Goal And Objectives The overall goal of this is to illustrate how systematic selection procedures can be used to select optimum materials and processes for a given component. General Steps In Material Selection : 1. Analysis of the performance requirements. 2. Development of alternative solutions to the problem. 3. Evaluation of the different solutions. 4. Decision on the optimum solution.L Analysis Of Material Performance Requirements The material performance requirements can be divided into 5 broad categories: + Functional requirements. + Processability requirements + Cost “+ Reliability requirements ** Resistance to service conditionsProduct Function Is Interdependent Material eee Properties Product Function Manufacturing Processes Product Geometry |Creating Alternative Solutions “Having specified the material requirements, the rest of the selection process involves the search for the material that would best meet those requirements. +The starting point is the entire range of engineering materials, * A steel may be the best material for one design concept while a plastic is best for a different concept, even though the two designs provide similar functions. “The importance of this phase is that it creates alternatives without much regard to their feasibility.Property Profiles By Family Characteristics strong ‘Ceramics strong —C Polymers ver. very some ductile brittle hardness corrosion resistan medium poor hard fatigue resistance conductivity (heat/electric) creep resistance good conductor good im pact resistance density em perature tolerance good heavy good medium superScreening: How Do We Choose A Material? Product function depends upon... material, manufacturing process, geometry We have to consider all three “ Do we select a few feasible materials first... then select the specific mfg process? OR Do we select a few feasible mfg processes... then select the specific material?Screening: Materials First Approach Application Information 1. Applied loads magnitude cyclic nature (steady, fatigue) rate (slow, impact) duration (creep) 2. Ambient conditions temperature moisture sunlight chemical liquids/vapors 3. Safety 4. CostScreening; Manufacturing Process First Approach Part Information Production volume Part size (overall) Shape capability (features) boss/depression 1D boss/depression >1D holes undercuts (internal/external) uniform walls cross sections (uniform /regular) rotational symmetry captured cavities aAshby’s Methodé = = € é Titanium alloys| AS' HBY D IAGRAM Aluminum alloyg Polymers and. elastomersMaterials Selection prospective materials and processes functional? << reening > eS rejected manufacturable? ~—— materials and processes feasible materials and ati processes rltve << ing performance? 8 best material(s) and processesRating: Material Indices + Given the same cost/volume... which is stronger? index = Strength/cost * Given the same cost/volume... which is stiffer? index = Young’s modulus/costComparing And Ranking Alternatives I Weighted Properties Method I In this method cach material requirement is assigned a certain weight, depending on its importance. +A weighted property value is obtained by multiplying the scaled value of the property by the weighting factor (a). “The weighted property values of each material are then summed to give a performance index (y). The material with the highest performance index (y) is optimum for the application. B = scaled property = numerical value of property x 100 maximum value in the listComparing And Ranking Alternatives I Weighted Properties Method II “For cost, corrosion loss, etc., a lower value is more desirable and the lowest value is rated as 100 Becciled propaty= alumi valuesin the Laie numerical value of property n Material performance index = y= 2 Bi ai is! where i is summed over all the n relevant properties.4. Reaching Final Decision * After ranking of alternatives, candidates that have the most promising performance indices can each now be used to develop a detail design. * Each detail design will exploit the points of strength of the material, avoid the weak points, and reflect the requirements of the manufacturing processes needed for the material. “» After completing the different designs, solutions are then compared, taking the cost elements into consideration in order to arrive at the optimum design-material-process combination.Case Study -Selecting A Beam Material For Minimum Cost + Asimply supported beam of rectangular cross section of length | meter, width 100 mm, and no restriction on the depth is subjected to a load of 20 kN in its middle. The main design requirement is that the beam should not suffer plastic deformation as a result of load application. Select the least expensive material for the beam.Case Study -Selecting A Beam Material For Minimum Cost Table Characteristics of candidate materials for the beam Material Workingstressa Specific Relative Costof MPa ksi gravity cost unit strength SteelAISI1020,normalized 117 17 7.86 1 0.73 SteelAISI4140,normalized 222 32 7.86 1.38 0.73 Aluminum6061,Té6temper 93 To | eae 6 1.69 Epoxy+70%glassfibers 70 102 |) 2 2.26 A The working stress is computed from yield strength using a FOS of 3. b The relative cost per unit weight is based on AISI1020 steel as unity. Material and processing costs are included in the relative cost.THANK YOU