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FUNCTION
SHAPE
MATERIAL
PROCESS
A
(m2)
I
(m4)
K
(m4)
r 2
4
r
4
4
r
2
ab
3 2
a
4
(ro2 ri 2 )
2rt
sec tion
b4
12
0.14b
3
ab
4
a 3 b 3
(a 2 b 2 )
bh
A = Cross-sectional area
bh
12
4
a
32 3
4
( ro ri 4 )
4
r 3t
b3h
b
1 0.58
3
h
(h b )
a
3
80
4
(ro ri 4 )
2
2r 3t
y 2 dA
where
sec tion
y 2by dy
y is measured vertically
by is the section width at y
K
where
TL
G
J 2r dr
3
sec tion
T is the torque
L is the length of the shaft
is the angle of twist
G is the shear modulus
A
(m2)
I
(m4)
K
(m4)
4bt
2 3
bt
3
t
b t 1
b
(a b )t
3
3b
a t 1
4
a
b(ho hi )
2bt
4 (ab )5 / 2 t
a2 b2
b 3
( ho hi3 )
12
btho2 / 2
2t ( h b )
1 3
3b
h t 1
6
h
2tb 2h 2
hb
2 3
4h
bt 1
3
b
2t ( h b )
t 3
( h 4bt 2 )
6
t3
(8b h )
3
2 3
4b
ht 1
3
h
2d 2
t 1
2
4
t d 2
8
Z
(m3)
Q
(m3)
3
r
4
3
r
2
b3
6
0.21b3
2
ab
4
a 2 b
2
(a b )
bh
6
a3
32
b 2h 2
3h 1.8b
(h b)
a3
20
4
(ro ri 4 )
4ro
4
(ro ri 4 )
2ro
r 2t
2r 2t
Z = Section modulus
I
ym
where
ym is the normal distance from the neutral axis
to the outer surface of the beam carrying the
highest stress
Q = Factor in twisting similar to Z
Q
where
Z
(m3)
4 2
bt
3
a 2t
3b
1
4
a
Q
(m3)
t
2b t 1
b
2t (a3b )1/ 2
(b a )
ho3 hi3
6ho
btho
h 2t
3b
1
3
h
2tbh
2 2
4h
bt 1
3
b
t
(h3 4bt 2 )
3h
t2
(8b h )
3
2 2
4b
ht 1
3
h
t d
4
TORSION
SB
C1EI
L3
ST
KG
L
Be
4 A2
Io r
4
4
SBo
Io
4I
so, 2
A
e
B
4 A2
Ko r
2
2
Te
ST
K
STo K o
so,
Te
2K
A2
TORSION
My m M
I
Z
3 A3 / 2
Zo r
4
4
Mfo
Zo
4 Z
so,
A3 / 2
f
B
T
Q
Tf Q f
Tf
3 A3 / 2
Qo r
2
2
Tf
Q
Tfo Qo
so, T
f
2 Q
A3 / 2
Rectangular sections
I-sections
SIZE
Shape Factors
Section
Shape
Stiffness
Failure/Strength
Bf
Tf
1.05
3
0.88
2
1.18
3
0.74
a
b
2ab
a b2
h
3b
2b
h
1 0.58
3h
b
(h b)
e
B
2
1.21
3 3
r
t
e
T
a
b
2
0.73
5 3
r
t
2
3
a
b
h
b
0.77
2r
1/ 2
1/ 2
(a b )
2 (b / h )1/ 2
3(1 0.6b / h )2
(h b )
0.62
2r
1/ 2
e
B
b
6t
a(1 3b / a )
t (1 b / a )2
Stiffness
b
t
1
8t
b
f
B
8(ab )5 / 2
t (a 2 b 2 )(a b )2
2 b
3 t
a
t
1/ 2
b 2h 2
t ( h b )3
t (1 4h / b )
3b(1 h / b )2
h(1 4bt 2 / h3 ) t (1 8b / h ) t (1 4b / h )
6t (1 b / h )2
6h(1 b / h )2 3h(1 b / h )2
d 2
2t
1/ 2
b
t
Tf
1/ 2
t
1
b
4a1/ 2
t 1/ 2 (1 a / b )3 / 2
(1 3b / a )
(1 b / a )3 / 2
2 h
( bt )1/ 2
h 2
2bt
h(1 3b / h )
6t (1 b / h )2
Failure/Strength
e
T
2
3
h
t
h
2 t
1/ 2
1/ 2
(1 3b / h )
2 h
3/2
1/ 2
(1 b / h ) (bt ) (1 h / b )3 / 2
(1 4bt 2 / h3 )
(1 b / h )3 / 2
d
(t )1/ 2
18h
1/ 2
(1 8b / h )
(1 b / h )3 / 2
t
b
1/ 2
(1 4h / b )
(1 b / h )3 / 2
2 t
3 h
1/ 2
(1 4b / h )
(1 b / h )3 / 2
2
3
4I
A2
Be
log I 2 log A log
4
Plot logI against logA
Be : parallel lines of slope 2
4 Z
A3 / 2
ELASTIC TORSION
2K
2 ;
A
e
T
Te
log K 2 log A log
2
2 Q
3/2 ;
A
f
T
3
Tf
logQ log A log
2
2
ELASTIC TORSION
4I
Shape factor: 2
A
e
B
4SB
m
C1
1/ 2
SB
C1EI
L3
C1EBe A2
so, SB
4L3
2
5/2
L
e
E B
2K
Shape factor:
A2
e
T
ST
KG
L
GTe A2
so, ST
2L
1/ 2
2
1/ 2
3/2
m 2ST L
e
GT
1/ 2
So, to minimize
(EBe )1/ 2
mass m, maximise M1
3
E So, to minimize
(ETe )1/ 2
8
mass m, maximise M 2
FAILURE IN TORSION
4 Z
f Bf A3 / 2
Shape factor:
so, Mf
A3 / 2
4
2 Q
f Tf A3 / 2
Shape factor:
so, Tf
A3 / 2
4
( f f 2)
f
B
3/2
2/3
m ( 4 Mf ) L
f
f B
2/3
f
T
m 4 Tf
2/3
3/2
L
f
f T
2/3
So, to minimize
( f Tf )2 / 3
mass m, maximise M 4
(BeE )1/ 2
M1
Ceramics
Search
Region
Composites
can be written as
M1
(E )
=10
E E
and density
=1
Woods
e 1/ 2
B
e
B
e
B
Be
Engineering
Polymers
Polymer
Foams
Engineering
Alloys
Elastomers
(Bf f )2 / 3
M3
can be written as
M3
( f ( ) )
( )
f 2 2/3
B
f 2
B
f f (Bf )2
and density
(Bf )2
Ceramics
Composites
Search
Region
Engineering
Alloys
Woods
=1
Engineering
Polymers
=10 Elastomers
Polymer
Foams
Micro-Shape Factors
Material
Macro-Shape from
Micro-Shaped Material,
Micro-Shape
Micro-Shaped Material,
Macro-Shape,
Micro-Shaped Material,
Micro-Shape Factors
Consider a solid cylindrical beam expanded, at constant
mass, to a circular beam with internal shape (see right).
Stiffness of the solid beam: SBo
C1EoIo
L3
r o
ro
Fibres embedded
in a foam matrix
Prismatic cells
2
2
The second moment
4 o 4 o
of area increases to I r
ro
Io
Concentric cylindrical
shells with foam between
Shape Factor: B
e
S o
So
Beam
Objective
Constraint
Minimum cost
Stiffness
Minimum weight
Shaft
Column
Mechanical
Thermal
Electrical..
Strength
Index
E 1/ 2
M1
Maximum stored
energy
Minimum
environmental
impact
Fatigue
Index
Geometry
f2 / 3
M2
CK IC
,
aC
K
aC C 2 IC
f
M1
K IC
f
Function
Objective
Maximum safety
Constraints
Minimum strength
pR
pR
, t
2t
2 f
M3 f
t
CK IC
2
t / 2
C 2pR K IC2
K IC2
M2
4
f
f
aC
K
M1 IC
f
M1 = 0.6 m1/2
M3 = 100 MPa
K IC2
M2
f
M3 f
Material
M1
(m1/2)
M3
(MPa)
Comment
Tough steels
Tough Cu alloys
Tough Al alloys
>0.6
>0.6
>0.6
300
120
80
Standard.
OFHC Cu.
1xxx & 3xxx
Ti-alloys
High strength Al
alloys
GFRP/CFRP
0.2
0.1
0.1
700
500
500
High strength,
but low safety
margin. Good
for light
vessels.
Pi fi (F ) g i (G ) hi (Mi )
3. If the first constraint is the most restrictive (known as the active constraint)
then the performance is given by P1, and this is maximized by seeking
materials with the best values of M1. If the second constraint is the active
one then the performance is given by P2 and this is maximized by seeking
materials with the best values of M2; and so on.
N.B. For a given Function the Active Constraint will be material dependent.
C1EI
L3
C I
Constraint 2: Strength Ff 2 f
y mL
12SB
so, m1
C1
where y m
6Ff
so,
2
C2
t
2
1/ 2
L5 / 2
2/3
L5 / 3
E 1/ 2
f2 / 3
If the beam is to meet both constraints then, for a given material, its weight is
determined by the larger of m1 or m2
or more generally, for i constraints
Choose a material
~
that minimizes m
Material
1020 Steel
6061 Al
Ti 6-4
~ max( m , m , m .....m )
m
1
2
3
i
E
(GPa)
205
70
115
m1
m2
(MPa)
(kgm-3)
(kg)
(kg)
~
m
(kg)
320
120
950
7850
2700
4400
8.7
5.1
6.5
16.2
10.7
4.4
16.2
10.7
6.5
f1(F1 )g1(G1 )
M 2 Cc M 2
f2 (F2 )g 2 (G2 )
M1
log Index M2
M1 Limited
Domain
A,
are limited by M1
, are limited by M2
M2 Limited
Domain
Coupling Line
M2 = CCM1
log Index M1
M1 Limited
Domain
Search
Area
A
log Index M2
Search
Area
A
log Index M2
B
Coupling Line
M2 = CCM1
M2 Limited
Domain
Coupling Line
M2 = CCM1
log Index M1
M2 Limited
Domain
log Index M1
DESIGN REQUIREMENTS
N Turns
Current i
2r
Function
Magnet windings
Objective
Constraints
Classification
Continuous
Long
Standard
Short
Ultra-short
Pulse
Duration
Field
Strength
1s-
100 ms-1 s
10 - 100 ms
10 - 1000 s
0.1 - 10 s
<30 T
30-60 T
40-70 T
70-80 T
>100 T
oNif
f ( , )
L
B2
p
2 o f ( , )
pr
B 2r
d 2o f ( , )d
Bfailure
B 2et pulse
T 2 2
o d Cp
where
Bheat
t pulse e
1/ 2
f ( , )
(MPa)
(Mg/m3)
High conductivity Cu
Cu-15%Nb composite
HSLA steel
250
780
1600
8.94
8.90
7.85
~
B min( Bfailure , Bheat ) e.g.
Cp
Bfailure
Bheat
(J/kgK)
(10-8m)
(wb/m2)
(wb/m2)
~
B
(wb/m2)
385
368
450
1.7
2.4
25
35
62
89
113
92
30
35
62
30
Pulse length = 10 ms
Bfailure
Bheat
2 od y f ( , )
1/ 2
t pulse e
1/ 2
f ( , )
o rdf f ( , )Tmax
M 2 CC M2
M1
2t pulse
Search Region:
short pulse
HSLA steels
M1 y
M2
Cu-Be-Co-Ni
Cu-Nb
Be-Coppers
Cu-Al2O3
Search Region:
long pulse
Cu-Zr
Cu-4Sn
GP coppers
HC Coppers
Al-S150.1
Cp
e
Cu
Material
Comment
Short pulse
Cu-Al2O3 composites
H-C Cu-Cd alloys
H-C Cu-Zr alloys
H-C Cu-Cr alloys
Drawn Cu-Nb comps
Ultra short pulse,
ultra high field
Cu-Be-Co-Ni alloys
HSLA steels