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    Materials Selection For Mechanical Design III

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    Salah Gasim Ahmed
    Materials Selection for Mechanical Design III a Brief Overview of a Systematic Methodology Process Selection a process is a method for shaping, joining, or finishing materials processes have many attributes Tolerance Surface Roughness Mass Range Size Range Economic Batch Size Capital Costs Production Rate Only certain materials can be shaped or formed by certain processes certain designs can be achieved with certain processes and certain materials.

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    Materials Selection For Mechanical Design III

    Uploaded by

    Salah Gasim Ahmed
    77 views12 pages
    Materials Selection for Mechanical Design III a Brief Overview of a Systematic Methodology Process Selection a process is a method for shaping, joining, or finishing materials processes have many attributes Tolerance Surface Roughness Mass Range Size Range Economic Batch Size Capital Costs Production Rate Only certain materials can be shaped or formed by certain processes certain designs can be achieved with certain processes and certain materials.

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    Material Selection1

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    Materials Selection for Mechanical Design III a Brief Overview of a Systematic Methodology Process Selection a process is a method for shaping, joining, or finishing materials processes have many attributes Tolerance Surface Roughness Mass Range Size Range Economic Batch Size Capital Costs Production Rate Only certain materials can be shaped or formed by certain processes certain designs can be achieved with certain processes and certain materials.

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    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    77 views12 pages

    Materials Selection For Mechanical Design III

    Uploaded by

    Salah Gasim Ahmed
    Materials Selection for Mechanical Design III a Brief Overview of a Systematic Methodology Process Selection a process is a method for shaping, joining, or finishing materials processes have many attributes Tolerance Surface Roughness Mass Range Size Range Economic Batch Size Capital Costs Production Rate Only certain materials can be shaped or formed by certain processes certain designs can be achieved with certain processes and certain materials.

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    The presentation discusses a systematic methodology for selecting materials and processes for mechanical design projects. It emphasizes considering material, shape, and process constraints together from an early stage.

    When selecting a process, it's important to consider the material to be shaped or joined, the geometry or shape involved, and the purpose of any surface treatments.

    Some processes can only work with certain materials - for example, molding can't be used with wood. Machining composites and ceramics is also difficult. Shape can also limit the possible forming processes.

    Materials Selection for Mechanical Design III

    A Brief Overview of a Systematic Methodology Process Selection

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 1

    Process Selection

    A process is a method for shaping, joining, or finishing materials Processes have many attributes Tolerance Surface Roughness Mass Range Size Range Economic Batch Size Capital Costs Production Rate Only certain materials can be shaped or formed by certain processes Certain designs can be achieved with certain processes and certain materials

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 2

    Manufacturing Processes: Shaping, Joining, or Surface Treating

    Shaping

    Shaping

    Sand casting

    Blow molding

    Joining

    Surface treating

    Fusion welding
    Massachusetts Institute of Technology Cambridge, Massachusetts
    Jeremy Gregory and Randolph Kirchain, 2005

    Induction hardening
    Materials Systems Laboratory
    Materials Selection III Slide 3

    Important Factors in Process Selection

    Shaping

    The material to be shaped The shape of the part The material(s) to be joined The geometry of the joint The purpose of the treatment The material to which it will be applied
    Materials Systems Laboratory
    Materials Selection III Slide 4

    Joining

    Surface Treating

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Examples of Process Selection Issues


    Can't use molding processes with wood Machining of Composites and Ceramics is very rare Can't use high pressure casting processes with refractory metals Shape can determine which processes can be used to form a material

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 5

    Shape Classification
    Some processes can make only simple shapes, others, complex shapes
    ALL SHAPES

    Prismatic
    Circular Non-circular Flat

    Sheet
    Dished Solid

    3D
    Hollow

    Wire drawing, extrusion, rolling, shape rolling: prismatic shapes

    Stamping, folding, spinning, deep drawing: sheet shapes

    Casting, molding, powder method: 3-D shapes

    Figure by MIT OCW.

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 6

    Example: Polyethylene Bottles

    Function:

    Shape a PE bottle

    Objective: N/A Constraints:


    Material: PE (thermoplastic) Shape: 3D Hollow Mass: 0.02 0.04 kg Minimum Section: 0.7-1 mm Tolerance: 1 mm Surface Roughness: 10 m Batch Size: >106 Choice of process
    Figure by MIT OCW.

    Free variables:

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 7

    Using constraints in limit stage, selected process is injection blow molding


    1e8

    Injection Blow m oulding


    1e7

    Injection m oulding, therm oplastics


    1e6

    Economic batch size (units)

    100000

    10000

    1000

    100

    10

    Chart from the CES EduPack 2005, Granta Design Limited, Cambridge, UK. (c) Granta Design. Courtesy of Granta Design Limited. Used with permission.

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 8

    Example combining material, shape, process: Lightweight Member Loaded in Bending


    From material index, nonferrous alloys are best choice Process Selection: Choose process that makes nonaxisymmetric prismatic shapes and can be used with nonferrous alloys
    Massachusetts Institute of Technology Cambridge, Massachusetts
    Jeremy Gregory and Randolph Kirchain, 2005

    Material Index including shape factor

    ( E ) M=
    e B

    1/ 2

    Cm

    Non-axisymmetric Prismatic Shape

    Nonferrous Alloys

    Materials Systems Laboratory


    Materials Selection III Slide 9

    Bending Member Example: Process Selection Procedure


    Die Casting Machining Machining Extrusion Die Casting Extrusion

    Only extrusion satisfies both processing constraints


    Massachusetts Institute of Technology Cambridge, Massachusetts
    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 10

    Bending Member Example: Final Selection


    Material, shape, and process combine to meet performance criteria
    Materials

    Aluminum

    Extrusion

    Process

    Shape

    I-beam

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

    Materials Systems Laboratory


    Materials Selection III Slide 11

    Summary

    Selection procedure should start early and keep all possibilities until eliminated by project considerations and constraints Use project objectives to establish constraints and project attributes Usually will have to rank priorities and make tradeoffs Material, shape, and process can be used in concert to meet project objectives
    Materials Systems Laboratory
    Materials Selection III Slide 12

    Massachusetts Institute of Technology Cambridge, Massachusetts


    Jeremy Gregory and Randolph Kirchain, 2005

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