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P roperty
Choose data-table:
materials, processes ...
stage
Min
Density
Limit
stage
Modulus
200
100
Strength
T-conduction
Max
10
Tree stage
Join
Process
Shape
Surface
Cast
Deform
Mold
Composite
Powder
Prototype
Getting Started
with CES EduPack
Cambridge
University
Version MFA 09
Science Notes
Specialist Databases
Advanced Software
Level 2
Level 3
Coverage
Around 70 of the most widely used materials
drawn from the classes: metals, polymers,
ceramics, composites, foams, and natural
materials.
Around 70 of the most widely used processes.
Around 100 of the most widely used
materials.
Around 110 of the most commonly used
processes.
The core database contains more than 3,000
materials, including those in Levels 1 and 2.
Specialist editions covering aerospace,
polymers, architecture, bio-materials, and ecodesign are also available.
Content
A description, an image of the material in a familiar
product, typical applications, and limited data for
mechanical, thermal, and electrical properties, using
rankings where appropriate.
All the content of Level 1, supplemented by more
extensive numerical data, design guidelines,
ecological properties, and technical notes.
Extensive numerical data for all materials, allowing
the full power of the CES selection system to be
deployed.
When the software opens you are asked to choose a Level. Chose Level 1 to start with.
BROWSING
SEARCHING
SELECTION
Use of powerful selection engine to find records that meet an array of design criteria.
CES EduPack does far more than this. But this is enough to get started.
File
Edit
View
Browse
Select
Tools
Search
Table:
MaterialUniverse
MaterialUniverse
Subset:
Edu
Edu Level
Level 11
Window
Select
MaterialUniverse
File
Edit
View
Select
Tools
Window
Browse
Search
Table:
ProcessUniverse
ProcessUniverse
Subset:
Edu
Edu Level
Level 22
Select
ProcessUniverse
Browse
Find what:
Search
Select
Polylactide
Joining
Shaping
Surface treatment
Injection molding
No other process has changed product design more than injection molding.
Injection molded products appear in every sector of product design:
consumer products, business, industrial, computers, communication,
medical and research products, toys, cosmetic packaging and sports
equipment. The most common equipment for molding thermoplastics is the
reciprocating screw machine, shown schematically in the figure. Polymer
granules are fed into a spiral press where they mix and soften to a doughlike consistency that can be forced through one or more channels ('sprues')
into the die. The polymer solidifies under pressure and the component is
then ejected.
Thermoplastics, thermosets and elastomers can all be injection molded. Coinjection allows molding of components with different materials, colors and
features. Injection foam molding allows economical production of large
molded components by using inert gas or chemical blowing agents to make
components that have a solid skin and a cellular inner structure.
General properties
Density
Price
Mechanical properties
Young's Modulus
Shear Modulus
Bulk modulus
Poisson's Ratio
Hardness - Vickers
Elastic Limit
Tensile Str ength
Compressive Strength
Elongation
Endurance Limit
Fracture Toughness
Loss Coefficient
0.91
Mg/m 3
1.102 -
1.61
USD/kg
0.896
0.31
2.5
0.40
6.2
20.7
27.6
25.1
100
11.0
3
0.025
1.55
0.54
2.6
0.42
11.2
37.2
41.4
55.2
600
16.5
4.5
0.044
GPa
GPa
GPa
0.89
HV
MPa
MPa
MPa
%
MPa
MPa.m1/2
Thermal properties
Thermal conductor or insulator?
Thermal Conductivity
Thermal Expansion
Specific Heat
Melting Point
Glass Temperature
Maximum Service Temperature
Minimum Service Temperature
Good insulator
0.113 - 0.167
122.4 - 180
1870 - 1956
149.9 - 174.9
-25.15 - -15.15
82.85 - 106.9
-123.2 - -73.15
Electrical properties
Electrical conductor or insulator?
Resistivity
Dielectric Constant
Power Factor
Breakdown Potential
Good insulator
3.3e22 - 3e23
2.2
- 2.3
5e-4 - 7e-4
22.7 - 24.6
_
Design guidelines
Standard grade PP is inexpensive, light and ductile but it has low strength. It is more rigid than PE
Re
and can be used at higher temperatures. The properties of PP are similar to those of HDPE but it
is stiffer and melts at a higher temperature (165 - 170 C). Stiffness and strength can be improved
further by reinforcing with glass, chalk or talc.When drawn to fiber PP has exceptional strength and
resilience; this, together with its resistance to water, makes it attractive for ropes and fabric. It is
more easily molded than PE, has good transparency and can accept a wider, more vivid range of
colors. PP is commonly produced as sheet, moldings fibers or it can be foamed. Advances in catalysis promise
new co-polymers of PP with more attractive combinations of toughness, stability and ease of processing. Monofilaments fibers have high abrasion resistance and are almost twice as strong as PE fibers. Multi-filament yarn or
rope does not absorb water, will float on water and dyes easily.
W/m.K
strain/K
J/kg.K
C
C
C
C
ohm.cm
1000000*V /m
Physical Attributes
Mass range
Range of section thickness
Tolerance
Roughness
Surface roughness (A=v. smooth)
0.01
0.4
0.2
0.2
A
Economic Attributes
Economic batch size (units)
Relative tooling cost
Relative equipment cost
Labor intensity
1e4 - 1e6
very high
high
low
25
6.3
1
1.6
kg
mm
mm
m
Shape
Circular Prismatic
Non-circular Prismatic
Solid 3-D
Hollow 3-D
True
True
True
True
Design guidelines
Injection molding is the best way to mass-produce small, precise, polymer components with complex shapes. The
surface finish is good; texture and pattern can be easily altered in the tool, and fine detail reproduces well.
Decorative labels can be molded onto the surface of the component (see In-mould Decoration). The only finishing
operation is the removal of the sprue.
Technical notes
Most thermoplastics can be injection molded, although those with high melting temperatures (e.g. PTFE) are
difficult. Thermoplastic based composites (short fiber and particulate filled) can be processed providing the fillerloading is not too large. Large changes in section area are not recommended. Small re-entrant angles and complex
shapes are possible, though some features (e.g. undercuts, screw threads, inserts) may result in increased tooling
costs. The process may also be used with thermosets and elastomers. The most common equipment for molding
thermoplastics is the reciprocating screw machine, shown schematically in the figure. Polymer granules are fed
into a spiral press where they mix and soften to a dough-like consistency that can be forced through one or more
channels ('sprues') into the die. The polymer solidifies under pressure and the component is then ejected.
Technical notes
The many different grades of polypropylene fall into three basic groups: homopolymers (polypropylene, with a
range of molecular weights and thus properties), co-polymers (made by co-Polymerization of propylene with other
olefines such as ethylene, butylene or styrene) and composites (polypropylene reinforced with mica, talc, glass
powder or fibers) that are stiffer and better able to resist heat than simple polypropylenes.
Typical uses
Extremely varied. Housings, containers, covers, knobs, tool handles, plumbing fittings, lenses, etc.
Typical uses
Ropes, general polymer engineering, automobile air ducting, parcel shelving and air-cleaners, garden furniture,
washing machine tank, wet-cell battery cases, pipes and pipe fittings, beer bottle crates, chair shells, capacitor
dielectrics, cable insulation, kitchen kettles, car bumpers, shatter proof glasses, crates, suitcases, artificial turf.
The economics
Capital cost are medium to high, tooling costs are usually high - making injection molding economic only for large
batch sizes. Production rate can be high particularly for small moldings. Multi-cavity moulds are often used.
Prototype moldings can be made using single cavity moulds of cheaper materials.
PROPERTY CHARTS
Exercise 4 Making PROPERTY CHARTS
Browse
1. Selection data
Edu
Edu Level
Level 2:
2: Materials
Materials
Select
2. Selection Stages
Search
Graph
X-axis
Limit
Tree
Y-axis
List of properties
Density
Yield strength
Youngs modulus
etc.
Tungsten carbides
A bar chart
Titanium alloys
100
Concrete
Copper
Nickel
Polypropylene (PP)
0.1
Polystyrene (PS)
Brick
Polyethylene (PE)
Aluminum alloys
Magnesium alloys
Polyester
10
EVA
10
Titanium alloys
Acrylic, PMMA
Metal foam
Lead alloys
PTFE
0.1
0.01
0.01
Polyurethane
Polyisoprene rubber (IIR)
0.001
Tungsten alloys
Boron carbide
A bubble chart
100
1000
Tungsten alloys
1000
1e-4
100
1000
Density (kg/m^3)
10000
Browse
> 200 C
THERMAL CONDUCTIVITY
> 25 W/m.C
ELECTRICAL CONDUCTOR
OR INSULATOR?
= GOOD INSULATOR
Search
1. Selection data
Search web
A Limit stage
Edu
Edu Level
Level2:
2: Materials
Materials
Mechanical properties
2. Selection Stages
Graph
Thermal properties
Limit
Select
Tree
Min.
Max
200
25
Specific heat
Results
Ranking
Prop 2
Material 1
2230
113
Material 2
2100
300
Material 3
1950
5.6
Material 4
1876
47
C
W/m.K
W
m.
/m.C
/
J/kg .C
Electrical properties
Electrical conductor
or insulator?
Good conductor
Poor conductor
Semiconductor
Poor insulator
Good insulator
etc...
GRAPH SELECTION
Exercise 6 Selection with a GRAPH stage
Browse
Select
Search web
1. Selection data
Use a BOX SELECTION to find materials with high strength and low density
2. Selection Stages
Graph
Results
Limit
Material 1
Tree
Ranking
2230
Prop 2
113
Material 2
2100
300
Material 3
1950
5.6
Material 4
1876
47
Bar chart
Yield strength
Edu
Edu Level
Level2:
2: Materials
Materials
Yield strength
Search
Box
selection
Bubble chart
Line
selection
etc...
Density
1000
Polypropylene (PP)
Lead alloys
CFRP
Nickel
10
Hardwood:
oak, across grain
Polystyrene (PS)
Cork
ABS
Neoprene
Concrete
0.1
0.01
Selection line,
slope 1
Phenolics
Epoxies
100
CFRP (isotropic)
1000
GFRP
Silica glass
Aluminum alloys
Selection box
Nickel
Magnesium alloys
Polyurethane
100
10
Concrete
Cork
0.1
1000
Density (kg/m^3)
10000
TREE SELECTION
Exercise 7 Selection with a TREE Stage
Browse
Search
Select
1. Selection data
Search web
Tree stage for material
Edu
Edu Level
Level2:
2: Materials
Materials
2. Selection Stages
Graph
Limit
Tree
Material
Results
X out of 95 pass
Material 3
Material 4
etc...
Steels
Al alloys
Metals
Cu alloys
Polymers
Ni alloys...
Material 1
Material 2
Ceramics
Hybrids
Join
Process
Deform
Shape
Mold
Surface
Composite
Powder
Prototype
DENSITY
> 60 MPa
THERMAL CONDUCTIVITY
(3 entries in a Limit Stage)
< 10 W/m.C
Browse
Search
Select
Search web
Stacked stages
1. Selection data
Edu
Edu Level
Level2:
2: Materials
Materials
Join
Process
2. Selection Stages
Graph
Limit
Shape
Surface
Tree
Density
Can be MOLDED
(a Tree Stage: ProcessUniverse Shaping Molding)
Strength
Ranking
2000
Modulus
Max
T-conduction
60
10
Prop 2
Material 1
2230
113
Material 2
2100
300
Material 3
1950
5.6
Price
Min
Cast
Deform
Mold
Composite
Powder
Prototype
etc...
PROCESS SELECTION
Exercise 10 Selecting PROCESSES
Change Selection Data to select Processes:
Select LEVEL 2, SHAPING PROCESSES
Browse
Search
Select
Edu
Edu Level
Level2:
2: Processes
Processes -- Shaping
Shaping
SHAPE
= Dished sheet
2. Selection Stages
MASS
= 10 12 kg
SECTION THICKNESS
= 4 mm
> 1000
Graph
Limit
Tree
Shape
Dished sheet
Ceramics
Material
Physical attributes
Made of a THERMOPLASTIC
(a Tree Stage: MaterialUniverse Polymers and elastomers
Polymers Thermoplastics)
Search web
1. Selection data
Mass
Section thickness
10
4
12
4
Hybrids
Metals
Thermoplastics
Polymers Thermosets
Process characteristics
Primary shaping
Economic attributes
1000
File
Edit
View
etc
View
etc
Open Project
Save Project
Print
...
File
Edit
Cut
Display a chart, click on it, then COPY and PASTE it into a document
Copy
Double click a selected material in the Results window to display its datasheet,
click on the datasheet, then COPY and PASTE it
Paste
...
Clipboard
Clipboard
Word
processor
(The datasheets in Exercise 3 and the selection charts in Exercises 4 and 6 were made in this way)
(Warning: There is a problem with WORD 2000: the image in the record is not transferred with
the text. The problem is overcome by copying the image and pasting it separately into the WORD
document as a DEVICE INDEPENDENT BITMAP.)
10
ECO AUDIT
1. Material, manufacture, and end of life
The Eco Audit Tool calculates the energy used and CO2 produced during five key
life phases of a product (material, manufacture, transport, use, and end of life) and
identifies which is the dominant phase. This is the starting point for eco-aware
product design, as it identifies which parameters need to be targeted to reduce the
eco-footprint of the product.
Component name
100
Bottle
View
Select
Tools
PET
Primary process
Mass (kg)
End of life
0%
Molding
0.04
Recycle
0%
Molding
Landfill
100%
Extrusion
Combust
Window
Downcycle
Edit
Recycle content
MaterialUniverse
Ceramics and glasses
File
Material
Recycle
Re-engineer
Elastomers
Reuse
Polymers
Thermoplastics
PET
100
Cap
100
Water
PP
0%
Molding
0.001
Combust
Eco Audit
...
2. Transport
Transportation from site of manufacture to point of sale
Product Definition
Stage name
New
PET Bottle
Transport type
14 tonne truck
Distance (km)
550
Sea freight
Open
Save
Rail freight
14 tonne truck
Air freight long haul
...
11
View Report
3. Use
4. Report
Product life:
years
United Kingdom
France
Germany
United Kingdom
...
Static mode
Energy used to refrigerate product at point of sale (average energy required to
refrigerate 100 bottles at 4C = 0.12 kW)
9
Power rating:
0.12
Usage:
Usage:
24
kW
Energy (MJ)
Energy (%)
CO2 (kg)
CO2 (%)
Material
344
85.7
9.6
47.1
Manufacture
86.8
21.6
6.94
34.1
Transport
48.7
12.1
3.46
17.0
Electric to thermal
Use
50.8
12.7
3.05
15.0
End of life
-129
-32.1
-2.68
-13.2
Total
401
100
20.4
100
...
Phase
12
New
Open
Save
Save
Save As
SAVE the product definition (give it a filename and directory location; CES Eco Audit product files have the extension .prd)
View Report
Export
Excel
Acrobat (PDF) file
(Note: You will require Microsoft Excel or a PDF reader such as Adobe Reader to view the exported eco audit report)
13
Appendices
14
Select entities
using design
criteria
Search for
text in the
database
Print contents
of the active
window
CES Help
and
Video Tutorials
Search for
information
on the Web
Un-zoom
Add envelopes
Black and white
chart
Result
intersection
Hide failed
materials
15
-273.2oC
9.807m/s2
6.022 x 1023
2.718
1.381 x 10-23 J/K
9.648 x 104 C/mol
Gas constant, R
Plancks constant, h
Velocity of light in vacuum, c
Volume of perfect gas at STP
8.314 J/mol/K
6.626 x 10-34 J/s
2.998 x 108 m/s
22.41 x 10-3 m3/mol
Angle,
Density,
Diffusion Coefficient, D
Energy, U
Force, F
Length, l
Mass, M
Power, P
Stress,
Specific Heat, Cp
Stress Intensity, K1c
Surface Energy
Temperature, T
Thermal Conductivity
Volume, V
Viscosity,
1 rad
1 lb/ft3
1cm3/s
See opposite
1 kgf
1 lbf
1 dyne
1 ft
1 inch
57.30o
16.03 kg/m3
1.0 x 10-4m2/s
0.1 nm
1 tonne
1 short ton
1 long ton
1 lb mass
See opposite
See opposite
1 cal/gal.oC
Btu/lb.oF
1 ksi in
1 erg/cm2
1oF
1 cal/s.cm.oC
1 Btu/h.ft.oF
1 Imperial gall
1 US gall
1 poise
1 lb ft.s
1000 kg
908 kg
1107 kg
0.454 kg
9.807 N
4.448 N
1.0 x 10-5N
304.8 mm
25.40 mm
MPa
lb.in2
kgf/mm2
bar
long ton/in2
MPa
10
1.45 x 10
0.102
10
6.48 x 10-2
dyn/cm2
10-7
1.45 x 10-5
1.02 x 10-8
10-6
6.48 x 10-9
lb/in2
6.89 x 10-3
6.89 x 104
703 x 10-4
6.89 x 10-2
4.46 x 10-4
kgf/mm2
9.81
9.81 x 107
1.42 x 103
98.1
63.5 x 10-2
bar
0.10
106
14.48
1.02 x 10-2
6.48 x 10-3
15.44
1.54 x 108
2.24 x 103
1.54
1.54 x 102
erg
10
-7
erg
10
cal
4.19
cal
6.24 x 10
-8
2.39 x 10
4.19 x 107
-12
Btu
18
0.239
1
-19
eV
1
-20
11
ft lbf
-4
0.738
-11
7.38 x 10-8
9.48 x 10
6.24 x 10
9.48 x 10
2.61 x 1019
3.97 x 10-3
3.09
1.52 x 10-22
1.18 x 10-19
eV
1.60 x 10
1.60 x 10
3.38 x 10
Btu
1.06 x 103
1.06 x 1010
2.52 x 102
6.59 x 1021
7.78 x 102
ft lbf
1.36
1.36 x 107
0.324
8.46 x 1018
1.29 x 10-3
kW (kJ/s)
erg/s
10
-10
hp
ft lbf/s
1.34
7.38 x 102
kW (kJ/s)
erg/s
10-10
1.34 x 10-10
7.38 x 10-8
hp
7.46 x 10-1
7.46 x 109
15.50 x 102
Ft lbf/s
1.36 x 10-3
1.36 x 107
1.82 x 10-3
* To convert row unit to column unit, multiply by the number at the column row intersection,
thus 1MPa = 1 bar
16
This is one of six CES EduPack teaching resource books. All are
available free of charge to users with a maintained CES EduPack license.
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M A T E R I A L
I N S P I R A T I O N
France T 08 00 76 12 90
F 01 53 01 69 66