Ken YoussefiProduct Design and Manufacturing, SJSU 1 Most Commonly Used Materials The following 25 materials are the most commonly used materials in the.

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Presentation transcript:

Ken YoussefiProduct Design and Manufacturing, SJSU 1 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 (plain carbon steel, hot-rolled or cold-drawn) (plain carbon steel, hot-rolled or cold-drawn) (heat-treated alloy steel, chromium-molybdenum) (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)

Ken YoussefiProduct Design and Manufacturing, SJSU 2 Most Commonly Used Materials Aluminum and Copper Alloys (aluminum, O, T3, T4 or T6) (aluminum, H12 or H16) (aluminum, T6) (aluminum, T6) 13.C268(copper) Other metals 14.Titanium AZ63A (magnesium)

Ken YoussefiProduct Design and Manufacturing, SJSU 3 Most Commonly Used Materials Plastics 16.ABS 17.Polycarbonate 18.Nylon 6/6 19.Polypropylene 20.Polystyrene Ceramics 21.Alumina 22.Graphite Composite materials 23.Douglas fir 24.Fiberglass 25.Graphite/epoxy

Ken YoussefiProduct Design and Manufacturing, SJSU 4 Application of Most Commonly Used Materials Component Material

Ken YoussefiProduct Design and Manufacturing, SJSU 5 Application of Most Commonly Used Materials Component Material

Ken YoussefiProduct Design and Manufacturing, SJSU 6 Application of Most Commonly Used Materials Component Material

Ken YoussefiProduct Design and Manufacturing, SJSU 7 Properties of Most Commonly Used Materials Ultimate Strength in tension

Ken YoussefiProduct Design and Manufacturing, SJSU 8 Properties of Most Commonly used Materials Yield strength

Ken YoussefiProduct Design and Manufacturing, SJSU 9 Properties of Most Commonly used Materials Fatigue endurance limit (strength under cyclic loading)

Ken YoussefiProduct Design and Manufacturing, SJSU 10 Properties of Most Commonly used Materials Density

Ken YoussefiProduct Design and Manufacturing, SJSU 11 Cost of Most Commonly used Materials

Ken YoussefiProduct Design and Manufacturing, SJSU 12 Example – Materials 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.

Ken YoussefiProduct Design and Manufacturing, SJSU 13 Example – Materials for table legs The Model The leg is a slender column of density ρ and modulus E. The load P and its length l are determined by design (fixed). The radius r of the leg is a variable. We wish to minimize the mass m of the leg. Objective function

Ken YoussefiProduct Design and Manufacturing, SJSU 14 Example – Materials for table legs The constraint is that the legs must support a design load without buckling. Euler’s buckling equation The weight is minimized by selecting the subset of materials with the greatest value of the material index. where I = πr 4 /4 Solving for the free variable, r, and substituting it into the equation for m gives, Material properties =

Ken YoussefiProduct Design and Manufacturing, SJSU 15 Example – Materials for table legs Solving the Euler’s formula for r, 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 the material index. Two material indices, To minimize the weight, both have to be maximize.

Ken YoussefiProduct Design and Manufacturing, SJSU 16 Procedure for deriving material indices

Ken YoussefiProduct Design and Manufacturing, SJSU 17 Modulus of Elasticity (E) vs. Density (ρ) Charts Constant guidelines

Ken YoussefiProduct Design and Manufacturing, SJSU 18 Modulus of Elasticity (E) vs. Density (ρ) Charts

Ken YoussefiProduct Design and Manufacturing, SJSU 19 Modulus of Elasticity (E) vs. Density (ρ) Charts

Ken YoussefiProduct Design and Manufacturing, SJSU 20

Ken YoussefiProduct Design and Manufacturing, SJSU 21 Summary of materials for table legs