Product Design

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541

BITS Pilani
Pilani | Dubai | Goa | Hyderabad
 BITS Pilani
Pilani | Dubai | Goa | Hyderabad

Session 11: Detail Design

 Pr o d u ct D e si g n Pr o ce ss

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

3 BITS-Pilani, Hyderabad Campus
DESIGN
 Ac ti vi ti e s a n d d e ci s io n in d e ta il d e si g n

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

4 BITS-Pilani, Hyderabad Campus
DESIGN
 M a ke o r b u y d e ci si o n

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

5 BITS-Pilani, Hyderabad Campus
DESIGN
 M a ke o r b u y d e ci si o n

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

6 BITS-Pilani, Hyderabad Campus
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 Ex a m p l e

• Furniture Inn manufactures computer tables. Recently a supplier has offered the tables of the
same quality @ $14 each with an assurance of continued supply. The following is the budget for
4000 units prepared for the quarter ending 30 September 2016:

(a) Should Furniture Inn accept the offer from the

supplier?

(b) (b) What would be the decision if the supplier

offered the tables at $12 each?

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 Ex a m p l e

a) As marginal cost of production is less than the buying price offered by the supplier so Furniture Inn should continue
production of tables. The distribution, administration and fixed production are irrelevant in the decision as
presumptively they will be incurred in either case.
b) As in this case they buy in price $12 is less than the marginal cost of production so Furniture Inn should buy the
tables from the supplier and discontinue production of tables provided other things are favorable.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

8 BITS-Pilani, Hyderabad Campus
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 Ex a m p l e

• Though quantitative considerations are important and may be decisive but make or buy decision
may not be appropriate if relevant qualitative factors are ignored. Some of the qualitative factors
relating to make or buy decision are as follows:
– Quality and reliability of goods to be bought as a defective component may damage the reputation and reliability of
the firm’s ability.
– Reliability of the supplier on timely deliveries of goods as an interruption in the delivery of a component part may
significantly affect a firm’s operations.
– Possibility of ceasing production in near or medium distance future.
– Can guarantee be obtained from the supplier about no price change in foreseeable future? A long term contract with
a reliable supplier may solve this problem.
– Can an alternative use be found for resources made idle by a decision to purchase from outside.
– How long it would take to start manufacturing the product/component again if supplier fails to deliver as promised.
Retaining and rehiring of personnel may be important considerations.
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 Ex a m p l e

– What would be the cost of closing down the production line?

– Foreign exchange rates and their effects on the decision.

– Import policies and their consistency.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

10 BITS-Pilani, Hyderabad Campus
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 C o m m u n ica ti n g d e si g n a n d m a n u fa ctu r i n g
i n fo r m a ti o n
• Critical to quality component – Embodiment design stage

• Yet to design: Outsource component, Dependent on test results

• Design freeze decision

• Complete engineering drawings

• Complete the bill of materials

• Revise the product design specification

• Complete verification prototype testing

• Final cost estimate

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

11 BITS-Pilani, Hyderabad Campus
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 Wr i tte n D o cu m e n ts

• Electronic Mail

• Memorandum reports

• The Design Notebook

• Formal technical reports

• Challenges in technical writing:

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 F i n a l D e si g n R e vi e w

• When to conduct:
– Detail drawings are complete and ready for release to manufacturing.
– In most cases beta-prototype testing will have been completed.
– Purpose is to compare the design against the most updated version of the product design
specification (PDS)

• Who will present:

– VP of engineering, the director of product development
– Production
– Quality
– Safety and Reliability
– Marketing
– Legal representative
– Trusted suppliers
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
13 BITS-Pilani, Hyderabad Campus
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 F i n a l D e si g n R e vi e w : In p u t d o cu m e n t

• PDS

• QFD analysis

• Key technical analyses like FEA and CFD, FMEAs

• Quality plan, including robustness analysis

• Testing plan and results of the verification tests

• The detail and assembly drawings

• Cost projections

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14 BITS-Pilani, Hyderabad Campus
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 R e vi e w M e e ti n g Pr o ce ss
• Selection of the people who will attend the review meeting.

• They must be authorized to make decisions about the design and have the ability and
responsibility to take corrective action.

• Meeting should be formally structured with a well-planned agenda.

• Receive a package of information well before the meeting.

• Briefing session at least 10 days before the formal review.

• The drawings, simulations, test results, FMEAs, and other elements are used to support the
evaluation.

• Any items that do not pass the review are tagged as action items with appropriate
responsibility.
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
15 BITS-Pilani, Hyderabad Campus
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 C h e ckli st fo r fi n a l d e sig n r e vi e w
1. Overall requirements - does it meet? 4. Manufacturing requirements- does it meet?
• Customer requirements • Use of standard components and subassemblies
• Product design specification • Tolerances consistent with process and equipment
• Applicable industry and governmental standards • Materials well defined and consistent with
performance requirements
2. Functional requirements – does it meet? • Have critical control parameters been identified?
• Mechanical, electrical, thermal and many more
• Use of existing equipment and requirement to set
• Size and weight new equipment
• Strength
• Projected life 5. Operational requirements – does it meet?
• Is it easy to install in the field?
3. Environment requirements - does it meet? • Are items requiring frequent maintenance easily
• Operating temperature range accessible?
• Extremes of humidity • Has service person safety been considered in
• Extremes of vibration design?
• Shock • Have human factors been adequately considered in
• Foreign material contamination design?
• Corrosion • Are servicing instructions clear? Are they derived
• Outdoor exposure extremes from FMEA or FTA?

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

16 BITS-Pilani, Hyderabad Campus
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 C h e ckli st fo r fi n a l d e sig n r e vi e w
6. Reliability requirements - does it meet? 8. Other requirements - does it meet?
• Have critical components been optimized for
• Have hazards been adequately investigated?
robustness?
• Has through safety analysis been conducted? • Has a search been conducted to avoid patent
• Have failure modes been investigated and infringement?
documented? • Has prompt action been taken to apply for
• Have life integrity tests been completed successfully? possible patent protection?
• Has derating been employed in critical components? • Does the product appearance represent the
7. Cost requirements – does it meet? technical quality and cost of the product?
• Has the product development process been
• Does the product meet the cost target
adequately documented for defense in possible
• Have the cost comparisons been made with product liability action?
competitive products?
• Does the product comply with applicable law and
• Have the service warranty costs been quantified and agency requirements?
minimized?
• Has value engineering analysis been made for
possible cost reduction?

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

17 BITS-Pilani, Hyderabad Campus
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 O u tp u t fr o m R e vi e w

• Decision can be taken as:

– Accepted as it is

– Further minor modifications are required

– Further major modifications are required

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

18 BITS-Pilani, Hyderabad Campus
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 D e si g n a n d b u sin e ss a cti vi ti e s b e yo n d
d e ta il d e si g n
Process planning
Develop production control plan
Design tools and fixtures
Develop quality assurance plan
Negotiate with suppliers
Develop detailed marketing plan
Develop distribution plan
Write user manual
Decide on warranty
Develop maintenance plan
Develop plan for customer service
Develop plan for retirement from service
Manufacturing production acceptance test
Product launch
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
19 BITS-Pilani, Hyderabad Campus
DESIGN
 Te c h n i ca l a cti vi ti e s

• Process planning

• Develop product development plan

• Designing of tooling and fixtures

• Develop quality assurance plan

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

20 BITS-Pilani, Hyderabad Campus
DESIGN
 Te c h n i ca l a cti vi ti e s
• Develop maintenance plan

• Develop plan for retirement from service

• Manufacturing production acceptance test

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

21 BITS-Pilani, Hyderabad Campus
DESIGN
 Bu sin e ss Acti vi ti e s
• Negotiate with suppliers

• Develop distribution plan

• Write the user manual

• Decide on warranty

• Develop a plan for customer service

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

22 BITS-Pilani, Hyderabad Campus
DESIGN
 F a ci l i ta ti n g d e si g n a n d m a n u fa ctu r i n g
w i th co m p u te r - b a se d m e th o d s

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

23 BITS-Pilani, Hyderabad Campus
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 Pr o d u ct L i fe cycl e M a n a g e m e n t ( PL M )

• Product Data Management (PDM)

• Manufacturing Process Management

(MPM)

• Customer Relationship Management

(CRM)
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
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 Su m m a r y

• Detail design is the phase of the design process where all of the details are brought
together, decisions finalized, and a decision is made by management whether to
release the design for production. Design freeze decision has to be taken in detail
design stage.
• The detail design phase also involves verification testing of a prototype, the
generation of a bill of materials (BOM) from the assembly drawings, a final cost
estimate, and decisions on whether to make each part in-house or to obtain it from
an outside supplier.
• Detail design ends when the design is reviewed and accepted by a formal design
review process.
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
25 BITS-Pilani, Hyderabad Campus
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 Su m m a r y

• The engineering design process, and in particular the detail design phase,
requires considerable skill and effort in communication on the part of design team
members.
• Technical reports will be used an effective medium to communicate the product
development process results to the design review team.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

26 BITS-Pilani, Hyderabad Campus
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 BITS Pilani
Pilani | Dubai | Goa | Hyderabad

Session 11: Design for Material Selection

 Pr o d u ct D e si g n Pr o ce ss

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

28 BITS-Pilani, Hyderabad Campus
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 C o n te n t: M a te r i a l Se le cti o n
• Introduction
• Performance characteristics of Materials
• Material selection process
• Sources of information on material properties
• Economics of materials
• Overview of methods of material selection
• Selection with computer aided data base
• Material selection with decision matrix
• Recycling and material selection
• Summary

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

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 In tr o d u cti o n

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DESIGN 30 BITS-Pilani, Hyderabad Campus
 R e l a tio n o f M a te r i a l s Se le cti o n to D e si g n

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 31 BITS-Pilani, Hyderabad Campus
 C l a ssi fi ca ti o n o f M a te r i a ls

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 C r i te r ia fo r M a te r i a l Se l e cti o n

Elvin Karana , Paul Hekkert, Prabhu Kandachar, Material considerations in product design: A survey on crucial material aspects used by
product designers, Materials and Design 29 (2008) 1081–1089.
AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T
DESIGN 33 BITS-Pilani, Hyderabad Campus
 Pe r fo r m a n ce C h a r a cte r i sti cs o f M a te r i a l s

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 34 BITS-Pilani, Hyderabad Campus
 C l a ssi fi ca ti o n o f M a te r i a l Pr o p e r ti e s

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DESIGN 35 BITS-Pilani, Hyderabad Campus
 M e ch a n ica l Pr o p e r ti e s

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DESIGN 36 BITS-Pilani, Hyderabad Campus
 G u i d e fo r Se le cti o n o f M a te r i a l

B. A . Miller , “ Materials Selection for Failure Prevention, ” Failure Analysis and Prevention, ASM Handbook, Vol. 11, ASM International, Materials Park, OH , 2002 , p. 35
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DESIGN 37 BITS-Pilani, Hyderabad Campus
 Ty p i ca l M e ch a n i ca l Pr o p e r ti e s o f Se le cte d
M a te r i a l s

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DESIGN 38 BITS-Pilani, Hyderabad Campus
 Sp e ci fi ca ti o n o f a M a te r i a ls
Ashby Charts

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DESIGN 39 BITS-Pilani, Hyderabad Campus
 As h b y C h a r ts: Exa m p le s

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DESIGN 40 BITS-Pilani, Hyderabad Campus
 As h b y C h a r ts: Exa m p le s

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 41 BITS-Pilani, Hyderabad Campus
 M a te r i a l s Se l e ctio n fo r a N e w Pr o d u ct o r
New Design
Define the functions that the design must perform and translate Stiffness, strength,
these into required materials properties. corrosion resistance
Define the manufacturing parameters. Size, complexity,
Compare the needed properties and parameters against a large manufacturability,
materials property database.
Screening
surface properties
finish, tolerance
and go/no go decision
Investigate the candidate materials in more detail.
Product performance, Cost,
Develop design data and/or a design specification Fabricability, and Availability

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 42 BITS-Pilani, Hyderabad Campus
 M a te r i a l s Su b sti tu ti o n i n a n Exi sti n g
D e si g n
Characterize the currently used material in terms of performance,
manufacturing requirements, and cost.

Determine which properties must be improved for enhanced product function.

Search for alternative materials and/or manufacturing routes.

Compile a short list of materials and processing routes, and use these to estimate
the costs of manufactured parts.

Evaluate the results of previous stage and make a recommendation for a

replacement material.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 43 BITS-Pilani, Hyderabad Campus
 M a te r i a l s Se l e ctio n in Em b o d i m e n t D e si g n

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 So u r ce s o f In fo r m a ti o n o n M a te r i a l s
Pr o p e r ti e s
• Metals Handbook Desk Edition, 2d ed., ASM International, Materials Park, OH, 1998. A
compact compilation of metals, alloys, and processes.
• Engineered Materials Handbook Desk Edition, ASM International, Materials Park, OH,
1995. A compact compilation of data for ceramics, polymers, and composite materials.
• M. F. Ashby, Materials Selection in Mechanical Design, 3d ed., Butterworth-Heinemann,
Oxford, UK, 2005. Extensive discussion of Ashby charts and materials selection, along
with tables of property data suitable for screening at conceptual design level. Appendix D
in this text provides 18 pages on sources of material property data.
• Cambridge Materials Selector, CES 06, Granta Design Ltd., Cambridge, UK. This
software implements the Ashby materials selection scheme and provides data on 3000
materials. http://www.granta.com.uk.
• K. G. Budinski and M. K. Budinski, Engineering Materials: Properties and Selection, 8 th
ed., Pearson Prentice Hall, Upper Saddle River, NJ, 2004. Broadbased, practically
oriented.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

DESIGN 45 BITS-Pilani, Hyderabad Campus
 So u r ce s o f In fo r m a ti o n o n M a te r i a l s
Pr o p e r ti e s
• www.matdata.net: Provides direct link to ASM International handbooks and
metals databases, as well as Granta Design databases. Most of these are
subscription services, but this site will provide locations in the 21 volumes of ASM
handbooks to data on specifi c materials. Most engineering libraries will have
these handbooks.
• www.matweb.com: Provides 59,000 material data sheets for free. Registered
viewers can make searches for materials using up to three criteria for free. For
more advanced searches a subscription is required.
• www.campusplastics.com: The “Computer Aided Materials Preselection by
Uniform Standards” is a database of polymers properties sponsored by a network
of worldwide plastic resin producers. In order to provide comparability between
the data of different suppliers, each participant is required to use a uniform
standard for the generation of the data. Use of the database is free.

AE ZG531/ AEL ZG531/ DE ZG541/DM ZG541/MM ZG541– P R O D U C T

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 Ec o n o m i cs Of M a te r i a l s
• Cost of Materials:

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 Ec o n o m i cs Of M a te r i a l s
• Cost of Materials:

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 An a l yti ca l M e th o d s Of M a te r i a l s Se le cti o n

Analytical
Methods

Selection with
computer- Decision Performance
aided matrices indices
databases

Weighted Pugh selection

property index method

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DESIGN 49 BITS-Pilani, Hyderabad Campus
 Se l e cti o n w i th C o m p u te r - a id e d D a ta b a se s

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 M a te r i a l Pe r fo r m a n ce In d i ce s

• A material performance index is a group of material properties that governs some

aspect of the performance of a component
• Example: Consider the tubular frame of a bicycle. The design requirement calls
for a light, strong tubular beam of fixed outer diameter. Its function is to carry
bending moments. The objective is to minimize the mass m of the frame. The
mass per unit length m/L can expressed by

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 M a te r i a l Pe r fo r m a n ce In d i ce s

• Above equation is the objective function , the quantity to be minimized.

• This optimization must be done subject to several constraints. The first constraint
is that the tube strength must be sufficient so it will not fail.
• Failure could occur by buckling, brittle fracture, plastic collapse, or fatigue caused
by repeated cyclic loads.

• If fatigue is the likely cause, then the cyclic bending moment Mb the tube can
withstand with infinite life is

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 M a te r i a l Pe r fo r m a n ce In d i ce s

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DESIGN 53 BITS-Pilani, Hyderabad Campus
 M a te r i a l Se l e cti o n u si n g Ash b y Pl o ts a n d
Pe r fo r m a n ce In d e xe s

Which material should we use?

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 D e si g n R e q u i r e m e n ts
• Design requirements: Affordable high performance bicycle.

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 G o ve r n i n g Eq u a ti o n s fo r M a te r i a l
Se l e cti o n

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DESIGN 56 BITS-Pilani, Hyderabad Campus
 G o ve r n i n g Eq u a ti o n s fo r M a te r i a l
Se l e cti o n

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DESIGN 57 BITS-Pilani, Hyderabad Campus
 M a te r i a l Se l e cti o n b y Ash b y C h a r t

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 C o m p a r in g Pe r fo r m a n ce In d e xe s

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 Pr a cti ca l C o n si d e r a ti o n s

• Does this mean we should make all the bicycles by wood

material?

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 Pr a cti ca l C o n si d e r a ti o n s

• Revisit the performance index by

adding more parameters!

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DESIGN 61 BITS-Pilani, Hyderabad Campus
 M a te r i a l s Se l e ctio n w i th D e ci si o n M a tr i ce s

• Pugh Concept Selection: The Pugh decision method is used to select a replacement
material for a helical steel spring in a wind-up toy train.

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DESIGN 62 BITS-Pilani, Hyderabad Campus
 We i g h te d Pr o p e r ty In d e x: Exa m p l e

• The material selection for a cryogenic storage vessel for liquefied natural gas is
being evaluated on the basis of the following properties:

1) Low-temperature fracture toughness

2) Low-cycle fatigue strength

3) Stiffness

4) Coefficient of thermal expansion (CTE)

5) Cost
• Since the tank will be insulated, thermal properties can be neglected in the
selection process.
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DESIGN 63 BITS-Pilani, Hyderabad Campus
 We i g h te d Pr o p e r ty In d e x: Exa m p l e

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DESIGN 64 BITS-Pilani, Hyderabad Campus
 R e cycl i n g a n d M a te r i a l s Se l e cti o n

• The steps in recycling a material are:

1. Collection and transport

2. Separation

3. Identification and sorting

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DESIGN 65 BITS-Pilani, Hyderabad Campus
 D e si g n fo r R e cycli n g

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DESIGN 66 BITS-Pilani, Hyderabad Campus
 THANK YOU!

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DESIGN 67 BITS-Pilani, Hyderabad Campus