METE 401 MATERIALS ENGINEERING DESIGN I

FINAL EXAM 12 January 2005

(80 minutes) Instructor: Cevdet Kaynak Team No:

Student Name:

Grade:

Formulas:

STRESSES: F tension = A

compressio n =

F A

bending =

My I

torsion =

Tr J

ELASTIC DEFORMATIONS:

tension = l = ...
STIFFNESS: F Stension = l

compressio n = l = ...

bending

Fl 3 Ml 2 = = c EI c EI

torsion =

Tl GJ

Scompressio n = Fcritical = ...

Sbending =

F M =

Storsion =

MOMENTS OF SECTIONS: wt 3 r 4 I rec tan gle = I round = 12 4 Others: FEuler = Others: K I = Y a

Leak-Before-Break:

K rec tan gle =

w 3t w 1 0.58 3 t

J round

r 4 = 2
2 Y 2E

n 2 2 EI l2

hoop =

Pr t

thermal = E T

U resilience =

t < aC

CR =

Cm C steel

Ctotal = m Cm +

CC C L + n n

*MATERIALS DATA TABLE Steel AISI 1020 (as rolled) GENERAL PROPERTIES Density (Mg/m3) Price (/kg) Energy Content (MJ/kg) Recycle Fraction MECHANICAL PROPERTIES Youngs Modulus (GPa) Shear Modulus (GPa) Bulk Modulus (GPa) Elongation (%) Poissons Ratio Yield Strength (MPa) Tensile Strength (MPa) Compressive Strength (MPa) Flexural Strength (MPa) Endurance Limit (MPa) Hardness (HV) Fracture Toughness (MPam) Shape Factor THERMAL PROPERTIES Melting Point (K) Glass Temperature (K) Max Service Temperature (K) Thermal Conductivity (W/m.K) Thermal Expansion Coefficient (strain/K) ELECTRICAL PROPERTIES Electrical Resistivity (ohm.cm) ENVIRONMENTAL PROPERTIES Resistance to Flammability Resistance to Fresh Water Resistance to Organic Solvents Resistance to Oxidation at 500 C Resistance to Sea Water Resistance to Strong Acids Resistance to Strong Alkalis Resistance to UV Resistance to Wear Al-alloy 2024-T3 (wrought) Composite Epoxy Matrix Carbon Fiber (woven 65%) 1.5 65 545 0.01 46 17 9 0.9 0.33 -600 570 600 335 17 47 8 -550 455 2 18

7.8 0.7 66 0.9 210 82 167 36 0.29 340 450 330 330 245 150 55 60 1774 -620 52 12

2.7 1.5 285 0.9 74 29 73 12 0.33 310 440 300 310 145 128 40 23 843 -400 126 24

17 A very good B good A very good B good C average D poor C average A very good A very good

5.5 B good A very good A very good E very poor B good A very good D poor A very good C average

6x105 B good A very good B good E very poor A very good C average A very good B good C average

Problem 1 ( 30 %)

Rank these three specific candidate materials for the following designs. STRONG AND ECONOMIC THERMOS Msteel= MAl alloy= Mcomposite= Ranking: M=

ENVIRONMENTALLY FRIENDLY SPRING Msteel= MAl alloy= Mcomposite= Ranking:

M=

DURABLE, LIGHT AND RECYCLABLE YACHT Msteel= MAl alloy= Mcomposite= Ranking:

M=

Problem 2 ( 30 %)

(a)

Suppose that the following is the simplest free body diagram of a plate under a specified bending moment (M) with given length (l) and width (w). Drive a Material Index for the following objective and constraint.
M M

1. Objective: MAXIMUM ELASTIC DEFLECTION 2. Objective Function: 3. Specified Variables: 4. Free Variable: THICKNESS (t) 5. Constraint: MAXIMUM LOAD WITHOUT YIELDING 6. Constraint Equation:

7. Free Variable Equation:

8. Substitution of Free Variable into Objective Function:

9. Grouping:

10. Material Index to be maximised M = Problem 3 ( 40 %) Suppose that for the Process Selection of a component, the required Tolerance and Roughness values should be not worse than 0.5 mm and 5 m respectively.

(a) Write these two Process Indices. P1 = P2 =

(b) Draw the design guidelines of these two Process Indices indicating your search region.

(c) Give the list of possible processes (classes and their members) that may be used to produce the component. Primary Shaping Processes for Metals-MMC

Primary Shaping Processes for Polymers-PMC

Secondary Processes

(d)

By using the Process Cost Data of the following specific processes, chose the most economic one if 106 components would be produced. (Note that process cost data are normalized to material cost of one component) Processes Material Cost (/component) 1 1 1 Capital Cost () 103 104 102 Labour Cost (/hr) 100 100 100 Production Rate (component/hr) 10 100 1

Green Sand Casting Closed Die Forging Machining Cost Equation: CGreen Sand Casting= CClosed Die Forging= CMachining= The most economic one: