Materials Selection in Mechanical Design (eBook)

Cover 1
Contents 6
Preface 12
Acknowledgements 13
Features of the Third Edition 14
Chapter 1 Introduction 16
1.1 Introduction and synopsis 17
1.2 Materials in design 17
1.3 The evolution of engineering materials 19
1.4 Case study: the evolution of materials in vacuum cleaners 21
1.5 Summary and conclusions 23
1.6 Further reading 23
Chapter 2 The design process 26
2.1 Introduction and synopsis 27
2.2 The design process 27
2.3 Types of design 31
2.4 Design tools and materials data 32
2.5 Function, material, shape, and process 34
2.6 Case study: devices to open corked bottles 35
2.7 Summary and conclusions 39
2.8 Further reading 40
Chapter 3 Engineering materials and their properties 42
3.1 Introduction and synopsis 43
3.2 The families of engineering materials 43
3.3 The definitions of material properties 45
3.4 Summary and conclusions 58
3.5 Further reading 59
Chapter 4 Material property charts 60
4.1 Introduction and synopsis 61
4.2 Exploring material properties 61
4.3 The material property charts 65
4.4 Summary and conclusions 92
4.5 Further reading 93
Chapter 5 Materials selection„the basics 94
5.1 Introduction and synopsis 95
5.2 The selection strategy 96
5.3 Attribute limits and material indices 100
5.4 The selection procedure 108
5.5 Computer-aided selection 114
5.6 The structural index 117
5.7 Summary and conclusions 118
5.8 Further reading 119
Chapter 6 Materials selection„case studies 120
6.1 Introduction and synopsis 121
6.2 Materials for oars 121
6.3 Mirrors for large telescopes 125
6.4 Materials for table legs 129
6.5 Cost: structural materials for buildings 132
6.6 Materials for flywheels 136
6.7 Materials for springs 141
6.8 Elastic hinges and couplings 145
6.9 Materials for seals 148
6.10 Deflection-limited design with brittle polymers 151
6.11 Safe pressure vessels 155
6.12 Stiff, high damping materials for shaker tables 159
6.13 Insulation for short-term isothermal containers 162
6.14 Energy-efficient kiln walls 166
6.15 Materials for passive solar heating 169
6.16 Materials to minimize thermal distortion in precision devices 172
6.17 Nylon bearings for ships’ rudders 175
6.18 Materials for heat exchangers 178
6.19 Materials for radomes 183
6.20 Summary and conclusions 187
6.21 Further reading 187
Chapter 7 Processes and process selection 190
7.1 Introduction and synopsis 191
7.2 Classifying processes 192
7.3 The processes: shaping, joining, and finishing 195
7.4 Systematic process selection 210
7.5 Ranking: process cost 217
7.6 Computer-aided process selection 224
7.7 Supporting information 230
7.8 Summary and conclusions 230
7.9 Further reading 231
Chapter 8 Process selection case studies 234
8.1 Introduction and synopsis 235
8.2 Forming a fan 235
8.3 Fabricating a pressure vessel 238
8.4 An optical table 242
8.5 Economical casting 245
8.6 Computer-based selection: a manifold jacket 247
8.7 Computer-based selection: a spark plug insulator 250
8.8 Summary and conclusions 252
Chapter 9 Multiple constraints and objectives 254
9.1 Introduction and synopsis 255
9.2 Selection with multiple constraints 256
9.3 Conflicting objectives, penalty-functions, and exchange constants 260
9.4 Summary and conclusions 269
9.5 Further reading 270
Appendix: Traditional methods of dealing with multiple constraints and objectives 271
Chapter 10 Case studies„multiple constraints and conflicting objectives 276
10.1 Introduction and synopsis 277
10.2 Multiple constraints: con-rods for high-performance engines 277
10.3 Multiple constraints: windings for high-field magnets 281
10.4 Conflicting objectives: casings for a mini-disk player 287
10.5 Conflicting objectives: materials for a disk-brake caliper 291
10.6 Summary and conclusions 296
Chapter 11 Selection of material and shape 298
11.1 Introduction and synopsis 299
11.2 Shape factors 300
11.3 Microscopic or micro-structural shape factors 311
11.4 Limits to shape efficiency 316
11.5 Exploring and comparing structural sections 320
11.6 Material indices that include shape 322
11.7 Co-selecting material and shape 327
11.8 Summary and conclusions 329
11.9 Further reading 331
Chapter 12 Selection of material and shape: case studies 332
12.1 Introduction and synopsis 333
12.2 Spars for man-powered planes 334
12.3 Ultra-efficient springs 337
12.4 Forks for a racing bicycle 341
12.5 Floor joists: wood, bamboo or steel? 343
12.6 Increasing the stiffness of steel sheet 346
12.7 Table legs again: thin or light? 348
12.8 Shapes that flex: leaf and strand structures 350
12.9 Summary and conclusions 352
Chapter 13 Designing hybrid materials 354
13.1 Introduction and synopsis 355
13.2 Filling holes in material-property space 357
13.3 The method: "A + B + configuration + scale" 361
13.4 Composites: hybrids of type 1 363
13.5 Sandwich structures: hybrids of type 2 373
13.6 Lattices: hybrids of type 3 378
13.7 Segmented structures: hybrids of type 4 386
13.8 Summary and conclusions 391
13.9 Further reading 391
Chapter 14 Hybrid case studies 394
14.1 Introduction and synopsis 395
14.2 Designing metal matrix composites 395
14.3 Refrigerator walls 397
14.4 Connectors that do not relax their grip 399
14.5 Extreme combinations of thermal and electrical conduction 401
14.6 Materials for microwave-transparent enclosures 404
14.7 Exploiting anisotropy: heat spreading surfaces 406
14.8 The mechanical efficiency of natural materials 408
14.9 Further reading: natural materials (see also Appendix D) 414
Chapter 15 Information and knowledge sources for design 416
15.1 Introduction and synopsis 417
15.2 Information for materials and processes 418
15.3 Screening information: structure and sources 422
15.4 Supporting information: structure and sources 424
15.5 Ways of checking and estimating data 426
15.6 Summary and conclusions 430
15.7 Further reading 431
Chapter 16 Materials and the environment 432
16.1 Introduction and synopsis 433
16.2 The material life cycle 433
16.3 Material and energy-consuming systems 434
16.4 The eco-attributes of materials 437
16.5 Eco-selection 442
16.6 Case studies: drink containers and crash barriers 448
16.7 Summary and conclusions 450
16.8 Further reading 451
Chapter 17 Materials and industrial design 454
17.1 Introduction and synopsis 455
17.2 The requirements pyramid 455
17.3 Product character 457
17.4 Using materials and processes to create product personality 460
17.5 Summary and conclusions 469
17.6 Further reading 470
Chapter 18 Forces for change 472
18.1 Introduction and synopsis 473
18.2 Market-pull and science-push (extreme right and left of Figure 18.1) 473
18.3 Growing population and wealth, and market saturation (sector 1, Figure 18.1) 479
18.4 Product liability and service provision (sector 2, Figure 18.1) 480
18.5 Miniaturization and multi-functionality (sector 3, Figure 18.1) 481
18.6 Concern for the environment and for the individual (sector 4, Figure 18.1) 482
18.7 Summary and conclusions 484
18.8 Further reading 484
Appendix A Useful solutions to standard problems 486
A.1 Constitutive equations for mechanical response 489
A.2 Moments of sections 491
A.3 Elastic bending of beams 493
A.4 Failure of beams and panels 495
A.5 Buckling of columns, plates, and shells 497
A.6 Torsion of shafts 499
A.7 Static and spinning disks 501
A.8 Contact stresses 503
A.9 Estimates for stress concentrations 505
A.10 Sharp cracks 507
A.11 Pressure vessels 509
A.12 Vibrating beams, tubes, and disks 511
A.13 Creep and creep fracture 513
A.14 Flow of heat and matter 515
A.15 Solutions for diffusion equations 517
A.16 Further reading 519
Appendix B Material indices 522
B.1 Introduction and synopsis 523
B.2 Uses of material indices 523
Appendix C Data and information for engineering materials 528
C.1 Names and applications: metals and alloys 529
C.2 Names and applications: polymers and foams 530
C.3 Names and applications: composites, ceramics, glasses, and natural materials 531
C.4 Melting temperature, Tm , and glass temperature, Tg1 533
C.5 Density, r 535
C.6 Young’s modulus, E 537
C.7 Yield strength, ry , and tensile strength, rts 539
C.8 Fracture toughness (plane-strain), K1C 541
C.9 Thermal conductivity, l 543
C.10 Thermal expansion, a 545
C.11 Approximate production energies and CO2 burden 547
C.12 Environmental resistance 549
Appendix D Information and knowledge sources for materials and processes 552
D.1 Introduction 553
D.2 Information sources for materials 553
D.3 Information for manufacturing processes 567
D.4 Databases and expert systems in software 568
D.5 Additional useful internet sites 569
D.6 Supplier registers, government organizations, standards and professional societies 570
Appendix E Exercises 572
E.1 Introduction to the exercises 573
E.2 Devising concepts 574
E.3 Use of material selection charts 574
E.4 Translation: constraints and objectives 577
E.5 Deriving and using material indices 580
E.6 Selecting processes 589
E.7 Multiple constraints and objectives 594
E.8 Selecting material and shape 602
E.9 Hybrid materials 609
Index 614