Materials Selection in Mechanical Design (eBook)

Front Cover 1
Materials Selection in Mechanical Design 4
Copyright 5
Table of Contents 6
Preface 12
Acknowledgments 13
Features of the Fourth Edition 14
Chapter 1. Introduction 18
1.1 Introduction and Synopsis 19
1.2 Materials in Design 19
1.3 The Evolution of Engineering Materials 21
1.4 The Evolution of Materials in Products 25
1.5 Summary and Conclusions 29
1.6 Further Reading 29
Chapter 2. The Design Process 32
2.1 Introduction and Synopsis 33
2.2 The Design Process 33
2.3 Types of Design 37
2.4 Design Tools and Materials Data 38
2.5 Function, Material, Shape, and Process 40
2.6 Case Study: Devices to Open Corked Bottles 40
2.7 Summary and Conclusions 43
2.8 Further Reading 44
Chapter 3. Engineering Materials and Their Properties 48
3.1 Introduction and Synopsis 49
3.2 The Families of Engineering Materials 49
3.3 Materials Information for Design 52
3.4 Material Properties and Their Units 55
3.5 Summary and Conclusions 72
3.6 Further Reading 72
Chapter 4. Material Property Charts 74
4.1 Introduction and Synopsis 75
4.2 Exploring Material Properties 76
4.3 The Material Property Charts 81
4.4 Summary and Conclusions 110
4.5 Further Reading 112
Chapter 5. Materials Selection—The Basics 114
5.1 Introduction and Synopsis 115
5.2 The Selection Strategy 116
5.3 Material Indices 123
5.4 The Selection Procedure 132
5.5 Computer-Aided Selection 137
5.6 The Structural Index 139
5.7 Summary and Conclusions 140
5.8 Further Reading 140
Chapter 6. Case Studies: Materials Selection 142
6.1 Introduction and Synopsis 143
6.2 Materials for Oars 144
6.3 Mirrors for Large Telescopes 147
6.4 Materials for Table Legs 151
6.5 Cost: Structural Materials for Buildings 155
6.6 Materials for Flywheels 159
6.7 Materials for Springs 164
6.8 Elastic Hinges and Couplings 168
6.9 Materials for Seals 171
6.10 Deflection-limited Design with Brittle Polymers 174
6.11 Safe Pressure Vessels 177
6.12 Stiff, High-damping Materials for Shaker Tables 182
6.13 Insulation for Short-term Isothermal Containers 186
6.14 Energy-efficient Kiln Walls 189
6.15 Materials for Passive Solar Heating 192
6.16 Materials to Minimize Thermal Distortion in Precision Devices 195
6.17 Materials for Heat Exchangers 198
6.18 Heat Sinks for Hot Microchips 203
6.19 Materials for Radomes 206
6.20 Summary and Conclusions 211
6.21 Further Reading 211
Chapter 7. Multiple Constraints and Conflicting Objectives 214
7.1 Introduction and Synopsis 215
7.2 Selection with Multiple Constraints 216
7.3 Conflicting Objectives 220
7.4 Summary and Conclusions 228
7.5 Further Reading 228
7.6 Appendix: Weight Factors and Fuzzy Methods 229
Chapter 8. Case Studies: Multiple Constraints and Conflicting Objectives 234
8.1 Introduction and Synopsis 235
8.2 Multiple Constraints: Light Pressure Vessels 235
8.3 Multiple Constraints: Con-rods for High-performance Engines 239
8.4 Multiple Constraints: Windings for High-field Magnets 243
8.5 Conflicting Objectives: Table Legs Again 249
8.6 Conflicting Objectives: Wafer-thin Casings for Must-have Electronics 250
8.7 Conflicting Objectives: Materials for a Disk-brake Caliper 254
8.8 Summary and Conclusions 258
Chapter 9. Selection of Material and Shape 260
9.1 Introduction and Synopsis 261
9.2 Shape Factors 263
9.3 Limits to Shape Efficiency 274
9.4 Exploring Material-shape Combinations 277
9.5 Material Indices That Include Shape 282
9.6 Graphical Coselecting Using Indices 286
9.7 Architectured Materials: Microscopic Shape 287
9.8 Summary and Conclusions 291
9.9 Further Reading 293
Chapter 10. Case Studies: Material and Shape 294
10.1 Introduction and Synopsis 295
10.2 Spars for Human-powered Planes 296
10.3 Forks for a Racing Bicycle 299
10.4 Floor Joists: Wood, Bamboo, or Steel? 301
10.5 Table Legs Yet Again: Thin or Light? 304
10.6 Increasing the Stiffness of Steel Sheet 306
10.7 Shapes that Flex: Leaf and Strand Structures 308
10.8 Ultra-efficient Springs 310
10.9 Summary and Conclusions 313
Chapter 11. Designing Hybrid Materials 316
11.1 Introduction and Synopsis 317
11.2 Holes in Material-property Space 320
11.3 The Method: “A + B + Configuration + Scale” 322
11.4 Composites 324
11.5 Sandwich Structures 333
11.6 Cellular Structures: Foams and Lattices 345
11.7 Segmented Structures 353
11.8 Summary and Conclusions 355
11.9 Further Reading 356
Chapter 12. Case Studies: Hybrids 358
12.1 Introduction and Synopsis 359
12.2 Designing Metal Matrix Composites 359
12.3 Flexible Conductors and Percolation 361
12.4 Extreme Combinations of Thermal and Electrical Conduction 364
12.5 Refrigerator Walls 366
12.6 Materials for Microwave-Transparent Enclosures 369
12.7 Connectors That Don’t Relax Their Grip 371
12.8 Exploiting Anisotropy: Heat-spreading Surfaces 373
12.9 The Mechanical Efficiency of Natural Materials 375
12.10 Further Reading: Natural Materials 382
Chapter 13. Processes and Process Selection 384
13.1 Introduction and Synopsis 385
13.2 Classifying Processes 386
13.3 The Processes: Shaping, Joining, Finishing 389
13.4 Processing for Properties 405
13.5 Systematic Process Selection 409
13.6 Ranking: Process Cost 423
13.7 Computer-aided Process Selection 428
13.8 Summary and Conclusions 430
13.9 Further Reading 430
Chapter 14. Case Studies: Process Selection 432
14.1 Introduction and Synopsis 433
14.2 Casting an Aluminum Con-Rod 433
14.3 Forming a Fan 436
14.4 Spark Plug Insulators 446
14.5 A Manifold Jacket 448
14.6 Joining a Steel Radiator 450
14.7 Surface-hardening a Ball-bearing Race 452
14.8 Summary and Conclusions 453
Chapter 15. Materials and the Environment 454
15.1 Introduction and Synopsis 455
15.2 The Material Life-Cycle 455
15.3 Material and Energy-Consuming Systems 457
15.4 The Eco-Attributes of Materials 459
15.5 Eco-selection 464
15.6 Case Studies: Drink Containers and Crash Barriers 470
15.7 Summary and Conclusions 474
15.8 Further Reading 475
Chapter 16. Materials and Industrial Design 478
16.1 Introduction and Synopsis 479
16.2 The Requirements Pyramid 480
16.3 Product Character 481
16.4 Using Materials and Processes to Create Product Personality 484
16.5 Summary and Conclusions 493
16.6 Further Reading 493
Chapter 17. Forces for Change 496
17.1 Introduction and Synopsis 497
17.2 Market Pull and Science Push 497
17.3 Growing Population and Wealth and Market Saturation 504
17.4 Product Liability and Service Provision 504
17.5 Miniaturization and Multifunctionality 506
17.6 Concern for the Environment and for the Individual 507
17.7 Summary and Conclusions 509
17.8 Further Reading 509
Appendix A. Data for Engineering Materials 512
Table A.1 Names and Applications: Metals and Alloys 514
Table A.1 Names and Applications: Polymers and Foams 515
Table A.1 Names and Applications: Composites, Ceramics, Glasses, and Natural Materials 516
Table A.2 Melting Temperature, Tm, and Glass Temperature, Tg 517
Table A.3 Density, . 519
Table A.4 Young’s Modulus, E 521
Table A.5 Yield Strength, sy, and Tensile Strength, sts 523
Table A.6 Fracture Toughness (plane strain), KIC 525
Table A.7 Thermal Conductivity, ., and Thermal Expansion, a 527
Table A.8 Heat Capacity, Cp 529
Table A.9 Resistivity and Dielectric Constant 531
Table A.10 Embodied Energy and CO2 Footprint 533
Table A.11 Approximate Material Prices, Cm 535
Ways of Checking and Estimating Data 537
Further Reading 540
Appendix B. Useful Solutions for Standard Problems 542
Introduction and Synopsis 544
B.1 Constitutive Equations for Mechanical Response 545
B.2 Moments of Sections 547
B.3 Elastic Bending of Beams 549
B.4 Failure of Beams and Panels 551
B.5 Buckling of Columns, Plates, and Shells 553
B.6 Torsion of Shafts 555
B.7 Static and Spinning Disks 557
B.8 Contact Stresses 559
B.9 Estimates for Stress Concentrations 561
B.10 Sharp Cracks 563
B.11 Pressure Vessels 565
B.12 Vibrating Beams, Tubes, and Disks 567
B.13 Creep and Creep Fracture 569
B.14 Flow of Heat and Matter 571
B.15 Solutions for Diffusion Equations 573
B.16 Further Reading 575
Appendix C. Material Indices 576
C.1 Introduction and Synopsis 577
C.2 Uses of Material Indices 577
Appendix D. Data Sources for Documentation 582
D.1 Introduction 583
D.2 Information Sources for Materials 583
D.3 Information for Manufacturing Processes 606
D.4 Databases and Expert Systems as Software 607
D.5 Additional Useful Internet Sites 609
Appendix E. Exercises 612
E.1 Introduction to Exercises 612
E.2 Material Evolution in Products (Chapter 1) 613
E.3 Devising Concepts (Chapter 2) 614
E.4 Using Material Properties (Chapter 3) 614
E.5 Using Material Property Charts (Chapter 4) 616
E.6 Translation: Constraints and Objectives (Chapters 5 and 6) 619
E.7 Deriving and Using Material Indices (Chapters 5 and 6) 622
E.8 Multiple Constraints and Objectives (Chapters 7 and 8) 630
E.9 Selecting Material and Shape (Chapters 9 and 10) 639
E.10 Hybrid Materials (Chapters 11 and 12) 646
E.11 Selecting Processes (Chapters 13 and 14) 650
E.12 Materials and the Environment (Chapter 15) 655
Index 658
Back Cover 665