Materials Selection for Engineering Design

Materials Selection The designer of any product, other than software must get involved with material selection. The designer of any product, other than software must get involved with material selection. Only occasionally will the exact grade of material be specified by the customer. Only occasionally will the exact grade of material be specified by the customer. Even then the designer must understand the material to be able to design the product. Even then the designer must understand the material to be able to design the product.

Decisions, decisions! So many materials, so much information. How do we decide? How do we begin to choose? First we need to look at the function of the product – product analysis

Product Analysis Just what it says – analyse the product! Just what it says – analyse the product! What does it do? What does it do? How does it do it? How does it do it? Where does it do it? Where does it do it? Who uses it? Who uses it? What should it cost? What should it cost?

Case Study – a bike What is the function of a bike – obvious? What is the function of a bike – obvious? How does the function depend on the type of bike? How does the function depend on the type of bike? Racing Racing Touring Touring Mountain bike Mountain bike Commuter Commuter Childs Childs

Case Study – a bike (2) How is it made to be easily maintained? How is it made to be easily maintained? What should it look like (colours etc.)? What should it look like (colours etc.)? What should it cost? What should it cost? How has it been made comfortable to ride? How has it been made comfortable to ride? How do the mechanical parts work and interact? How do the mechanical parts work and interact?

Component or system? 1 st problem is……. 1 st problem is……. Is it one component or a system of components working together? A spanner is a component, a cordless screwdriver is a system.

System Analysis When we analyse a system we need to break the system down into individual components and then analyse each one. When we analyse a system we need to break the system down into individual components and then analyse each one.

Cordless screwdriver

System Analysis – the bike The bike breaks down (we hope not!) into various parts: Frame Frame Forks Forks Wheels Wheels Saddle Saddle Etc. Etc.

System Analysis – the bike (2) We now need to look at the following for each part: Requirements (mechanical, ergonomic, aesthetic etc.) Requirements (mechanical, ergonomic, aesthetic etc.) Function Function How many are going to be made? How many are going to be made? What manufacturing methods are we going to use? What manufacturing methods are we going to use?

Manufacturing Oh No! We have to actually make it! This is a key question which has a massive influence on materials selection. e.g. The frame, what materials could we use?

Frame Materials Steel – Steel – Strong, stiff, heavy, but cheap Aluminium – Aluminium – weaker, lighter, more expensive than steel Composite (CFRP) – Composite (CFRP) – strong, stiff, very light, but expensive to buy and to fabricate

Bike Frame

Frame Design Detail

What Properties? Mechanical – Mechanical – Strength, modulus etc. Physical – Physical – Density, melting point. Electrical – Electrical – Conductivity, resistivity. Aesthetic – Aesthetic – Appearance, texture, colour Processability – Processability – Ductility, mouldability And last, but not least………. And last, but not least………. Cost, cost, cost!

Where do I find the data? Textbooks Textbooks Databooks Databooks Manufacturer’s literature Manufacturer’s literature Internet Sites Internet Sites

Textbooks Good for general information Good for general information Some have tables of properties Some have tables of properties Not good for detailed specifications and properties. Not good for detailed specifications and properties. A useful first point of call A useful first point of call

Databooks One of the quickest sources of detailed information. One of the quickest sources of detailed information. Usually contain grades and specifications as well as properties. Usually contain grades and specifications as well as properties. Small and perfectly formed – pocketbooks Small and perfectly formed – pocketbooks Easy to navigate around Easy to navigate around

Manufacturer’s literature Variable in quality and usefulness. Variable in quality and usefulness. Often only cover their products. Often only cover their products. Usually do not compare materials. Usually do not compare materials. Can be biased. Can be biased. Good for final selection before ordering. Good for final selection before ordering.

Internet Sites Can be a real minefield. Can be a real minefield. Lots of poorly presented information. Lots of poorly presented information. Google searches bring up lots of rubbish. Google searches bring up lots of rubbish. Hard to find technical information. Hard to find technical information. Best to use non-commercial sites. Best to use non-commercial sites.

Materials Selection Charts

23 Modulus - Density Chart Modulus spans 5 orders of magnitude Modulus spans 5 orders of magnitude 0.01 GPa for foams to 1000 GPa for diamond 0.01 GPa for foams to 1000 GPa for diamond The charts therefore use logarithmic scales, where twice the distance means ten times. The charts therefore use logarithmic scales, where twice the distance means ten times. This makes it possible to show the full range on one chart, This makes it possible to show the full range on one chart,

Materials Selection Charts

Allow easy visualisation of properties Allow easy visualisation of properties Show lots of different materials Show lots of different materials Can be ‘drilled down’ to specifics Can be ‘drilled down’ to specifics Show balances of properties e.g. strength v cost Show balances of properties e.g. strength v cost Ideal for a first ‘rough cut’ selection Ideal for a first ‘rough cut’ selection

Summary 1. Think about the design from ergonomic and functional viewpoint. 2. Decide on the materials to be used. 3. Choose a suitable process that is also economic Steps 2 & 3 may be iterative. Don’t forget the ……………

Bigger Picture Is the product performance driven or cost driven? This makes a huge difference when choosing materials.

Manufacturing Process Although we usually choose materials first sometimes it is the shape and process which is the limiting factor.

Case Study (2) Drink Container What are the requirements? What are the requirements?

Case Study (2) Drink Container Provide leak free environment for storing liquid. Provide leak free environment for storing liquid. Comply with food standards & protect liquid from health hazards. Comply with food standards & protect liquid from health hazards. For fizzy drinks, withstand pressure. For fizzy drinks, withstand pressure. Brand image & identity Brand image & identity Easy to open Easy to open Easy to store & transport Easy to store & transport Cheap for high volumes Cheap for high volumes

Possible Materials Steel Steel Aluminium Aluminium Glass Glass Plastic Plastic Paper Paper