Chapter 9 The Materials Selection Process-Books Pdf

Chapter 9 THE MATERIALS SELECTION PROCESS
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Chapter 9 Goal and objectives, The overall goal of this chapter is to illustrate how systematic. selection procedures can be used to select optimum materials and. processes for a given component, The main objectives are to illustrate how to. 1 Analyze material performance requirements for a given. application, 2 Create alternative solutions screen them and then rank the viable. candidates, 3 Use quantitative methods in materials selection. 4 Incorporate computer methods in the selection process. 5 Find reliable sources of material properties, Materials and Process Selection for Engineering Design Mahmoud Farag 2.
The nature of the selection process, Selecting the optimum combination of material and process. cannot be performed at one certain stage in the history of a. project it should gradually evolve during the different stages of. product development, After identifying the function of the component the following. questions become important, What are the primary design and material requirements. What are the secondary requirements and are they necessary. Materials and Process Selection for Engineering Design Mahmoud Farag 3. General steps in materials selection, 1 Analysis of the performance requirements. 2 Development of alternative solutions to the problem. 3 Evaluation of the different solutions, 4 Decision on the optimum solution.
Materials and Process Selection for Engineering Design Mahmoud Farag 4. Fig 9 1 Major stages of design and the related stages of materials selection I. Stages of Design Stages of Materials Selection, Preliminary and Conceptual Analysis of material performance. Design requirements, Translate marketing ideas into Creating alternative material and. industrial design leading to broad process solutions for the optimum. description of the product What is concept, it What does it do How does it do. it How much should it be, Formulate product specifications Initial Screening. develop various concepts and select, the optimum concept Use the critical requirements of each.
Decompose the product into part to define the performance. subassemblies and identify the requirements of the material Start. different parts of each subassembly with all materials available and. Specifying the main function of narrow down the choices on the basis. each part and identify their critical of the rigid requirements. requirements, Materials and Process Selection for Engineering Design Mahmoud Farag 5. Fig 9 1 Major stages of design and the related stages of materials selection II. Stages of Design Stages of Materials Selection, Configuration Embodiment Comparing Alternative Solutions. Use soft material requirements to, Develop a qualitative sketch of each further narrow the field of possible. part giving only the order of materials to a few optimum. magnitude of the main dimensions but candidates, showing the main features walls. bosses ribs holes grooves etc, Materials and Process Selection for Engineering Design Mahmoud Farag 6.
Fig 9 1 Major stages of design and the related stages of materials selection III. Stages of Design Stages of Materials Selection, Detail Parametric Design Selection of Optimum Solution. Determine the dimensions and Use the optimum materials and. features of the parts based on a matching manufacturing processes. specific material and a manufacturing to make detail designs. process taking into account the design Compare alternative combinations. limitations the manufacturing taking into account the elements of. process weight concerns space cost, limitations etc The cost must now be Select optimum combination of. considered in detail design material manufacturing. Generation of an alternative detail process, design which requires selecting a. design based on alternative materials, and evaluation against requirements. Materials and Process Selection for Engineering Design Mahmoud Farag 7. Analysis of material performance, requirements, The material performance requirements can be divided into 5 broad.
categories, Functional requirements, Processability requirements. Reliability requirements, Resistance to service conditions. Materials and Process Selection for Engineering Design Mahmoud Farag 8. Creating alternative solutions, Having specified the material requirements the rest of the selection. process involves the search for the material that would best meet. those requirements, The starting point is the entire range of engineering materials. At this stage it is essential to open up channels in different. directions A steel may be the best material for one design. concept while a plastic is best for a different concept even. though the two designs provide similar functions, The importance of this phase is that it creates alternatives without.
much regard to their feasibility, Materials and Process Selection for Engineering Design Mahmoud Farag 9. Initial screening of solutions I, Rigid materials and process requirements. Initial screening of materials can be achieved by first classifying their. performance requirements into two main categories, Rigid or go no go requirements. Soft or relative requirements, Materials that do not satisfy the rigid requirements are eliminated. For example metals and alloys are eliminated when selecting. materials for an electrical insulator, Materials and Process Selection for Engineering Design Mahmoud Farag 10.
Initial screening of solutions II, Cost per unit property method. In the case of tensile members the cost of unit strength. can be used for initial screening Materials with lower cost. per unit strength are preferable If an upper limit is set for. the quantity C S then materials satisfying this, condition can be identified and used as possible candidates. for more detailed analysis in the next stage of selection. Table 9 1 gives some formulas for cost per unit property. under different loading conditions, Materials and Process Selection for Engineering Design Mahmoud Farag 11. Initial screening of solutions III, Table 9 1 Formulas for estimating cost per unit property. Cross section and loading condition Cost per unit strength Cost per unit stiffness. Solid cylinder in tension or compression C S C E, Solid cylinder in bending C S 2 3.
Solid cylinder in torsion C S 2 3, Solid cylindrical bar as slender column C E1 2. Solid rectangle in bending C S 1 2, Thin walled cylindrical pressure vessel C S. Materials and Process Selection for Engineering Design Mahmoud Farag 12. Initial screening of solutions IV, Case study 9 1 Selecting a beam material for minimum cost I. A simply supported beam of rectangular cross section of length. 1 meter width 100 mm and no restriction on the depth is. subjected to a load of 20 kN in its middle, The main design requirement is that the beam should not suffer. plastic deformation as a result of load application. Select the least expensive material for the beam from Table 9 2. Materials and Process Selection for Engineering Design Mahmoud Farag 13. Initial screening of solutions IV, Case study 9 1 Selecting a beam material for minimum.
Table 9 2 Characteristics of candidate materials for the beam. Material Working stress a Specific Relative Cost of. MPa ksi gravity cost b unit, Steel AISI 1020 normalized 117 17 7 86 1 0 73. Steel AISI 4140 normalized 222 32 7 86 1 38 0 73, Aluminum 6061 T6 temper 93 13 5 2 7 6 1 69. Epoxy 70 glass fibers 70 10 2 2 11 9 2 26, a The working stress is computed from yield strength using a factor of safety of 3. b The relative cost per unit weight is based on AISI 1020 steel as unity Material and processing. costs are included in the relative cost, Materials and Process Selection for Engineering Design Mahmoud Farag 14. Initial screening of solutions IV, Case study 9 1 Selecting a beam material for minimum.
Based on Table 9 2 and the appropriate formula from. Table 9 1 the cost of unit strength for the different. materials is calculated and the results are given in the last. column of Table 9 2, The results show that steels AISI 1020 and 4140 are. equally suitable while Al 6061 and epoxy glass are more. Materials and Process Selection for Engineering Design Mahmoud Farag 15. selection procedures can be used to select optimum materials and processes for a given component The main objectives are to illustrate how to 1 Analyze material performance requirements for a given application 2 Create alternative solutions screen them and then rank the viable candidates 3 Use quantitative methods in materials

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