Materials Selection in Mechanical Design Book

	Preface	xi
	Acknowledgements	xiii
1	Introduction	1
1.1	Introduction and synopsis	1
1.2	Materials in design	1
1.3	The evolution of engineering materials	3
1.4	The evolution of materials in vacuum cleaners	4
1.5	Summary and conclusions	6
1.6	Further reading	7
2	The design process	8
2.1	Introduction and synopsis	8
2.2	The design process	8
2.3	Types of design	10
2.4	Design tools and materials data	11
2.5	Function, material, shape and process	13
2.6	Devices to open corked bottles	14
2.7	Summary and conclusions	18
2.8	Further reading	19
3	Engineering materials and their properties	20
3.1	Introduction and synopsis	20
3.2	The classes of engineering material	20
3.3	The definitions of material properties	22
3.4	Summary and conclusions	31
3.5	Further reading	31
4	Materials selection charts	32
4.1	Introduction and synopsis	32
4.2	Displaying material properties	32
4.3	The material property charts	36
4.4	Summary and conclusions	63
4.5	Further reading	64
5	Materials selection - the basics	65
5.1	Introduction and synopsis	65
5.2	The selection strategy	65
5.3	Deriving property limits and material indices	69
5.4	The selection procedure	77
5.5	The structural index	82
5.6	Summary and conclusions	83
5.7	Further reading	83
6	Materials selection - case studies	85
6.1	Introduction and synopsis	85
6.2	Materials for oars	85
6.3	Mirrors for large telescopes	89
6.4	Materials for table legs	93
6.5	Cost - structural materials for buildings	97
6.6	Materials for flywheels	100
6.7	Materials for high-flow fans	105
6.8	Golf-ball print heads	108
6.9	Materials for springs	111
6.10	Elastic hinges	116
6.11	Materials for seals	119
6.12	Diaphragms for pressure actuators	122
6.13	Knife edges and pivots	125
6.14	Deflection-limited design with brittle polymers	129
6.15	Safe pressure vessels	133
6.16	Stiff, high damping materials for shaker tables	137
6.17	Insulation for short-term isothermal containers	140
6.18	Energy-efficient kiln walls	143
6.19	Materials for passive solar heating	147
6.20	Materials to minimize thermal distortion in precision devices	151
6.21	Ceramic valves for taps	154
6.22	Nylon bearings for ships' rudders	157
6.23	Summary and conclusions	160
6.24	Further reading	161
7	Selection of material and shape	162
7.1	Introduction and synopsis	162
7.2	Shape factors	162
7.3	The efficiency of standard sections	172
7.4	Material limits for shape factors	175
7.5	Material indices which include shape	180
7.6	The microscopic or micro-structural shape factor	182
7.7	Co-selecting material and shape	186
7.8	Summary and conclusions	188
7.9	Further reading	190
Appendix	Geometric constraints and associated shape factors	190
8	Shape - case studies	194
8.1	Introduction and synopsis	194
8.2	Spars for man-powered planes	194
8.3	Forks for a racing bicycle	198
8.4	Floor joists: wood or steel?	200
8.5	Increasing the stiffness of steel sheet	204
8.6	Ultra-efficient springs	206
8.7	Summary and conclusions	209
9	Multiple constraints and compound objectives	210
9.1	Introduction and synopsis	210
9.2	Selection by successive application of property limits and indices	210
9.3	The method of weight-factors	212
9.4	Methods employing fuzzy logic	214
9.5	Systematic methods for multiple constraints	215
9.6	Compound objectives, exchange constants and value-functions	218
9.7	Summary and conclusions	226
9.8	Further reading	227
10	Case studies: multiple constraints and compound objectives	228
10.1	Introduction and synopsis	228
10.2	Multiple constraints - con-rods for high-performance engines	228
10.3	Multiple constraints - windings for high field magnets	232
10.4	Compound objectives - materials for insulation	237
10.5	Compound objectives - disposable coffee cups	241
10.6	Summary and conclusions	245
11	Materials processing and design	246
11.1	Introduction and synopsis	246
11.2	Processes and their influence on design	246
11.3	Process attributes	261
11.4	Systematic process selection	262
11.5	Screening: process selection diagrams	264
11.6	Ranking: process cost	274
11.7	Supporting information	279
11.8	Summary and conclusions	279
11.9	Further reading	280
12	Case studies: process selection	281
12.1	Introduction and synopsis	281
12.2	Forming a fan	281
12.3	Fabricating a pressure vessel	284
12.4	Forming a silicon nitride micro-beam	289
12.5	Forming ceramic tap valves	290
12.6	Economical casting	292
12.7	Computer-based selection - a manifold jacket	293
12.8	Computer-based selection - a spark plug insulator	298
12.9	Summary and conclusions	301
12.10	Further reading	301
13	Data sources	303
13.1	Introduction and synopsis	303
13.2	Data needs for design	303
13.3	Screening: data structure and sources	305
13.4	Further information: data structure and sources	307
13.5	Ways of checking and estimating data	309
13.6	Summary and conclusions	312
13.7	Further reading	313
Appendix	Data sources for material and process attributes	313
14	Case studies: use of data sources	334
14.1	Introduction and synopsis	334
14.2	Data for a ferrous alloy - type 302 stainless steel	334
14.3	Data for a non-ferrous alloy - Al-Si die-casting alloys	335
14.4	Data for a polymer - polyethylene	338
14.5	Data for a ceramic - zirconia	340
14.6	Data for a glass-filled polymer - nylon 30% glass	342
14.7	Data for a metal-matrix composite (MMC) - Ai/SiC[subscript p]	344
14.8	Data for a polymer-matrix composite - CFRP	345
14.9	Data for a natural material - balsa wood	347
14.10	Summary and conclusions	349
14.11	Further reading	350
15	Materials, aesthetics and industrial design	351
15.1	Introduction and synopsis	351
15.2	Aesthetics and industrial design	351
15.3	Why tolerate ugliness? The bar code	354
15.4	The evolution of the telephone	355
15.5	The design of hair dryers	357
15.6	The design of forks	359
15.7	Summary and conclusions	361
15.8	Further reading	361
16	Forces for change	363
16.1	Introduction and synopsis	363
16.2	The market pull: economy versus performance	363
16.3	The science-push: curiosity-driven research	366
16.4	Materials and the environment: green design	367
16.5	The pressure to recycle and reuse	373
16.6	Summary and conclusions	373
16.7	Further reading	374
Appendix A	Useful solutions to standard problems	375
A.1	Constitutive equations for mechanical response	376
A.2	Moments of sections	378
A.3	Elastic bending of beams	380
A.4	Failure of beams and panels	382
A.5	Buckling of columns and plates	384
A.6	Torsion of shafts	386
A.7	Static and spinning discs	388
A.8	Contact stresses	390
A.9	Estimates for stress concentrations	392
A.10	Sharp cracks	394
A.11	Pressure vessels	396
A.12	Vibrating beams, tubes and discs	398
A.13	Creep and creep fracture	400
A.14	Flow of heat and matter	402
A.15	Solutions for diffusion equations	404
A.16	Further reading	406
Appendix B	Material indices	407
Appendix C	Material and process selection charts	413
C.1	Introduction	413
C.2	The materials selection charts	418
Chart 1	Young's modulus, E against density, [rho]	418
Chart 2	Strength, [sigma][subscript f], against density, [rho]	420
Chart 3	Fracture toughness, K[subscript Ic], against density, [rho]	422
Chart 4	Young's modulus, E, against strength, [sigma][subscript f]	424
Chart 5	Specific modulus, E/[rho], against specific strength, [sigma][subscript f]/[rho]	426
Chart 6	Fracture toughness, K[subscript Ic], against Young's modulus, E	428
Chart 7	Fracture toughness, K[subscript Ic], against strength, [sigma][subscript f]	430
Chart 8	Loss coefficient, [eta], against Young's modulus, E	432
Chart 9	Thermal conductivity, [lambda], against thermal diffusivity, a	434
Chart 10	T-Expansion coefficient, [alpha], against T-conductivity, [lambda]	436
Chart 11	Linear thermal expansion, [alpha], against Young's modulus, E	438
Chart 12	Normalized strength, [sigma][subscript t]/E, against linear expansion coeff., [alpha]	440
Chart 13	Strength-at-temperature, [sigma](T), against temperature, T	442
Chart 14	Young's modulus, E, against relative cost, C[subscript R][rho]	444
Chart 15	Strength, [sigma][subscript f], against relative cost, C[subscript R][rho]	446
Chart 16	Dry wear rate against maximum bearing pressure, P[subscript max]	448
Chart 17	Young's modulus, E, against energy content, q[rho]	450
Chart 18	Strength, [sigma][subscript f], against energy content, q[rho]	452
C.3	The process-selection charts	454
Chart P1	The material-process matrix	454
Chart P2	Hardness, H, against melting temperature, T[subscript m]	456
Chart P3	Volume, V, against slenderness, S	458
Chart P4	The shape classification scheme	460
Chart P5	The shape-process matrix	462
Chart P6	Complexity against volume, V	464
Chart P7	Tolerance range, T, against RMS surface roughness, R	466
Appendix D	Problems	469
D1	Introduction to the problems	469
D2	Use of materials selection charts	469
D3	Deriving and using material indices	472
D4	Selection with multiple constraints	480
D5	Selecting material and shape	483
D6	Selecting processes	488
D7	Use of data sources	490
D8	Material optimization and scale	491
	Index	495