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6 Exercises with
Worked Solutions
Cambridge
University
Version MFA 09
Materials selection in mechanical design, 3rd edition
Mike Ashby
Engineering Department,
Cambridge, CB2 1 PZ, UK
Version 1
Part 1
E1 Introduction to exercises
E2 Devising concepts
E3 Use of material selection charts
E4 Translation: constraints and objectives
E5 Deriving and using material indices
Part 2
E6 Selecting processes
E7 Multiple constraints and objectives
Part 3
E 8 Selecting material and shape
E9 Hybrid materials
C1 Conduction
Answer. Four working principles are listed below: thermal conduction, Compact, requiring back-up by coupling to convection,
convection by heat transfer to a fluid medium, evaporation exploiting evaporation or radiation
the latent heat of evaporation of a fluid, and radiation, best achieved
with a surface with high emissivity. Free convection not requiring fan or pump.
The best solutions may be found by combining two of these: conduction
coupled with convection (as in the sketch an often-used combination) C2 Convection
or radiation coupled with evaporation (a possibility for short-life space Forced convection with fan or pump
structures).
C3 Evaporation
Confined, utilising heat-pipe technology
C4 Radiation
Radiation to cooled surface, from high emissivity
surface to highly absorbent surface
Sketch.
Answer. Metals that are stiffer than brass are listed in the table. Answer. (a) No metals in Figure 4.3 are both stiffer and less dense than steel.
(b) Several ceramics qualify: Boron carbide, B4C, silicon carbide, SiC,
Material Comment silicon nitride Si3N4 and alumina Al203.
Steels The cheapest stiff, strong structural
metal, widely used. Material Comment
Nickel alloys More expensive than steel Alumina Al203 Alumina is the most widely used
Tungsten alloys Refractory (high-melting) and of all technical
relatively expensive Silicon nitride Si3N4 ceramics (spark plugs, circuit
boards) All
Boron carbide, B4C ceramics are brittle they have
low values of
Silicon carbide, SiC fracture toughness K1c and
toughness G1c .
Answer. The strongest steels, titanium alloys (Ti-alloys) and carbon fiber
Answer. Parallel to the grain, woods have much higher specific stiffness
reinforced polymers (CFRP) meet these limits.
than epoxies. Perpendicular to the grain, woods have about the same
value as epoxies. Material Comment
Material E/ (GPa/(Mg/m ) 3
High strength steels
Woods parallel to the grain 8 30 High strength nickel alloys All have f above 1000 MPa,
Woods transverse to the grain 0.8 3.5
Titanium alloys a very large value
Epoxies 1.75 2.4
CFRP
Answer. PTFE and polyethylene (PE) have low coefficient of friction when
sliding on steel (and on most other materials). Both are used for the
sliding surface of skis.
List function and constraints; set the objective to minimize cost and E4.5 A furnace is required to sinter powder-metal parts. It operates
the free variables to choice of material. continuously at 650 oC while the parts are fed through on a moving
belt. You are asked to select a material for furnace insulation to
minimize heat loss and thus to make the furnace as energy-efficient as
possible. For reasons of space the insulation is limited to a maximum
thickness of x = 0.2 m. List the function, constraints, objective and
free variable.
Answer. This is a problem involving steady-state heat flow. The heat lost
by conduction per unit area of insulation per second, q, is
T
Figure E1. q =
x
where is the thermal conductivity, x the insulation thickness and
Answer. If the C-clamp is to reach temperature quickly it must, according to T the temperature difference between the interior of the furnace and
the equation givenin the question, be made of a material with a high its surroundings. The aim is to minimize q, leading (via the equation)
thermal diffusivity, a. It carries loads, so it must have adequate to the objective of minimizing the thermal conductivity of the
strength, and it must not charge up, so it must be an electrical conductor. insulation material. There are two constraints: one on thickness, the
other on service temperature.
and C p is the specific heat of the material of the core (in J/kg.C) and
is its density (in kg/m3). Thus the most compact storage heater is
one made from a material with a high C p . Even a small storage
heater contains a considerable quantity of core (that is why they are
heavy), so it is probable that an objective will be to minimize its cost
per unit volume. If, however, space were critical, maximizing C p
might become the objective.
Answer.
The model. A thin, taut wire slackens and sags when the strain due to
thermal expansion,
th = T
exceeds the elastic strain caused by the pre-tension,
Figure E3
= .
F L3
=
3 EI
F L3 1
= 4
t4 E
The magnitude of the load F and the dimensions L and t are all
given. The deflection is minimized by maximizing
M1 = E
Figure E4 (b) The design requirements for part (b) are listed below
Function Self-loaded cantilever beam
Constraints Length L specified
Section t x t specified
Objective Minimize the deflection,
Free variables Choice of material only
E
M2 =
(d) The design requirements for part (d) are listed below
Function End-loaded cantilever beam
Constraints Length L specified
(c) The design requirements for part (c) are listed below End-load F specified
Function Self-loaded cantilever beam Maximum deflection, , specified
Constraints Length L specified Objective Minimize the mass, m
Maximum deflection, , specified Free variables Choice of material
Objective Minimize the mass, m Section area A = t 2
Free variables Choice of material
Section area A = t 2 The section is square, but the dimension t is free. The objective
function is
The beam deflects under its own weight but now the section can be m = t2L
varied to reduce the weight provided the deflection does not exceed ,
as in the figure. The objective function (the quantity to be minimized) The deflection is, as in part (a)
is the mass m of the beam F L3 1
= 4
m = t2 L t4 E
Using this to eliminate the free variable, t, gives
1/ 2
F L5
m = 2
1/ 2
E
In the last two exercises the objective has been that of minimizing weight.
m = (6 F ) L
2/3 5 / 3 There are many others. In the selection of a material for a spring, the
2/3 objective is that of maximizing the elastic energy it can store. In seeking
f materials for thermal-efficient insulation for a furnace, the best are those
The mass is minimized by selecting materials with the largest values with the lowest thermal conductivity and heat capacity. And most
of the index common of all is the wish to minimize cost. So here is an example
involving cost.
2/3
f Columns support compressive loads: the legs of a table; the pillars of the
M= Parthenon. Derive the index for selecting materials for the cheapest
cylindrical column of specified height, H, that will safely support a load F
without buckling elastically. You will need the equation for the load
Fcrit at which a slender column buckles. It is
If the cantilever is part of a mechanical system it is important that it
have sufficient fracture toughness to survive accidental impact loads.
n2E I
For this we add the requirement of adequate toughness: Fcrit =
H2
K 1c > 15 MPa .m 1 / 2
where n is a constant that depends on the end constraints and
I = r 4 / 4 = A 2 / 4 is the second moment of area of the column (see
Appendix A for both). The table lists the requirements.
E1 2
M=
Cm
*
Cm is the cost/kg of the processed material, here, the material in the form of
a circular rod or column.
Figure E7
m = a2 t
m = 2 a 2 ( A S a )1 / 2 f ( )
where is the density of the material of which the plate is made. The E1/ 2
thickness t is free, but must be sufficient to meet the constraint on The lightest shell is that made from a material with a large value of the
stiffness. Inverting the first equation in the question gives, for the plate, index
1/ 3
3 S a2
t = f 1 ( ) E1/ 2
4 E M2 =
where f 1 ( ) is simply a function of , and thus a constant.
1 F L3
= 2 E
48 E I m = 9 S max L
2f
and that for the deflection at which failure occurs
Figure E10 The selection can be implemented using Figures 16.8 and 16.9 of the
text. If the CES software is available, make a chart with the stiffness
index as one axis and the strength index as the other. The materials that
Establish an appropriate material index for selecting materials for best meet both criteria lie at the top right.
energy-economic forks. Model the eating implement as a beam of fixed
length L and width w, but with a thickness t that is free, loaded in
bending, as in the figure. The objective-function is the volume of
material in the fork times its energy content, H p , per unit volume
( H p is the production energy per kg, and the density). The limit on
flexure imposes a stiffness constraint (Appendix A, Section A3). Use
this information to develop the index.
Flexure, in cutlery, is an inconvenience. Failure whether by plastic
deformation or by fracture is more serious: it causes loss-of-function;
it might even cause hunger. Repeat the analysis, deriving an index
when a required strength is the constraint.
x (2 a t )1 / 2
( ) (Ts Ti )
q = C p 1/ 2
Function High heat-transfer rocket fins x
Constraints All dimensions specified
where is the density and C p the specific heat of the material of the
Must not suffer surface melting during
exposure to gas at 1700 C for 0.3 sec. fin.
Objective Minimize the surface temperature rise during Proceed by equating the two equations for q, solving for the surface
firing temperature Ts to give the objective function. Read off the
Maximize the melting point of the material
combination of properties that minimizes Ts ; it is the index for the
Free variables Choice of material
problem.
This is tricky. Heat enters the surface of the fin by transfer from the The selection is made by seeking materials with large values of the
gas. If the heat transfer coefficient is h, the heat flux per unit area is index and with a high melting point, Tm . If the CES software is
available, make a chart with these two as axes and identify materials
q = h ( T g Ts ) with high values of the index that also have high melting points.
where Ts is the surface temperature of the fin the critical quantity we
wish to minimize. Heat is diffuses into the fin surface by thermal
conduction.
h Tg t + C p Ti Copper alloys
Ts =
cold. When t is large, Ts = T g and the surface temperature is equal to Zinc alloys
the gas temperature. For a given t, Ts is minimized by maximizing 100000 Magnesium alloys Tungsten alloys
M 2 = Tm
10
100 1000 10000
The selection. The figure shows the two indices, created using the CES M2 = Melting Point (C)
Edu 2 database. The top-ranked candidates are listed below.
Material Comment
Silicon carbide, SiC Silicon carbide out-performs all metals except
tungsten, and is much lighter. If used, its
brittleness would have to be reckoned with..
Copper alloys The exceptional thermal conductivity of copper
is dominating here it is able to conduct heat
away from the surface quickly, limiting the
surface heating.
Aluminum alloys An attractive choice, since Al-alloys are also
light
Aluminum Silicon This metal matrix composite has almost the
carbide MMC thermal conductivity of aluminum and is stiffer
and stronger.
(c) Using CES to apply the constraints gives the selection shown in the
below.
Selection using CES Comment
CES Level 2 links the shape (3-D solid) to
Investment casting closed die forging, for which the economic
batch size is > 1000. The charts give a range
Machining from solid that includes open die forging, not practical for
such a complex shape.
Figure E13
(c) Using CES to apply the constraints gives the selection shown in the
below.
Selection using CES Comment
Injection molding The selection is identical with that derived
Compression molding from the charts, but the software also
delivers data files containing supporting
information for each process.
Figure E14
(c) Applying CES to the problem gives the selection shown in the
below.
Selection using CES Comment
(c) Applying CES to the problem gives the selection shown in the
below.
Selection using CES Comment
(c) Applying CES to the problem gives the selection shown in the
below.
Selection using CES Comment
(a) Use CES to select a surface treatment process to meet the following
requirements. Selection using CES Level 1 or 2 Comment
Carburizing and carbonitriding
Nitriding
There are many ways to
Induction and flame hardening
Function Increase the surface hardness and wear increase the surface hardness
Laser surface hardening
resistance of a high carbon steel component of carbon steel.
Electro plating
Constraints Material class: carbon steel Vapor metallizing
Purpose of treatment: increase surface
hardness and wear resistance
(b) Applying CES to the problem gives the selection shown in the
Objective -- below.
Free variables Choice of process
(b) Use CES to select a joining process to meet the following Selection using CES Level 1 or 2 Comment
requirements. Cubic printing
Pad printing
All are practical
Electroless plating
Organic-solvent based painting
Function Apply color and pattern to the curved
Water-based painting
surface of a polymer molding
Constraints Material class: thermoplastic
Purpose of treatment: aesthetics, color
Curved surface coverage: good or very
good
Objective --
Free variables Choice of process
Answer. The derivation of performance equations and the indices they contain is laid out here:
Substitute for A
F E A F
Stiffness constraint = m1 = L2 M1 = (1)
L E E
m= AL
Substitute for A
Strength constraint F =y A m2 = L F M2 = (2)
y y
(a) Write, first, a performance equation for the mass m of the pressure
vessel. Assume, for simplicity, that it is spherical, of specified radius R,
and that the wall thickness, t (the free variable) is small compared with
R. Then the tensile stress in the wall is
p R
=
2t
Figure E21
Granta Design, January 2009
Answer. The objective function is the mass of the pressure vessel:
m = 4 R 2t
The tensile stress in the wall of a thin-walled pressure vessel (Appendix A, Section A11) is
p R
=
2t
Equating this first to the yield strength y , then to the fracture strength K 1c / c and substituting for t
in the objective function leads to the performance equations and indices laid out below.
pR
Yield constraint = y m1 = 2 p.R 3 M1 = (1)
2 t f y
Substitute for t
m = 4 R 2t
pR K 1c
Fracture constraint = m 2 = 2 p R 3 ( c )1 / 2 M2 = (2)
2 t c K 1c K 1c
Substitute for t
The coupling equation is found by equating m1 to m2, giving a relationship between M1 and M2:
M 1 = ( c)1/2 M 2
The position of the coupling line depends on the detection limit, c1 for cracks, through the term ( c)1/2.
The figure shows the appropriate chart with two coupling lines, one for c = 5 mm and the other for c = 5m.
The resulting selection is summarised in the table.
2 EI
F
H2
The right-hand side is the Euler buckling load in which E is Youngs
modulus. The second moment of area for a circular column (Appendix A,
Section A2) is
4
Figure E23 I= D
64
The subsequent steps in the derivation of performance equations are laid out
on the next page:
Substitute for D
D2 C
Crushing constraint Ff c C1 = F H m (1)
4 c
C = D 2 H Cm
4
Substitute for D
2 EI 3 D4 E 2 C
Buckling constraint F = C2 = F 1/2 H 2 m (2)
1/2
H2 64 H 2 E 1/2
C C
The first performance equation contains the index M 1 = m , the second, the index M 2 = m .
c E 1/2
~
This is a min-max problem: we seek the material with the lowest (min) cost C which itself is the larger
(max) of C1 and C2. The two performance equations are evaluated in the Table, which also lists
~
C = max ( C1 , C 2 ). for a column of height H = 3m, carrying a load F = 105 N. The cheapest choice is
concrete.
Coupling
lines
Large F/H2
Small F/H2
m C
Function Air cylinder for truck Z* = * +
Constraints Must not fail by yielding mo Co
Diameter 2R and length L specified. where * is a relative exchange constant, and plot a contour that is
Objectives Minimize mass m approximately tangent to the trade-off surface for * = 1 and for * =
Minimize material cost C 100. What selections do these suggest?
Free variables Wall thickness, t
Choice of material
Figure E24
(a) Show that the mass and material cost of the tank relative to one made of
low-carbon steel are given by
m y ,o C y ,o
= and = Cm
mo y o Co y C m ,o o
Figure E25
m = 2R L t + 4 R 2 t = 2R L t ( 1 + Q )
Trade off
where Q, the aspect ratio 2R/L, is fixed by the design requirements.
surface
The stress in the wall of the tank caused by the pressure p must not
exceed y , is the yield strength of the material of the tank wall,
meaning that
pR
= y
t
Substituting for t, the free variable, gives
m = 2R 2 L p ( 1 + Q )
y
The material cost C is simply the mass m times the cost per kg of the
material, Cm, giving
C
C = C m m = 2R 2 L p ( 1 + Q ) m
y *
Z* with * = 1 Z* with * = 100
from which the mass and cost relative to that of a low-carbon steel
(subscript o) tank are
m y ,o
= and To get further we need a penalty function. The relative penalty function
mo y o
m C
Z* = * +
mo Co
C y ,o
= Cm
Co y C m ,o o plots as a family of curves for a given value of *. If the axes were linear
these would be straight lines, but because the axes are logarithmic Z
The figure shows the trade-off surface. Materials on or near this contours are curved. Two that are tangent to the trade-off surface are
surface have attractive combinations of mass and cost. Several are shown. The first, for * = 1 (meaning the halving the weight doubles the
better low-carbon steel. allowable price) identifies higher strength steels as good choices. This is
because their higher strength allows a thinner tank wall. The contour for *
= 100 touches near CFRP, aluminum and magnesium alloys if weight
saving is very highly valued, these become attractive solutions.
Figure E27
1 Penalty line
Z = 1 + 2
E for 1/2 = 100
Figure E28
h1 / 2 h2 / 2
I =2 y 2 h1 dy 2 y 2 h2 dy
0 0
=
1 4
12
(
h 1 h 42 ) =
2 3
th
3 1
and
Figure E29 A = h12 h22 4 h1 t
Answer. Assembling these results, and inserting h1 = 10t gives
1 h1
(a) The shape factor for elastic bending of a tubular beam (left-hand Be = =5
figure) is defined by 2 t
12 I
Be =
A2
where I is the second moment of area and A is the area. The second
moment of area, I, of the tube about the axis shown as a dotted line is
I = (5 t )4 (4 t )4 = 92.25 t 4
4 4
Its cross section area is A = (5 t )2 (4 t )2 = 9 t 2
12 I
from which Be = = 4.35
A2
(b) The second moment, Z, of the channel about the axis shown as a f 2 / 3
B f
dotted line is M =
I
Z = = 49.2 t 3
5t
6Z
from which Bf = = 3.87
A3 / 2
(b) The shape factor is given in terms of m, L and SB by the equation Function Light weight beam
given in the question. Substituting S B 300 mg / L gives
Constraints Specified strength
3600 L4 g 2 Length L specified
Be =
C1 m E Objective Minimum mass m
Inserting C1 = 384/5 (Appendix A, Section A3) and the data from the Free variables Choice of material
table gives the results shown below.
Section shape and scale
f 2 / 3
B f
M3 =
(i) structural steel with a shape factor Be of 20, modulus E = 210 GPa (b) Direct calculation of E * / * with E * = E / Be and
and density = 7900 kg/m3
* = / Be is shown in the table.
(ii) carbon fiber reinforced plastic with a shape factor Be of 10,
modulus E = 70 GPa and density = 1600 kg/m3, and
E* = E / Be * = / Be E* / *
Material
(iii) structural timber with a shape factor Be of 2, modulus E = 9 GPa (N/m ) 2
(kg/m ) 3
(N/m2 )1/2/(kg/m3)
and density = 520 kg/m 3.
Steel 10.5 x 10 9
395 259
The schematic Figure E31 illustrates the method. CFRP 7.0 x 109 160 523
Softwood 4.5 x 109 260 258
The higher the value of E* / * the lighter is the beam. The ranking is
the same as that arrived at in Part (a).
Figure E31
(b) Show, by direct calculation, that the conclusions of part (a) are
consistent with the idea that to minimize mass for a given stiffness one
should maximize E * / with E * = E / Be and * = / Be .
2/3
The higher the value of Bf f / the lighter is the beam. The
Figure E32
ranking is the same.
(b) Show, by direct calculation, that the conclusions of part (a) are
consistent with the idea that to minimize mass for a given stiffness one
Bf f
should maximize .
(c) Compare wood and steel in a second way. Construct a line of slope 1,
passing through carbon steels on the Modulus / Production energy
chart of Figure 16.8, and move steels down both axes by the factor 15,
as in Figure 11.16. Move Wood (// to grain) down by a factor of 2
The shaped steel can be compared with other materials wood, say
using the ordinary guide-lines which are shown on the figure. Is the
conclusion the same?
(d) Repeat the procedure for strength, using the Strength / Production
energy chart of Figure 16.9.
What do you conclude about the relative energy-penalty of design with
wood and with steel?
where E is the modulus, the density, Hp the energy content per Steel 200 198 4 0.4
unit weight, and Be is the shape factor for stiffness controlled design.
The first Table shows values of M1 for the wood, the concrete and the (a) The first figure below shows the chart of Figure Chart 16.8 with the
shaped steel beam. Wood wins. shaped wood and steel marked on it, and with a line for M1. Even
with shape, the steel beam is less energy efficient than the wooden
one.
Material E H p Be M1
(GPa) (GPa /GJ/m3)
1/2
(d) The second figure below shows the chart of Figure Chart 16.9 with
(GJ/m3) the shaped wood and steel marked on it, and with a line for M2. Again,
Wood 10 10.5 2 0.43 the steel beam is less energy efficient than the wooden one, despite its
Concrete 35 9.3 2 0.9 large shape factor.
(b) The index for an energy efficient beam of prescribed strength is,
from Table 7.4 of the book:
2/3
f
B f
M2 =
H p
f
Where B is the shape factor for failure in bending. The next table
shows that, as before, wood is the most efficient material. The same
conclusion is reached by shifting wood and steel on the Strength-Energy
Content chart (Chart 18) by the appropriate factor
Z f h 1
Bf = = =
Z s f ,s t ( / s )1 / 2
The shape-efficiency factor for strength is equal to the reciprocal of the
square root of the relative density.
Figure E35
E9.1 Concepts for light, stiff composites. Figure E36 is a chart for
exploring stiff composites with light alloy or polymer matrices. A
construction like that of Figure 13.10 of the text allows the potential of
any given matrix-reinforcement combination to be assessed. Four
matrix materials are shown, highlighted in red. The materials shown in
gray are available as fibers (f), whiskers (w) or particles (p). The
criteria of excellence (the indices E / , E 1 / 2 / and E 1 / 3 / for
light, stiff structures) are shown; they increase in value towards the top
left. Use the chart to compare the performance of a titanium-matrix
composite reinforced with (a) zirconium carbide, ZrC, (b) Saffil
alumina fibers and (c) Nicalon silicon carbide fibers. Keep it simple:
use equations 13.1 13.3 to calculate the density and upper and lower
bounds for the modulus at a volume fraction of f = 0.5 and plot these
points. Then sketch arcs of circles from the matrix to the reinforcement
to pass through them. In making your judgement, assume that f = 0.5 is
the maximum practical reinforcement level.
Figure E36
Figure E37
(b) Do the same thing for strength with a copy of Figure 14.12, using the
(b) The comparison for strength, using criterion of excellence,
flexural strength index 2f / 3 / (where f is the failure stress) as criteria
2f / 3 / , is highlighted. Again, natural materials excel. CFRP alone
of excellence.
competes with wood, bamboo and palm.
The table lists the necessary data.
(a) Cement
Answer. The modulus and density of compact bone match closely those of
magnesium and glass fiber reinforced epoxy, GFRP. These materials (b) Wood
work well for external braces. For prostheses, bio-compatibilty is
important. This leads to the used of cobalt and titanium-based alloys (c) Polypropylene
even though the match of mechanical properties is very poor. Efforts (d) Steel
are underway to develop a bio-compatible polyethylene/hydroxyapatite
composites with a near perfect match of properties. Hydroxyapatite is a (e) Copper.
natural ceramic that is found in real bone it appears on the charts for
natural materials.
0
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M A T E R I A L I N S P I R A T I O N
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