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ces edupack material selection
- 1. Advance Material and Manufacturing Technologies By Shobin John 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 1 CASE1:Material Selection
- 2. MATERIAL WORLD The material world serves a huge list of functions. The evolution was faster and the range of properties more varied. The birth of materials is dated back to the birth of the first invention , though it existed even before New materials were invented with time and its applications varied From wheel to the ultra modern Nano-technology instruments – material is vital Ashby’s chart depicts the material invention and its usage over the years 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se2
- 3. • Classifying materials is vital for the ease of identification in practical applications • Periodic table was one great invention but not good enough as it does not include the whole list of engineering materials • Ashby’s classification of materials can overcome this drawback and is as depicted in the picture 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 3
- 4. SELECTION OF MATERIALS • The task of material selection can be simplified by its ordered classification into kingdom, family, class, subclass, member and attributes (Ashby’s selection method) • This can be used to arrive at a point specific from a diverse wide • An example is as depicted in the diagram 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 4
- 5. SELECTION TECHNIQUE and its structure • The myriad number of materials and its diverse properties, makes material selection process peccable • CES EduPack is a software to overcome this dilemma • It helps to identify the apt material from the material classification world. The structure of the software is as shown in the second figure 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 5
- 6. CES SOFTWARE AND TYPES OF CHARTS • CES software makes the material selection process less tedious • A huge list of material properties and its applications are included in its database • Chart is the main tool used in this software for screening the choices • It can be done making use of either the bubble chart or the bar chart as depicted • Comparison of the selected materials can be made through the graph based on the desired characteristics 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 6
- 7. MATERIAL SELECTION FOR PRODUCT DEVELOPMENT PROCESS DISC CLUTCH Project involves flywheel installed on bicycle and is named as Flywheel on bicycle. System requires a component clutch which is used to adjust the gear and flywheel. The engagement and disengagement for changing gear and flywheel is the function of clutch Importance was low to moderate as identified in the QFD 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se7
- 8. IDENTIFYING ATTRIBUTES Primary feature being machinability and possessing high hardness. Price factor has to be low due to the relatively low importance shown from the QFD analysis Aesthetically high will add value Heat carrying capacity has to be moderately high to overcome friction and heat generation. Chemical inertness and recyclability can help in improving environmental aspects 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se8
- 9. RANKING ATTRIBUTES AND GRAPH SELECTION SL NO ATTRIBUTES 1 MACHINABILITY 2 PRICE 3 SPECIFIC HEAT CAPACITY 4 RECYCLABILITY 5 ELECTRICAL PROP 6 TENSILE STRENGTH 7 HARDNESS RANK ATTRIBUTES 1 MACHINABILITY 2 SPECIFIC HEAT CAPACITY 3 PRICE 4 HARDNESS 5 RECYCLABILITY 6 TENSILE STRNGTH 7 ELECTRICAL PROP Attribute ranking shows that the material has to be identified on the properties of hardness, specific heat capacity, machinability and price Following graphs are selected for material selection • Hardness vs. Specific heat • Price vs. Specific heat • Machinability vs Price 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se9
- 10. Hardness vs. specific heat capacity this graph is used for the primary screening of material as identified from the attribute ranking the desired category is identified as the Hardness section the materials have higher specific heat and hardness of the graph is assumed to serve the purpose and compared against the other graphs as identified Aluminum alloy, high carbon steel and aluminum/silicon carbide composite are chosen to start with 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se10
- 11. PRICE vs. SPECIFIC HEAT CAPACITY Trivial importance of the component realizes the vital importance of the material cost The price range is chosen as shown as the desired category This eliminates ALUMINUM/SILICON CARBIDE COMPOSITE which was chosen in the first graph as it costs around 5 USD/lb. ALUMINUM ALLOY and HIGH CARBON STEEL exist Specific heat capacity (BTU/lb.°F) 0.05 0.1 0.2 0.5 Price(USD/lb) 0.01 0.1 1 10 100 1000 10000 Price vs Specific heat capacity Cast iron, gray High carbon steel Cast Al-alloys Aluminum/Silicon carbide composite 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se11
- 12. MACHINABILITY VS PRICE The final graph indicates CAST ALUMINUM ALLOY as the material to be selected Though HIGH CARBON STEEL can be an alternative, the machinability aspect indicates that it cannot be apt Further the recyclability, high melting point and service temperatures, electrical insulation and chemical inertness shows that CAST ALUMINUM ALLOY can be selected over HIGH CARBON STEEL and ALUMINUM/SILICON CARBIDE COMPOSITE Price (USD/lb) 0.1 1 10 Machinability 1 2 3 4 5 Machinability vs Process Cast iron, gray High carbon steel Aluminum/Silicon carbide composite Cast Al-alloys 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se12
- 13. Final selection and alternatives MATERI AL HARDNE SS PRICE HEAT CAPACIT Y MACHIN ABILITY RECYCLE CHEMIC AL RESISTA NCE ELECTRI CAL RESISTIV ITY CAST ALUMIN UM ALLOY 60- 150HV 0.989- 1.09USD /lb 0.215- 0.238BT U/lb.°F 4.5 YES YES 2.5- 8µohm.c m HIGH CARBON STEEL 400HV 0.2USD/ LB 0.18BTU /LB,F 3.5 YES YES 200MIC ROOHM. CM ALUMIN UM/SILI CON CARBIDE COMPOS ITE 70- 140HV 2.82- 3.76USD /lb 0.191- 0.215BT U/lb.°F 1.7 YES YES 5- 12µohm. cm 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 13
- 14. CONCLUSION: CAST ALUMINUM ALLOY WAS THE APT MATERIAL AS IT COVERED A WIDE RANGE OF DESIRED CHARACTERISTICS. Mechanical properties Young's modulus 10.4 - 12.9 10^6 psi Shear modulus 3.63 - 4.93 10^6 psi Bulk modulus 9.57 - 10.4 10^6 psi Poisson's ratio 0.32 - 0.36 Yield strength (elastic limit) 7.25 - 47.9 ksi Tensile strength 9.43 - 56 ksi Compressive strength 7.25 - 47.9 ksi Elongation 0.4 - 10 % strain Fatigue strength at 10^7 cycles 4.64 - 22.8 ksi Mechanical loss coefficient (tan delta) 1e-4 -0.002 ALTERNATIVES: Suggestion 1: HIGH CARBON STEEL Reason: The table indicates HIGH CARBON STEEL to have a desired characteristics except machinability. aspect in context of the product. Suggestion 2: ALUMINUM/SILICON CARBIDE COMPOSITE Reason: The table indicates ALUMINUM/SILICON CARBIDE COMPOSITE to possess the highest electrical resistance and the moderate hardness. The price being on the higher end is a concern but can still be used where reliable is valued over price. 1/10/2017 halmstad university, masters in mechanical engineering 2015. shojoh15@student.hh.se 14