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THE NEED FOR MATERIAL SELECTION

Rapid Development in Material Technology:
- Many new materials - Increased use of advanced materials
- New manufacturing methods - Entirely new design configurations feasible
- Properties of existing materials improved - Increased competition between materials
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INTUITIVE METHODS IN MATERIAL SELECTION

1. First best material
The material is selected among the few materials the design engineer is familiar
with
2. Same material as for a similar part
3. Problem solving material selection
A property has given rise to problems. A new material is chosen in the same group
of material with a higher value of the property.
4. Searching material selection
The designer takes more or less randomly into account one requirement at the time.

Drawbacks with Intuitive Methods:
- Important requirements have often given rise to failures in operation.
- First solution at hand is taken which is not very likely to be good solution.
- Unconventional solutions are not considered e.g. advanced materials are not
analysed.
- The solution is typically far from the optimum giving the part poor competitiveness.


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SYSTEMATIC MATERIAL SELECTION

Why? - To make full use of the engineereing materials.
- To avoid unnecessarily expensive structures.
- To avoid failures.


When? - A new product is developed.
- A product is modified and redesigned.
- Failures have occured.


Who? - Design engineers in collaboration with materials engineers.


How ? - Specify the requirements for the component.
- Transfer the requirements to materials properties.
- Find the material groups that satisfy the specification.
- Find the individual materials that satisfy the specification.
- Identify the "best" materials that satisfy the specification.
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CASE STUDY: THE EVOLUTION OF MATERIALS IN VACUUM CLEANERS







(a) the hand-powered bellows cleaner of 1900, largely made of wood and leather
(b) the cylinder cleaner of 1950
(c) the lightweight cleaner of 1985, almost entirely made of polymer
(d) a centrifugal dust-extraction cleaner of 1997









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DESIGN INTRODUCTION
Mechanical design deals with the physical
principles, the proper functioning and the
production of mechanical systems (
Industrial design is the professional service of
creating and developing concepts and
specifications that optimize the function,
value and appearance of products and
systems for the mutual benefit of both user
and manufacturer (Industrial Designers Society of
America)
Types of design:
Original design: involves a new idea or working principle (the ball-point pen, the
compact disc). Need new materials: high-purity silicon enabled the transistor; high-
purity glass, the optical fiber; high coercive-force magnets.
Adaptive or developmental design: takes an existing concept and seeks an incremental
advance in performance through a refinement of the working principle. polymers
replacing metals in household appliances; carbon fiber replacing wood in sports goods.
Variant design: involves a change of scale or dimension or detailing without change of
function or the method of achieving it: the scaling up of boilers, turbines
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DESIGN PROCESS



















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APPROACH TECHNICAL SYSTEM
The analysis of a technical system as
a breakdown into assemblies and
components. Material and process
selection is at the component level.












This approach helps thinking about
alternative designs.

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DESIGN TOOLS AND MATERIALS DATA

















DFM:Design for Manufacture
DFA: Design for Assembly
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FUNCTION, MATERIAL, SHAPE, AND PROCESS
Design problem involving materials investigation and design of materials













- Select the right material from the many thousands that are available.
- Select the right process and manufacture.
- Deterioration of material properties that may occur during service operation
- Consideration is that of economics: What will the finished product cost?
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CASE STUDY: DEVICES TO OPEN CORKED BOTTLES



The market need: a device is
sought to allow access to wine
contained in a corked bottle.













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SOME CORK REMOVERS







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THE FAMILIES OF ENGINEERING MATERIALS



Advanced material:
those used in high-
technology
applications:
semiconductors,
biomaterials, smart
materials, and
nanoengineered
materials.







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METALS
Metals: composed of
one or more metallic
elements (such as iron,
aluminum, copper,
titanium, gold, and
nickel), and often also
nonmetallic elements
(for example, carbon,
nitrogen, and oxygen) in
relatively small amounts.








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CERAMICS
Ceramics: are
compounds between
metallic and
nonmetallic elements;
they are most
frequently oxides,
nitrides, and carbides.











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POLYMERS
Polymers: are organic
compounds that are chemically
based on carbon, hydrogen, and
other nonmetallic elements
(viz.O,N, and Si) and they have
very large molecular structures,
often chain-like in nature that
have a backbone of carbon
atoms.









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COMPOSITES
Composite is composed of two (or more) individual materials, which come from
the categories discussed aboveviz., metals, ceramics, and polyme.
The design goal of a composite is to achieve a combination of properties that is not
displayed by any single material, and also to incorporate the best characteristics of each
of the component materials.










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PROPERTY-PROFILE

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MECHANICAL PROPERTIES



















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OTHERS PROPERTIES