MATERIALS

1. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Selection materials for drive shaft between rack and the clock
Function – Transmitting power gain from movement of the float due tides to clock.
Constraints - The shaft must be strength enough to bear the load and should have a better
Resistance to corrosion due to salinity environment
Objective - To design a power transmission shaft which having high strength, durable, high.
Corrosive resistance, Light weight, and low price

2. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Making of performance index for the graph use to find out materials for the drive shaft between
rack and clock.
By applying formula for torsion of the shaft
𝜎
𝑟
=
𝑇
𝐽
𝜎 − 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 (𝑀𝑃𝑎 )
T – Torque (Nm)
r- Radius (mm)
𝐽 − 𝑃𝑜𝑙𝑎𝑟 𝑚𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎
To make shear stress as subject of the formula
𝜎 =
𝑇 𝑥 𝑟
𝐽
𝜎 =
𝑇 𝑥 𝑟
𝐽
---------- 1
𝐽 is polar moment of inertia, which for solid cylinder?
𝐽 =
𝜋𝑥 𝑟4
2
-------------(2)
By substituting the values from 2 to 1
𝜎 =
2𝑇
𝜋𝑟3
--------------- (3)
The mass can derive as form of density and volume.
m = 𝜋𝑥 𝑟2
x L x
√
𝑚
𝜋 𝑥 𝐿 𝑥 𝑝
= 𝑟 ------------------- (4)

3. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
By substituting the (4) in (3)
𝜎 =
2𝑇
𝜋 ( √
𝑚
𝜋 𝑥 𝐿 𝑥 𝑝
3
)
By solving the formula expression for mass
m = (2𝑇)3 𝑋 (
2
𝜋3 𝑥 𝐿 ) (
1 𝑝
𝜎3
2 )
By considering the cost of the material
Total cost = mass x unit cost
K = (2𝑇)3 𝑋 (
2
𝜋3 𝑥 𝐿 ) (
1 𝑝
𝜎3
2 ) x U. c
K1 =
𝑝 .𝑈.𝑐
𝜎3
2 --------------- (A)
Getting reciprocal of (A) to reduce the cost of the material.
1
𝐾1
=
𝜎3
2
𝑝 .𝑈.𝑐
K2 =
𝜎3
2
𝑝 .𝑈.𝑐
𝑝 . 𝑈. 𝑐 x K2 = 𝜎 2
3
⁄
To form 𝑦 = 𝑚𝑥 + 𝑐 function getting log values for both side of the function

4. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
log10 𝜎 =
3
2
log10( 𝑝 . 𝑈. 𝑐) +
3
2
log10( 𝐾2 )
𝑦 = 𝑚𝑥 + 𝑐
Material Selection for the drive shaft
By using performance index, with the help of CES software graph was plotted yield strength versus
density into price of the materials. The gradient of the graph is 1.5.
Figure 1- The graph from CES

5. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
By using performance index, with the help of the CSE software in here I selected three materials
which are suitable for manufacturing drive shaft between rack and the clock.
• Cast Iron
• Stainless Steel
• Medium carbon steel
Properties of the materials
Property
Medium Carbon Steel
AISI 1045, Normalized
condition
(Annexure 1.0)
Stainless Steel
AISI 316
Cold work
(Annexure 2.0)
Cast iron Ductile.
ASTM A536,
(Annexure 3.0)
Density 7870 kg/𝑚3
7900 kg/𝑚3
7100 kg/𝑚3
Tensile Strength,
Yield
310 MPa
215 MPa 276 Map
Tensile Strength 565 MPa 515 MPa 413 MPa
Shear Modulus 80 GA 81 GA 65 GA
Brinell Hardness 163 MPa 175 MPa 173 MPa
Table 1- Properties of the selcted materials for the shaft

6. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Advantages and disadvantages of the materials
Advantages Of medium carbon steel (080M46 or 43A, AISI 1045)
• It is appropriate for demanding applications because it possesses exceptional tensile
strength and hardness.
• It is simple to machine into many shapes and forms, enabling effective manufacturing
procedure.
• AISI 1045 is appropriate for welding when medium-carbon steel joining methods are
applied.
• The wear-resistance of this material is a result of its distinctive structure. Because of the
higher wear resistance provided by the carbides in the pearlite structure, 1045 carbon
steel is excellent for components that are subjected to wear and friction.
.
• Suitable material for manufacturing shafts.
• When normalized or hot-rolled, AISI 1045 steel possesses good machinability. Operations
including tapping, milling, broaching, drilling, turning, and sawing can be done on AISI
1045 steel using the right feeds, tool types, and speeds.
Disadvantages of medium carbon steel
• Corrosion resistance is not very good, especially in severe conditions. To stop corrosion, it
might need additional protective coatings or upkeep.
• Compared to some other steel grades, it can only be partially heat treated to become harder.
This may prevent it from being used in situations where high hardness is necessary.
• Components made of 1045 carbon steel are susceptible to distortion or cracking from
improper heat treatment or welding methods.
• When compared to some specialty steels, 1045 carbon steel is not regarded as a high-cost
material, although it can be more expensive than lower-grade carbon steels.

7. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Advantages Of Stainless Steel (AISI 304)
• 316 Stainless Steel is More Corrosion Resistant than Other Types of Steel
• 316 Stainless Steel is Non-Magnetic
• 316 Stainless Steel is Easy to Clean
• 316 Stainless Steel is Strong and Durable
Disadvantages Of Stainless Steel (AISI 316)
• 316 stainless steel is less strong than other types of steel.
• It is susceptible to corrosion from certain chemicals and environments.
• It can be challenging to weld 316 stainless steels.
• It is more expensive than other types of stainless steel.
• It is not as heat resistant as other types of stainless steel.
Advantages Of Ductile Cast Iron
• Ductile Cast Iron High Strength and Durability Compared to grey cast iron.
• Ductile iron has higher tensile strength, yield strength, and elongation, making it suitable
for heavy-duty applications requiring stress resistance.
• Good Machinability Ductile cast iron is more accessible to machines than steel or
aluminum due to its lower hardness and better lubrication properties.
• Good Casting Properties Ductile iron has excellent fluidity, filling complex molds with
intricate details and thin sections. It can also be cast in larger sizes without porosity or
cracking.

8. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
• Corrosion Resistance Due to its high carbon content and protective graphite layer, ductile
iron is resistant to corrosion from many chemicals, water, and atmospheric conditions.
Disadvantages of the ductile cast iron
• Although ductile iron is more malleable than grey iron, it can still fracture
suddenly and without warning under the high impact, making it unsuitable for
shock-sensitive applications or structures.
• Ductile iron is difficult to weld due to its high carbon content, tendency to
crack, and limited heat conductivity.
• Ductile iron is prone to variations in its mechanical and physical properties,
depending on the manufacturing process.
• The production of ductile iron involves high energy consumption and
emissions of greenhouse gases, such as carbon dioxide and methane.
Manufacturing Methods of shaft by selected materials
Medium Carbon Steel AISI 1045, Shaft can be manufactured by turning a shaft by
using CNC or manual lathe. Then after hardening
can be done for increase the hardness of the shaft
Stainless Steel AISI 304
Shaft can be manufactured by turning a shaft by
using CNC or manual lathe
Cast iron Ductile ASTM A536, GRADE
60-40-18
A rigid shaft can be produced by using quality
casting or ready-made cast-iron shaft can be
machined or turning by using lathe
Table 2-Manufacturing method

9. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Performance index
Price of the materials Kg/ GBR
Material Kg / GBR
Medium Carbon Steel AISI 1045 (annexure -1a) 2.1
Stainless steel AISI 316 (annexure-1b) 2.38
Cast Iron Ductile (annexure-1c) 1.34
Table 3- Unit price of materials in GBR
Material K1=
𝜎2/3
𝑝
Rank
𝑘2 =
𝜎2/3
𝑝 . 𝑈. 𝑐
Rank
Medium Carbon
Steel AISI 1045
23.59 2 11.23 2
Stainless Steel
AISI 316
23.69 1 9.95 1
Cast Iron Ductile
GRADE 60-40-18
22.76 3 16.98 3
Table 4- Performance index comparison

10. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Ethical and environmental consideration
Material Corrosion against sea water and other
chemical parameters
Medium Carbon Steel
(AISI 1045)
They are also very corrosion-resistant,
which makes them ideal for marine
applications where exposure to salt
water or other corrosive substances may
be a problem.
Stainless Steel (AISI 316)
Compared to other metals, stainless
steel is better able to withstand
saltwater corrosion.
Cast iron Ductile (ASTM A536, GRADE
60-40-18)
Cast iron's ability to resist corrosion in
calm saltwater is not significantly
impacted by the existence of fissures.
Non-alloyed cast iron, on the other
hand, gets severely corroded by brief
exposure to seawater.
Carbon Emission
Material C02 emission per ton of
material
Rank
Medium Carbon Steel 1.5 – 3 Tons 1
Stainless Steel 0.39 Tons 3
Cast Iron Ductile 0.76 Tons 2
Annexure_ 03 Annexure _04

11. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
Conclusion
Rank Medium
Carbon Steel
(AISI 1045)
Stainless
steel
(AISI 316)
Ductile Cast Iron
GRADE 60-40-18
Low Density Kg/𝑚3
2 3 1
High Hardness 3 1 2
Perform Index 𝑘1=
𝜎2/3
𝑝
2 1 3
Perform Index cost
𝑘2 =
𝜎2/3
𝑝 . 𝑈. 𝑐
2 1 3
Environment
Consideration CO2
emission
3 1 2
Corrosion Resistance 3 1 2
Shear Modula’s 2 1 3
Table 5- Data conclusion table
According to above table Number 1 is given for the best performance for each criterion’s which
are discussed above. By considering. Performance index and cost stainless steel (AISI 316) can be
selected as the best material for the shaft when comparing other two materials. High shear modules mean
less angular deflection, so there for stainless steel has the rank 1 in that property and corrosion resistance.
When focusing on environmental considerations stainless steel is the best material which having low carbon
emission and its good for country like Britain where environmental laws are higher. So there for overall
STAINLESS STEEL AISI 316 perfects for producing drive shaft between rack and clocks.

12. MATERIALS FOR SHAFT- CHRISHAN MADUSHAN
ANNEXURES