Mechanical Materials Selection

Mechanical Design 1
(MCE 321)
Materials
Dr. Lotfi Romdhane
lromdhane@aus.edu
Mechanical Design I (MCE 321)
Summer 2016
L. Romdhane, Summer 2016, 11:16 AM -- 1--
Chapter 2
Materials
2 Materials
Chapter
Outline
2-1
Material Strength and Stiffness
2-2
The Statistical Significance of Material Properties
2-3
Strength and Cold Work
2-4
Hardness
2-5
Impact Properties
2-6
Temperature Effects
2-7
Numbering Systems
2-8
Sand Casting
2-9
Shell Molding
2-10
Investment Casting
2-11
Powder-Metallurgy Process
2-12
Hot-Working Processes
2-13
Cold-Working Processes
2-14
The Heat Treatment of Steel
2-15
Alloy Steels
2-16
Corrosion-Resistant Steels
2-17
Casting Materials
2-18
Nonferrous Metals
2-19
Plastics
2-20
Composite Materials
2-21
Materials Selection
Engineering Materials
The menu of engineering materials. The basic families of metals, ceramics, glasses,
polymers, and elastomers can be combined in various geometries to create hybrids
Tests and Mechanical Properties
Schematically structured data for design allowable and the characteristics of a material
that relate to its ability to be formed, joined, and finished; records of experience with its
use; and design guidelines for its use
Tests and Mechanical Properties

Basic Design-Limiting Material Mechanical Properties and Their Usual SI Units*
HB
Standard Tensile Test
Figure illustrates a typical tension-test specimen and its

characteristic dimensions. The original diameter d0 and the gauge
length l0 , used to measure the deflections, are recorded before the
test is begun
The specimen is then mounted in the test machine and slowly

loaded in tension while the load P and deflection are observed.
The deflection, or extension of the gage length, is given by l-l0 where
l is the gauge length corresponding to the load P. The normal strain
is calculated from
In the linear range, the uniaxial stress-strain relation is given by

Hooks law as
Engineering Stress-Strain Curve (steel)

Point el is called the elastic limit.
S is the yield point.
Point a is usually 0.2 percent of the original
gauge length.
S or S is the ultimate, or tensile, strength.
y
ut
Engineering Materials
Torsional Strength
Torsional strengths are found by twisting solid circular bars and

recording the torque and the twist angle.
ismaxrelated to the angle of twist by
The maximum shear stress
where is in radius, is the radius of the specimen, 0 is the

gauge length, and is the material stiffness property called the
shear modulus or the modulus of rigidity.
The maximum shear stress also related to the applied torque as

1 4
J
r is the polar second moment of area of the cross

where
2
section.
Statistical Significance of Material Properties

The stress-strain diagram depicts the
result of a single tension test. If there
were 1000 nominally identical
specimens, the values of strength
obtained would be distributed between
some minimum and maximum values.
The bar chart depicts the histogram of the probability density. If the data is in
the form of a Gaussian or normal distribution, the probability density function
determined by
1 x 438.3 2
1
f ( x)
exp

17.9 2
2 17.9
has the mean stress 438.3 MPa and the standard deviation 17.9 MPa,
denoted as = 438,17.9 .
Engineers, when ordering property tests, should couch the instructions

so the data generated are enough for them to observe the statistical
parameters and to identify the distributional characteristic.
Hardness
The resistance of a material to penetration by a pointed tool is

called hardness.
Two most common used hardness measuring systems :
Rockwell hardness, the indenters are described as a diamond, a 1.6-mmdiameter ball, and a diamond for scales A, B, and C, respectively, where the load
applied is either 60, 100, or 150 kg.
Brinell hardness, the indenting tool through which force is applied is a ball and
the hardness number HB is found as a number equal to the applied load divided
by the spherical surface area of the indentation .
For steels, the relationship between the minimum ultimate strength

and the Brinell hardness number for 200 HB 450 is found to be
0.5
=
3.4
0.23 12.5
For cast iron =
1.58 86
Temperature Effect
Strength and ductility, or brittleness,
are properties affected by the
temperature for the operating
environment.
The effect of temperature on the
static properties of steels is typified by
the strength versus temperate chart.
There is a substantial increase in
ductility, as might be expected, at
higher temperatures.
Material Selection Process

1. The selection of a material for a machine part or structural member
is one of the most important decisions the designer is called on to
make.
2. The selection process can be as physical, economical, and
processing parameters.
3. One of the basic techniques is to list all important material

properties associated with the design, e.g., strength, stiffness,
density, and cost.
4. Next, for each property, list all available materials and rank them in
order beginning with the best material.
5. Once the lists are formed, select a manageable amount of materials
from the top of each list.
The universe of materials and their attributes

Material Selection
Function, constraints, objectives, and free variables define the boundary

conditions for selecting a material andin the case of load-bearing
componentsa shape for its cross section.
Choosing a material. Design requirements are first

expressed as constraints and objectives. The constraints
are used for screening
The strategy for materials selection. The
four main stepstranslation, screening,
ranking, and documentation
Material Selection Chart : Youngs Modulus
Selection Chart : Youngs Modulus-Density
Example related to material selection

Performance metric P of a structural element is deduced as:
functional
P
requiremen ts
or
geometric material
,
,
F parameters G properties M
P=f(F, G, M) and P= f1(F). f2(G). f3(M)
The example is related to how to select an appropriate materiel to design a light, stiff, end-loaded
cantilever beam having a circular cross section. is the mass of the beam, the stiffness is related to its
material and geometry and = /. Note that = = (3)/(3), where is the end load,
deflection, Youngs modulus, the second moment of area
3EI
D 4 A 2
k 3
with I
64
4
l
and are the diameter and area of the cross section, respectively , we can obtain
F
4kl 3
A
3E
1/ 2
The mass of the beam is given by:
m2

(k )1/ 2 l 5 / 2 1/ 2
3
E
Example related to material selection

We have 3() given by:
f3 (M )
E1 / 2
To minimize m, we need to maximize 3() or maximize
E1 / 2
1
is called material index, and . So, we return now to the draw lines of various
2
values of this ratio in the bubble chart.
Selection Chart : Youngs Modulus-Density
Material Selection
The specification of function, objective, and constraint leads to a materials index.

The combination in the highlighted boxes leads to the index /.
Material Selection Chart : Strength-density

Course
framework
Performance Maximizing criteria
Performance Maximizing criteria
A selection based on the index M = E1/3/ together with the property limit E > 50 GPa.
The materials contained in the search region become the candidates for the next stage
of the selection process.
Material Selection Chart : Strength-density

Specific strength
To minimize weight
Material Selection Chart : Strength-Cost
Example: Material selection

A furniture designer conceives of a lightweight table (see figure): a flat sheet of
toughened glass supported on slender, unbraced cylindrical legs. The legs must be
solid (to make them thin) and as light as possible. They must support the table top
and whatever is placed upon it without buckling. What materials could one
recommend?
Two objectives should be considered:

1) Weight is to be minimized
2) Slenderness should be maximized
having a ratio of:
Max. resistance to buckling/Min weight
We wish to minimize the mass of the leg, given by the objective function
= 2
material density and modulus its legs length. The radius of a leg is a free
variable.
The leg is a slender column of and the maximum load, , it must carry are
determined by the design without buckling.
The elastic buckling load of a column of length and radius is
with = 4/4 where is the second moment of the area of the column. The
load must not exceed . Solving for the free variable, , and substituting it
into the equation for gives
The material properties are grouped together in the last pair of brackets. The weight is
minimized by selecting the subset of materials with the greatest value of the material
index
Now slenderness
Inverting Equation (2) with Fcrit set equal to F gives an equation for the thinnest leg that
will not buckle:
The thinnest leg is that made of the material with the largest value of the material index
2 =
The selection
We seek the subset of materials that have high values of
E2
and . We need the
chart again.
Case study: legs of a Table
Material selection
Maximize for slenderness
Maximize
1/2
to avoid buckling
Possible choices:
Wood
Ceramics
GFRP (glass fibers)
CFRP (carbon fibers)
What about hollow tubes!
Stiffness and strength vs cost

Mechanical Materials Selection

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Mechanical Design 1

L. Romdhane, Summer 2016, 11:16 AM -- 1--

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 2--

Mechanical Design I (MCE 321)

Material Strength and Stiffness

The Statistical Significance of Material Properties

Strength and Cold Work

The Heat Treatment of Steel

L. Romdhane, Summer 2016, 11:16 AM -- 3--

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 4--

Tests and Mechanical Properties

L. Romdhane, Summer 2016, 11:16 AM -- 5--

Tests and Mechanical Properties

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 6--

Standard Tensile Test

Figure illustrates a typical tension-test specimen and its

The specimen is then mounted in the test machine and slowly

In the linear range, the uniaxial stress-strain relation is given by

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 7--

Engineering Stress-Strain Curve (steel)

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 8--

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 9--

Torsional strengths are found by twisting solid circular bars and

where is in radius, is the radius of the specimen, 0 is the

The maximum shear stress also related to the applied torque as

r is the polar second moment of area of the cross

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 10--

Statistical Significance of Material Properties

Engineers, when ordering property tests, should couch the instructions

L. Romdhane, Summer 2016, 11:16 AM -- 11--

The resistance of a material to penetration by a pointed tool is

For steels, the relationship between the minimum ultimate strength

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 12--

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 13--

Material Selection Process

3. One of the basic techniques is to list all important material

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 14--

Material Selection Process

The universe of materials and their attributes

L. Romdhane, Summer 2016, 11:16 AM -- 15--

Function, constraints, objectives, and free variables define the boundary

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 16--

Material Selection Process

Choosing a material. Design requirements are first

L. Romdhane, Summer 2016, 11:16 AM -- 17--

Material Selection Chart : Youngs Modulus

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 18--

Selection Chart : Youngs Modulus-Density

Mechanical Design I (MCE 321)

L. Romdhane, Summer 2016, 11:16 AM -- 19--

Example related to material selection