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Section 3: Materials
Class Notifications
Jason Carey will be providing information about graduate
opportunities
B and A group meeting sign-up outside of 10-227
Quiz 1: early Feb
I posted: old A3 and soln online
Class notes purchased through MECE club for $20
Many extra examples, detailed notes
Teams are notified of projects
Relaxed design specifications as long as explained
5 pages of writing: figure out story, and write
Keys success : bearing, connections, fatigue, creativity
Objectives
Initial considerations
Materials, loading, failure
Presentation on designing materials
Outline
Material considerations
Uncertainties in material properties (+/- 30%)
Basic engineering materials
Selecting the right material
Ashby charts
Manufacturing processes
Material Considerations
(p.3-2)
applied
y ,C ,T
n
Material Considerations
3. Rigidity/stiffness
Designs are often limited by the amount of deflection
between mating components for alignment and proper
mating.
Deflection is dependent on elastic modulus (E) and
geometry.
4. Hardness and ductility
Is scratch resistance or large deformation important?
Contact problems: wear
Material Considerations
5. Resistance to fatigue
Steel and aluminium have different fatigue behaviour.
Material Considerations
7. Resilience
The energy before yielding is important for combined
loading, temperature effects.
8. Friction coefficient
Different applications require different surfaces or
mediums for proper functions, e.g. bearings low, and
clutches high
9. Weight
Some designs are weight critical: consider polymers,
wood, foams, aluminium or titanium.
Uncertainty
(p.3-3)
140
Number of test
120
100
80
60
40
20
0
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
Sy (kpsi)
Engineering Materials
Metals: Magnesium
Ceramic: alumina
Carbon-reinforced-composite
Metals
(p.3-6)
Polymers
(p.3-7)
Polymers
Properties change
significantly with
increasing temperature
Modulus drops
Should not used above
glass transition
temperature
Composite Materials
(p.3-9)
Composite Materials
Several laminae combined form a laminate
Laminates can be quasi-isotropic
Laminate layup can
be tailored to meet
specific strength and
stiffness requirements
Ceramics
Only for compressive
loading
Poor in tension,
cracks propagate
catastrophically
Reinforced with steel,
or fibre reinforced
polymers
Good thermal and
electrical insulators
More later
(p.3-8)
Comparison
Material
(p.3-10)
Advantages
Disadvantages
Steel
Heavy
Aluminum
Brass
Heavy, cost
Titanium
Polymers
FRP
Composites
Material Selection
(p.3-16)
1. Decision matrix
Simple, basic design
Need specifications/requirements
Select material that best meets the specs
See previous sections for example
2. Ashby charts
Advanced methodology
Allows for optimization
Need information on function, objective, constraints
examples will be presented in Seminar #3
Ive never seen this in a 460 report, attempt to incorporate here
Material Selection:
Ashby Charts
Used with permission: Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
Material Selection:
Ashby Charts
Three basic elements are required for the selection charts:
Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
Material Selection:
Ashby Charts
Functional
Geometric Material
p f
, F ,
, G ,
, M
requirements parameters properties
p f1 F f 2 G f 3 M
Comments
Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
Jamie Hogan
Assistant Professor
Mechanical Engineering
University of Alberta
38
Take Away
PADB4C-Microstructure
50 um
PADB4C- Fragments
www.galls.com
1.
2.
10 um
Twinning in Mg (Dixit)
Failure: Defects nucleate mechanisms, which lead to macro-cracks, and often to catastrophic failure
Defects: grain boundaries, secondary phases, initial cracks (we want to identify key defects)
Objective: Control failure mechanisms by designing the defect populations (microstructure design)
Fracture
2.
Granular flow
3.
Plasticity
4.
500 microns
Manifest in fragmentation
1. See it:
Microstructure Characterization
and Experimentation
10 um
2.5 mm
2.5 mm
2 Mfps, exposure= 500 ns
Strain rates: ~10-3 (MTS) and ~10+3 s-1 (Kolsky bar) and Stress-states: compression, confined, tension (BD)
Crack speeds set deformation time scales: 2,000 +/- 300 m/s (left) vs. 510 +/- 130 m/s (right)
Unconfined Configuration
Hot Pressing Axis
Confined Configuration
Rate-Dependent Strength
2. Understand it:
Compressive Brittle
Fragmentation Model
Initial Damage
Crack Nucleation
Self-Consistant
Scheme
Flaw Density
Damage Evolution
Irreversible
Damage Strain
Anisotropic Damage
Crack Growth
Crack Coalescence
Stiffness
Definition
Flow Behavior
Granular Flow
EOS
Micromechanics
Evolution as a
function of Damage
Influence of Bulking
Visco-Plastic Flow
Porosity
Figure
Figure
11.
9.Orientation
Inclusion number/area
of inclusionsfraction
in relation
vs. to
the hot pressing
inclusion
axis
size
(AR
distribution.
is the aspect ratio).
1000 s-1
6 m
10 m
20 m
40 m
2
1.5
1.5
1
10
0.5
0.5
0
0
0.002
0.004
Strain
0.006
0
0.008
Normalized Size
Stress (GPa)
2.5
2.5
Tr(Damage)
10
10
10
10
10
3
Grady 2006
Glenn and Chudnovsky 1986
Zhou et al. 2006
Levy and Molinari 2010
Mod. Grady (vc c)
Spinel
PAD B4C
0
-1
PAD SiC-N
-2
10
Basalt
-4
10
-3
10
-2
10
-1
10
Stony meteorite
0
10
10
3. Control it:
Materials Design
Probability of Penetration
PS B4C
HP B4C
0.8
0.6
0.4
0.2
0
0.7
Hot-pressed (PAD-B4C)
0.75
0.8
0.85
0.9
0.95
1.05
Normalized Velocity
Highlights power of simple model to inform design decisions
Remember: consider physics of problems (whats important
and what isnt)
5. Summary
Take Away
Acknowledgements
NSERC Engage
Be creative
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