Cambridge Engineering Selector CES 4 EduPack Rolling Presentation This presentation will roll automatically. Use the up-arrow  and down-arrow  keys to move at your own speed, or ‘Esc’ to quit...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Introduction: The CES4 EduPack The CES4 EduPack contains a complete educational resource toolkit for courses on Material and Process Selection. The main elements are: Professor Mike Ashby’s best-selling textbook ‘Materials Selection in Mechanical Design’: the methodological base A comprehensive set of Powerpoint presentations for lecturers Exercises and solutions for students Handouts for students The CES4 software: for demonstrations, exercises, and projects

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Introduction This presentation focuses on the CES4 Educational software and its unique graded databases of materials and manufacturing processes. Three different levels of information are provided in the databases: The Level 1 package helps to inspire newly-enrolled engineering students with real interest in materials, and encourages exploration of the world of materials. The Level 2 package provides a serious tool with a structured methodology for use in intermediate courses (years 2-4). It assists understanding of the role of materials and processes in design and skill in selecting them. The Level 3 package provides senior year and graduate students of engineering materials and design with a professional tool: to assist major design and research projects.

The Level 1 Database...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The Browse tool in CES4 is used to view the contents of the database. The Material Universe data table contains all of the main classes of materials...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Tree View the contents of the Metals branch of the tree

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Tree

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Tree Double-clicking on Copper Alloys displays its data sheet

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Copper Alloys Each datasheet contains a description of the material... … a picture of its use in a well-known product...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Copper Alloys Some General Properties… Mechanical Properties… Thermal, Electrical and Optical Properties… Typical uses

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION … and at the end of every datasheet, links between this material and items in other tables. Clicking on the Process link shows ways to process Copper Alloys

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Processes for Copper alloys. Clicking on one displays its details

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Tree Very similar data is available for all other materials - eg examine information for Polycarbonate...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Tree

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Browse Polycarbonate

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Level 1 Material Datasheet Polycarbonate

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The EduPack Level 1 database contains 68 typical material records...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Materials Tree Ceramics and Glasses...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Composites: Polymer matrix Metal matrix...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Polymer Foams...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Metals...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Natural Materials...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

and Polymers.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Level 1 Process tree The Process Universe data table contains three main classes of processes... The EduPack Level 1 database also contains 65 typical process records...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Joining processes...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Shaping processes...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

… and Surface Treatment processes.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

The datasheet for Die Casting is typical of all datasheets for Shaping processes

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Level 1 Process Datasheets Diecasting It contains a description of the process... … a schematic diagram of how the process works...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Some Physical Attributes… Some Economic Attributes… Process and Shape types... Typical uses... … and links to other tables

The Level 2 Database

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Materials in the EduPack Level 2 database contain more information than the materials in the Level 1 database...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Energy Content (a measure of environmental impact)... 4 more Mechanical properties, 2 more Thermal properties...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION 4 more Electrical properties Resistance to 11 common Environments

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Similarly, Processes in the EduPack Level 2 database contain more information than the processes in the Level 1 database. … and useful supporting information, Tradenames, etc.

Searching the database

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The Search tool is used to search the database…

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Search Plexiglas What is “Plexiglas?” Click on this search result to find out...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The search tool can be used to search for material designations, tradenames, typical uses, etc

Optimal Selection

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Select The Select view is used to select materials and processes from the database, using the Ashby methodology, described in the text book: ‘Materials Selection in Mechanical Design’ The selection process involves performing a series of independent selection stages. CES4 keeps track of the results...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION There are three selection tools… Graphical selection will be discussed here. The selection Results window shows the number of materials that have passed all selection stages so far. (All materials currently pass because no stages have been performed.)

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Case Study: Materials for Flywheels Ashby shows that to maximise kinetic energy per unit mass, it is necessary to find the material with the highest value of strength/density, with an adequate fracture toughness and reasonable price. Consider selecting a material for the rotor of a high-speed flywheel... Perform two materials selection stages...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The first selection stage is a chart of Elastic Limit (strength) vs Density. Each bubble represents a material. The size of the bubble indicates the range of its properties. Clicking on a bubble adds a label... …double-clicking opens the datasheet.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

A line of gradient = 1 is a contour of constant strength/density ratio. Materials above the line have a high value of strength/density… …they pass the selection and appear in the results list. Materials below the line have low values of strength/density. They fail the selection and are plotted in gray.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Flywheel case study The second selection stage is a chart of Fracture Toughness vs raw material price

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Select tough materials with a modest price

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Display only the materials that passed both selection stages...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Now return to the previous selection stage...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION … and show only the materials that passed both stages...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Now zoom-in to the area of interest...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION … and move the selection line upwards to maximize the strength/density performance...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Two remaining materials are: Carbon Fibre Reinforced Plastic (CFRP) & Glass Fibre Reinforced Plastic (GFRP) CFRP has high performance and a high price… good for flywheels to be used in aerospace applications; … for example, energy storage in satellites. GFRP has lower (but still good) performance, but a considerably lower price… it is good for flywheels in automotive and other cost-sensitive applications.

The Level 3 Database

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The EduPack Level 3 database is the full professional version of CES4. It contains over 3000 materials… all of the main classes; covered in considerable depth.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

For example, there are 13 different records for Aluminium 7075, representing the most widely used heat treatments.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Each material has a substantially expanded data set, including: composition details; tradenames; equivalent designations; and many more mechanical, thermal, electrical and other properties.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The information in the database is impressive in its detail...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION It has 1700 Metals...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION …520 Polymers...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION 470 Ceramics & Glasses

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION 310 Composites

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION 75 Natural materials

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION and 130 polymer and metal foams

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The process database is expanded in a similar way. For example, it has 21 deformation processes, instead of 3 in the level 1 & 2 database

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Each process has a long list of attributes, including a cost model. This estimates the cost of making a component by the process, in terms of the important production variables, batch size, overhead rate, etc.

Optional Add-On CES4 CAMPUS Plastics Database

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION CAMPUS The optional CES4 CAMPUS database contains grade-specific polymer data on 5,500 industry-standard plastics resins from 31 producers. It is particularly useful for Polymer science and engineering courses and polymer research.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION For example, there are 327 specific polymer grades from BASF...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Each record has a large amount of pedigreed information, including functional data. It is measured to exacting ISO standards.

Optional Add-On Mil-Handbook 5 and 17 Databases

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The CES4 MIL-Handbook database contains industry- standard design data for aerospace metals (MIL-HDBK-5) and composites (MIL-HDBK-17). It is particularly suited to senior year and graduate aerospace engineers.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION There are 60 different records for Aluminium 7075-T6, in the MIL-HDBK-5 table.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Each record has a large amount of pedigreed information, measured on a specified statistical basis, including functional data.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION The MIL-HDBK-17 table has ‘raw’ handbook data for several important aerospace composite systems, as well as special summary records which combine the results of a number of tests into ‘designer- friendly’ form.

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION ‘Raw’ Handbook data...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION ‘Summarised’ data...

UNLOCK THE POTENTIAL OF MATERIALS INFORMATION Conclusions The CES4 EduPack provides a complete educational resource toolkit for courses in material and process selection. It includes a best-selling text, lecture notes, student handouts, exercises, user-friendly software and unique databases. Aspects of the material can be used throughout an engineering course: from the freshman (first) year to ‘Capstone’ and graduate level. The approach is tried and tested, and used in over 400 Universities world-wide. Visit: for further information