Material Selection Optimization

in Manufacturing Process

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FUNCTIONAL CYCLE CONCEPT ADDED VALUE
Improvement
Invention
PRODUCT OPPORTUNITY/ Innovation
DEVELOPMENT MARKET/NEED/  BMW/CQT
CUSTOMER CONCEPTUAL
RECYCLING
DESIGN
DISPOSAL

PRODUCT
INTEGRATED
CUSTOMER INTEGRATED DESIGN
DATABASE
INTEGRATED
SERVICES DATABASE
INTEGRATED
DATABASE
DATABASE PRODUCTION
DELIVERY PREPARATION

PROCESS
PRODUCTION PLANNING
CONTROL
PROCESS R&D
PROCESSING LOGISTIC &
PROCRUMENT 2
4
Product design specification (PDS)

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 Added Value

Performance:

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 The world of materials, processes
•
•
and shapes
Deformation
Moulding
• Ceramics
• Glasses
• Powder methods • Polymers
• Casting • Metals
• Machining • Elastomers
• Composite forming • Composites
• Molecular methods
MATERIALS
• Natural materials

PROCESSES

• Axisymmetric
• Prismatic
• Flat sheet
SHAPES • Dished sheet
• 3-D solid
• 3-D hollow

A
4 7
 Data organisation: materials
Kingdom Class &
Family member Attributes
Density
1000
Ceramics Modulus
2000
Glasses Steels
3000 Strengths ...
Polymers Cu-alloys
Al-alloys 4000 Thermal props.
MATERIAL Metals 5000 A material
Ti-alloys Electrical props.
Elastomers Ni-alloys 6000 record
Corrosion props.
Composites Zn-alloys 7000
Natural 8000 Processes
Shapes
Pointers to
unstructured
information

• “Handbook” data
• Hierarchical structure
• Idea of a “generic” and “specific” records
• Data-ranges stored at each level
A
5 8
 Case: Structured data for ABS
Acrylonitrile-butadiene-styrene (ABS) - (CH2-CH-C6H4)n
Thermal Properties
•General Properties Glass Temperature 350 - 360 K
• Max Service Temp 350 - 370 K
•Density 1.05 - 1.07 Mg/m^3 Min Service Temp 150 - 200 K
•Price 2.1 - 2.3 USD/kg Specific Heat 1500 - 1510 J/kg.K
Thermal Conductivity 0.17 - 0.24 W/m.K
Thermal Expansion 70 - 75 10-6/K
•
•Mechanical Properties Electrical Properties
Breakdown Potential 14 - 15 MV/m
•Bulk Modulus 4.1 - 4.6 GPa
Dielectric Constant 2.8 - 3.3
•Compressive Strength 55 - 60 MPa
Resistivity 6.3x1021 - 1.6x1022  ohm.cm
•Ductility 0.06 - 0.07
Power Factor 0.008 - 0.009
•Elastic Limit 40 - 45 MPa
•Endurance Limit 24 - 27 MPa
•Fracture Toughness 2.3 - 2.6 MPa.m1/2 Corrosion and Wear Resistance
•Hardness 100 - 140 MPa Flammability Average
•Loss Coefficient 0.009 - 0.026 Fresh Water Good
•Modulus of Rupture 50 - 55 MPa Organic Solvents Average
•Poisson's Ratio 0.38 - 0.42 Oxidation at 500C Very Poor
•Shear Modulus 0.85 - 0.95 GPa Sea Water Good
•Tensile Strength 45 - 48 MPa Strong Acid Good
•Young's Modulus 2.5 - 2.8 GPa Strong Alkalis Good
UV Good
Wear Poor
Weak Acid Good
Weak Alkalis Good
A
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 Function, object, constraint ...
 Function
Tie
 Objective
Beam
• Minimum cost
Shaft
• Minimum weight
Column
• Maximum energy
storage  Constraint
• etc. Stiffness
Strength
Geometry
Corrosion
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 Optimasi Material:

Performance = f [F,G,M]

P = f [(Functional requirements),

(Geometric constraints),
(Material properties)]
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 Design requirements  Material specification
Design concept
“Translation”

Analyse: Function What does the component do ?

Objective(s) What is to be maximised or minimised ?
Constraints What essential conditions must be met ?
Free variables Which design variables are free ?

From which we obtain …

• Screening criteria expressed as numerical limits on

material property-values
Or expressed as requirements for processing,
corrosion, ….

• Ranking criteria based on material indices that

characterise performance.
B
2
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 Screening using constraints
“Eliminate materials that can’t do the job”

Screen on attributes Example: heat exchanger tubes

Requirements: must Retain materials with:

• operate at 100oC • max operating temp > 100C
• be electrical insulator • resistivity R > 1020 .cm
• conduct heat well • T-conduct.  > 100 W/m.K

Screen on links Example: cheap metal window frame

Requirements: must Retain materials with:

• be extrudable • links to “extrusion”

Screen on both attributes and links

B
3
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 Screening using attribute limits
Search region
Diamond
Steel CFRP

Silica
GFRP

Copper Polyethylene Fibreboard

Cement PP

Lead PTFE

Ceramics Metals Polymers Composites

B
4
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 Screening using attribute limits
Search region
Diamond Tungsten, Commercial Purity ee
CFRP
1000. Silicon Nitride

Acetal
Elastic Limit (MPa)

100.
PolyUrethane

Fibreboard
Silica Copper

10.
Lead MDF

Butadiene
1.
Aerated Concrete

Ceramics Metals Polymers Composites

Materials:\Ceramic Materials:\Metal Materials:\Polymer Materials:\Composite
Material Class
B
5
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 Material indices: the light, strong tie-rod
Strong tie of length L and minimum mass

F F

Area A L
Length L is specified
Function Tie-rod Contraints
Must not fail under load F

Objective Minimise mass m Free variable Cross-section area A is free

Equation for objective: m = AL (1)

Equation for constraint: F/A < y (2)

Eliminate A in (1) using (2): m  FL 
 y 
  
Minimise the material index  
 y 
 
B
6
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 Materials indices
Function Has a
Each combination of Objective characterising
Constraint material index
FUNCTION Free variable
Tie
OBJECTIVE
Beam
Minimum cost CONSTRAINTS

Shaft Minimum INDEX

weight Stiffness
specified   
Column Maximum energy M   1/ 2 
storage Strength E 
specified
Minimum
environ. impact Fatigue limit
Mechanical, Minimise this!
Thermal,
Geometry
Electrical...
specified
B
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 Case Study
• Choose one product
• Find the mechanical properties, thermal
properties, electrical properties and corrosion
and wear resistance properties
• Analyze the functions, objectives, constraints,
and free variables of your product.

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 Material indices: the key to optimised choice
Material properties -- Material indices --

the “Physicists” view of materials, e.g. the “Engineers” view of materials

Cost, Cm Objective: minimise mass
Density,  Function Stiffness Strength
Modulus, E
Tension (tie) ρ/E ρ/σ y
Strength, y
Endurance limit, e Bending (beam) ρ/E1/2 ρ/σ 2/3
y
Thermal conductivity,  ρ/E1/3
Bending (panel) ρ/σ1/2
y
T- expansion coefficient, 

Minimise these!
Many more: see Appendix B of the Text

B
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 Optimised selection using charts
  
ρ C C C
Index M  1/2 E1/ 3 E1/ 2 E
E
1000

2 2
Ceramics
E  ρ /M

Young’s modulus E, (GPa)

100 Composites
LogE  2 Log  2 LogM
Woods
10

1 Metals
1 2 3
Polymers
0.1
Contours of constant
M are lines of slope 2 Foams Elastomers
on an E- chart 0.01
0.1 1 10 100
3
Density (Mg/m )
B
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 Selection using hard-copy charts

Search
region


1/ 2
C
E

B1
0
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 Selection using the CES software
1000.
Diamond
Search Ceramics Tungsten

region
100. CFRP Carbon Steel
Composites
Aluminium alloys) Metals
Young's Modulus (GPa)

10.
Woods
Sandstone

PTFE

1.

Polyethylene
Polymers

0.1

 PVC foam

1/ 2
C PolyUrethane
E Foams Elastomers

1. 10. 100.
Density (Mg/m3)
Density (Mg/m^3)
B1
1
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 MATERIALS SELECTION
ECONOMIC, ENVIRONMENTAL, & DESIGN ISSUES

ISSUES TO ADDRESS...
• Price and availability of materials.
• How do we select materials based on optimal
performance?
• Applications:
--shafts under torsion
--bars under tension
--plates under bending
--materials for a magnetic coil.

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 PRICE AND AVAILABILITY
• Current Prices on the web(a):
--Short term trends: fluctuations due to supply/demand.
--Long term trend: prices will increase as rich deposits
are depleted.
• Materials require energy to process them:
--Energy to produce --Cost of energy used in
materials (GJ/ton) processing materials ($/GJ)(g)
Al 237 (17)(b) elect resistance 25
PET 103 (13)(c) propane 11
Cu 97 (20)(b) natural gas 9
steel 20(d) oil 8
glass a http://www.statcan.ca/english/pgdb/economy/primary/prim44.htm

13(e) a
b
http://www.metalprices.com
http://www.automotive.copper.org/recyclability.htm
paper c http://members.aol.com/profchm/escalant.html
9(f) d http://www.steel.org.facts/power/energy.htm
e http://eren.doe.gov/EE/industry_glass.html
Energy using recycled f http://www.aifq.qc.ca/english/industry/energy.html#1
g http://www.wren.doe.gov/consumerinfo/rebriefs/cb5.html
material indicated in green.
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RELATIVE COST, $, OF MATERIALS

$ /kg
$
($ /kg )ref material

• Reference material:
--Rolled A36 plain
carbon steel.
• Relative cost, $,
fluctuates less
over time than
actual cost.
Based on data in Appendix
C, Callister, 6e.
AFRE, GFRE, & CFRE = Aramid,
Glass, & Carbon fiber reinforced
epoxy composites.

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STIFF & LIGHT TENSION MEMBERS
• Bar must not lengthen by more than d
under force F; must have initial length L.
-- Stiffness relation: -- Mass of bar:
F d
E ( = Ee) M  Lc 2
c2 L

• Eliminate the "free" design parameter, c:

FL2 
M
d E
minimize for small M
specified by application

E
• Maximize the Performance Index: P 
(stiff, light tension members) 
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STRONG & LIGHT TENSION MEMBERS
• Bar must carry a force F without failing;
must have initial length L.
-- Strength relation: -- Mass of bar:
f F
 M  Lc 2
N c2

• Eliminate the "free" design parameter, c:


M  FLN
f
minimize for small M
specified by application
f
• Maximize the Performance Index: P 
(strong, light tension members) 

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STRONG & LIGHT TORSION MEMBERS
• Bar must carry a moment, Mt ;
must have a length L.
-- Strength relation: -- Mass of bar:
 f 2Mt
 M  R2 L
N R3

• Eliminate the "free" design parameter, R:


M  2  NM t 
2/3
L

2f / 3
specified by application minimize for small M

2f / 3
• Maximize the Performance Index: P 
(strong, light torsion members) 
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 DATA: STRONG & LIGHT TENSION/TORSION
MEMBERS
Increasing P
Strength,  (MPa) for strong
f
104 Ceramics
torsion members
Cermets
103 PMCs
Steels
|| grain Metal
102
alloys Adapted from Fig. 6.22,
Callister 6e. (Fig. 6.22
10 Polymers adapted from M.F. Ashby,
Materials Selection in
Mechanical Design,
Increasing P grain
1 Butterworth-Heinemann Ltd.,
1992.)
for strong
tension 0.1
members 0.1 1 10 30
Density,  (Mg/m3)
7 29
 DATA: STRONG & LIGHT
BENDING MEMBERS
 1/ 2
• Maximize the Performance Index: P 
Increasing P 
for strong
Strength, f (MPa)

104 Ceramics
bending members
Cermets
103 PMCs
Steels
|| grain Metal
102 Adapted from Fig. 6.22,
alloys Callister 6e. (Fig. 6.22
adapted from M.F. Ashby,
10 Polymers Materials Selection in
Mechanical Design,
grain Butterworth-Heinemann Ltd.,
1 1992.)

0.1
0.1 1 10 30
Density,  (Mg/m3)
8 30
 DETAILED STUDY I: STRONG,
LIGHT TORSION MEMBERS
2f / 3
• Maximize the Performance Index: P 

• Other factors:
--require f > 300MPa.
--Rule out ceramics and glasses: KIc too small.
• Numerical Data:
material  (Mg/m3) f (MPa) P (MPa)2/3m3/Mg)
CFRE (vf=0.65) 1.5 1140 73
GFRE (vf=0.65) 2.0 1060 52
Al alloy (2024-T6) 2.8 300 16
Ti alloy (Ti-6Al-4V) 4.4 525 15
4340 steel (oil 7.8 780 11
quench & temper)
Data from Table 6.6, Callister 6e.

• Lightest: Carbon fiber reinf. epoxy

(CFRE) member. 9 31
DETAILED STUDY I: STRONG, LOW
COST TORSION MEMBERS
• Minimize Cost: Cost Index ~ M$ ~ $/P (since M ~ 1/P)
• Numerical Data:
material P (MPa)2/3m3/Mg) $ ($/P)x100
CFRE (vf=0.65) 73 80 112
GFRE (vf=0.65) 52 40 76
Al alloy (2024-T6) 16 15 93
Ti alloy (Ti-6Al-4V) 15 110 748
4340 steel (oil 11 5 46
quench & temper)
Data from Table 6.7, Callister 6e.

• Lowest cost: 4340 steel (oil quench & temper)

• Need to consider machining, joining costs also.

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