1. Design in Materials Engineering
MSE 401

2. Course Description
Classes of materials and materials data in design.
Materials indices in design and designing against failure.
Selection of materials and manufacturing processes in design.
Process data and indices.
Materials and industrial design, materials and the environment, Engineering ethics (law, contracts, code of ethics).
Capable of working individually and within a team especially

3. Grading Scheme:
Absence from a quiz, lab. or an examination will result in zero grade.
Midterm
20%
Lab work
10%
Final
30%
Project
40%

4. Books
Text book
1) M. F. Ashby, Materials Selection in Mechanical Design, 3rd edition, Butterworth-Heinemann, ) Charles B. Fleddermann, Engineering Ethics, 3rd edition, Prentice Hall, 2007.
Reference Books
1) M.M. Farag, Materials Selection for Engineering Design, Prentice Hall, ) G.E. Dieter, L.C. Schmidt, Engineering Design, 4th edition, McGraw-Hill, 2008.

5. M. F. Ashby, Materials Selection in Mechanical Design
This book (5 chapters) is about mechanical design, and the role of materials in it.
Mechanical components have mass; they carry loads; they conduct heat and electricity; they are exposed to wear and to corrosive environments; they are made of one or more materials; they have shape; and they must be manufactured.

6. Course Outline Week Topics 1
Introduction to Materials Design and Process 2
Classes and Properties of Engineering Materials in Design 3
Materials Data and Property Charts in Design 4
Materials Data and Property Charts in Design (cont.) 5
Material Selection in Design (steps of materials selection and design, screening, ranking, decision making) 6
Material indices in design (structural and material index) 7
Designing against failure
(types of failure, safety factor, loading types, designing for high temperature and cyclic loading, resilience, etc.) 8
Midterm I 9
Student Project Presentations 10 11 12 13 14

7. Road Map
Explain the interdependency of product function, material, process, and geometry
Describe fundamental material classes
Define and characterize mechanical and physical properties
Describe and apply methods to evaluate material selection
Differentiate and select primary, secondary , and tertiary processes
Understand and apply methods to select appropriate manufacturing processes
Estimate the costs of manufacturing a product.

8. Materials 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.
Even then the designer must understand the material to be able to design the product.

9. Evolution of engineering materials

10. Engineering materials are evolving faster, and the choice is wider than ever before.
Examples of products in which a new material has captured a market are as common
plastic bottles.
aluminium cans.
polycarbonate eyeglass lenses.
carbon-fiber golf club shafts.

11. 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

12. Design Process Starting point Market need or a new idea End point
product specification of a product that embodies the idea

14. Product Technical system Sub-assembles Components
Design converts the inputs into the outputs
The resulting arrangement is called the function-structure or function decomposition of the system. The function-structure gives a systematic way of assessing design options.

15. The design proceeds by developing concepts to perform the functions in the function structure, each based on a working principle.
The next stage, embodiment, takes the promising concepts and seeks to analyze their operation at an approximate level.
The embodiment stage ends with a feasible layout, which is then passed to the detailed design stage.

16. The consequences of choices made at the concept or embodiment stages may not become apparent until the detail is examined.
The trial paths have dead-ends, and they loop back. It is like finding a track across difficult terrain — it may be necessary to go back many times if, in the end, we are to go forward. Once a path is found, it is always possible to make it look linear and logical.

17. Types of design Original design; (a new idea or working principle)
Adaptive design (seeks an incremental advance in performance through a refinement of the working principle)
Variant design (a change of scale or dimension or detailing without change of function)

18. Design Tools

19. Materials selection enters each stage of the design.
Ex; a polymer may be the best choice for one concept, a metal for another, even though the function is the same. The problem, at this stage, is not precision and detail; it is breadth and speed of access: how can the vast range of data be presented to give the designer the greatest freedom in considering alternatives?
At the embodiment stage the landscape has narrowed. Here we need data for a subset of materials, but at a higher level of precision and detail. These are found in the more specialized handbooks and software that deal with a single class or sub-class of materials
The final stage of detailed design requires a still higher level of precision and detail, but for only one or a very few materials. Such information is best found in the data-sheets issued by the material producers themselves, and in detailed databases for restricted material classes

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

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

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

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

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

25. Cordless screwdriver

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

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

28. Manufacturing
This is a key question which has a massive influence on materials selection.
e.g. The frame, what materials could we use?

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

30. Bike Frame

31. Frame Design Detail

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

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

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

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

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

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

38. The interaction between function, material, shape, and process lies at the heart of the material selection process

39. Case study: devices to open corked bottles

42. End of chapters 1 and 2