Department of Mechanical Engineering

MCEN90012 Design for Manufacture

Material Selection Design Project: DP1

MATERIAL SELECTION IN MECHANICAL DESIGN
and
COMPUTERISED MATERIAL SELECTION TOOLS

A.

MATERIAL SELECTION IN MECHANICAL DESIGN

1.

AIMS

1.

To derive performance indices appropriate for material selection of engineering components,

2.

Apply performance indices to material selection charts, identifying the optimal material, and

3.

Understand the modifying influence of shape factor on material selection.

2.

YOUR TASKS

Task 2.1

60%

5 marks

Consider the axial loading of a tie-rod with a circular cross section.

2.1.1 For an axially loaded tie-rod, derive the mass objective function based on both a circular and
square cross-sectional area;
2.1.2 Based on these equations, propose an appropriate material index, M that could subsequently
be used on a Youngs modulus versus density chart to minimise the objective function
obtained in 2.1.1; and,
2.1.3 State whether your proposed material index is dependent on the actual cross-sectional area
of the tie-rod.
For this task, complete the development of the material index, M for both solid:

circular (area, A = r2 with radius, r), and

square (A = 2r 2r)
sections.
Tie-rod parameters:

length = L

Youngs modulus = E

material density =
Applied tensile load = F
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Task 2.2

5 marks

Complete a detailed derivation of material indices for a stiff (i.e. limited deflection under load) and
light (i.e. minimal mass) beam with the following sections:
circular (area, A = r2 with radius, r)
square (A = 2r 2r) and
panel (A = w t, i.e. base height).
Your derivation will substitute a numerical value for the (beam deflection equation) constant that
varies with load distribution.
The beam is simply supported at each end and has a concentrated, load, F applied centrally (refer to
lecture presentation for images).
Clearly identify any references that you used to solve this task, in particular, the equation for
deflection, = fn(F, L, E, I).
Beam parameters:
length = L
Youngs modulus = E
material density =
second moment of area = I
Information about material selection charts
Refer to the relevant material selection chart, available from the subject LMS website where guide
lines for minimum weight design are indicated as the inverse of:
M = / E, M = / E1/2, or M = / E1/3.
To find a minimum mass design, the designer needs to maximize
M1 = C = E / , M1 = C = E1/2 / , or M1 = C = E1/3 / .
There is some ambiguity in the literature about the correct symbol for the maximized objective
material index. Material selection charts will be used to complete tasks 2.3 to 2.5.
Task 2.3

5 marks

With reference to the relevant material selection chart, locate the bound region for steels and
confirm that the Youngs (elastic) modulus, E and density, are consistent with values sourced
from another reference.
Are any materials available on the material selection chart that have at least the same Youngs
modulus, E as steel that could also float on water?
Does the density of tin alloys significantly vary from that for steels?
Answers must use the appropriate material selection chart (i.e. graphical solution is required).
Task 2.4

5 marks

When considering a strong, light tie-rod, is there an obvious best candidate material from the
available engineering alloys? Again, your answer must be based around the appropriate material
selection chart (i.e. graphical solution is required).
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Task 2.5

10 marks

Consider the cross-section of a steel beam with a rectangular section with proportions
height, h = 9.55 r and base, b = r.
Find the shape factor, Be of this selected shape and clearly show the effect of this section,
compared to a solid-circular section, when designing a stiffness limited, minimum weight beam.
When steel is formed into this rectangular shape, are there any materials that have comparable
performance when formed into a solid circular section?
Your answer must be based around the appropriate material selection chart (i.e. graphical solution is
required).
Task 2.6 Diaphragm for pressure actuators

30 marks

A barometer is a pressure actuator. Changes in in atmospheric pressure, acting on one side of the
diaphragm, cause it to deflect. This deflection is transmitted through mechanical linkage or an
electromagnetic sensor to a display. Similar diaphragms form the active component of altimeters,
pressure gauges, and gas-flow controls for diving equipment. Their design requirements include
(table 1):
Must be sensitive to pressure changes.
Must remain elastic.
To offer accurate pressure measurement, have low hysteresis or damping.
Use systematic material selection methods to offer recommendations for the best material to make
diaphragms?
Figure 1 shows an image of a circular diaphragm
A pressure difference p = p1 p2 acts across the diaphragm.
Table 1. Diaphragm requirements
Function
Objective
Constraints

Diaphragm for pressure sensing

Maximise displacement for given pressure difference
Must remain elastic (no yield, no creep)
Damping must be low to enable quick, precise response
Cost is a consideration in some applications

Figure 1. A circular diaphragm for a pressure sensor.

It must deflect under differential pressure, i.e. p1 p2.

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Designers seek to maximise the deflection of the centre of the diaphragm, subject to the constraint
that it remains elastic. The stresses throughout the material of manufacture must be less than the
yield or fracture stress, f.
The deflection, , of the diaphragm caused by p depends upon whether its edges are clamped or
free. Both scenarios will be considered in this investigation.
Use the following equation for deflection:

=
where
and

C1 p a 4 1 2
Et

C1 = 3/16 for clamped edges

C1 9/8 for free edges

E = Youngs modulus, = Poissons ratio.

The maximum stress, max, in the diaphragm is calculated using:
a2
max = C2 p 2
t
where C2 = 1/2 for clamped edges
and
C2 3/2 for free edges
The maximum stress must not exceed the yield or failure stress, f.
For this investigation, consider f as being the modulus of rupture, MOR (i.e. the surface stress, in
bending, at which yielding or fracture occurs).
The radius of the diaphragm is generally determined by the design Initial Appreciation. The
thickness, t, is generally the free variable. Formulate an equation of the general form,
= fn MOR

This equation can be used to discern a suitable material selection index.

The quantity (1 2) is close to unity for most solids.
Candidate materials must also accommodate damping () and cost (Cm, $/kg) requirements.
Complete a series of analyses using manual Material Selection charts and Cambridge Engineering
Selector (CES) as required to investigate candidate materials for this application.
Your resulting table of candidate materials will include no fewer than eight candidate materials,
including: high-carbon steels, glasses, bronzes, suitable aluminium alloys, polymers, elastomers.
Offer a final recommended material, based on the material selection design requirements and
research into existing products.

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B.

COMPUTERISED MATERIAL SELECTION TOOLS

3.

AIMS

3.1

To apply the material selection concepts developed in lectures to a database of potential

materials; and,

3.2

To provide experience in computerised material selection for engineering design using the
Cambridge Engineering Selector (CES) software.

4.

YOUR TASKS

Task 4.1 Constraint-limited material property selection

30%

10 marks

Apply a limit stage selection to find the material(s) with both

Youngs Modulus, E > 60 GPa, and

Density, < 2 Mg/m3.

Graphically identify the associated subset of materials and save for inclusion in your report.
Task 4.2 Graphic material property search

10 marks

Graphically compare the specific yield strength1 (Sy / ) of titanium (Ti) alloys and tungsten (W)
alloys.
Hint:
Initially, plot the specific strength as a combined property on the y-axis and leave the x-axis blank.
Applying a limit stage to include only Ti and W alloys will make the resulting material selection
chart more readable. Use the CES search tool to find specific materials.
Task 4.3 Multiple stage, graphic material property search

10 marks

Graphically identify the subset of materials with fracture toughness, KIc > 25 MPa m1/2.
Identify the subset of materials with both:

Youngs Modulus, E > 100 GPa, and

M = E1/3 / > 2.15 (GPa)1/3 (Mg/m3) 1 .

Graphically identify the intersection of materials that satisfy both these conditions.
Hint:
The performance index constraint, M, may be satisfied by a combined property axis, or by use of a
material selection guideline on a material selection chart of E versus .

CES uses the symbol, f as a general failure strength. Here, f Sy y

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REPORT PRESENTATION

10%

A mark out of 10% is associated with the presentation of your submitted report.
Refer to your MCEN90012 Subject Outline document and revisit your Technical Report writing
seminar for advice about how to prepare a report of acceptable quality.
For DP1, it is recommended that the main body of your final report be no longer than 20 A4 singlesided pages (12pt font, single-line spaced).
Long reports that delve deeply (and correctly) into tasks are acceptable if not laudable, especially if
the report is essentially concise and easily read.
Overly long, rambling, non-cohesive, poorly-structured reports will incur significant presentation
penalties.
It is expected that all reports will be of a professional standard.
PROJECT SUBMISSION
Submit your DP1 material selection assignment as a single report, with headings that match those
used in this document.
One report per team.
The correct Melbourne School of Engineering COVER SHEET must be used.
Workshop sessions for DP1 are yet to be finalized.
Workshop locations:
Week-2 workshop sessions: School of Engineering Design Office, room D207
Week-3 workshop sessions: computer laboratories to be confirmed 2
Submission deadline: midday Monday 23 March 2015
Submission location:

the correct Department of Mechanical Engineering (DME) submission slot

(4th floor, block-E)

Postgraduate Computer Centre room B102 (Building 175, Block B) is often used by MCEN90012 students to
complete assignment DP1. Enter via external stairs between Blocks B and C.

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