for table legs

    Solving the Eulers formula forr, gives an equation for the thinnest leg

    which will not buckle:

    Material properties

    The thinnest leg is that made of the material with the largest value of thematerial index.

    Two material indices,

    To minimize the weight, both have to be maximize.

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    Ken Youssefi SJSU, ME dept. 19

    Procedure for deriving material indices

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    Ken Youssefi SJSU, ME dept. 20

    Modulus of Elasticity (E) vs. Density () Charts

    Constant

    guidelines

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    Ken Youssefi SJSU, ME dept. 21

    Modulus of Elasticity (E) vs. Density () Charts

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    Ken Youssefi SJSU, ME dept. 22

    Modulus of Elasticity (E) vs. Density () Charts

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    Ken Youssefi SJSU, ME dept. 23

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    Ken Youssefi SJSU, ME dept. 24

    Summary of materials for table legs


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