DESIGN FOR MANUFACTURING AND ASSEMBLY

ASSIGNMENT 2
LAST DATE OF SUBMISSION (Hard copy): 30 September 2019
Construct a spreadsheet for Table 1 shown below. Use this to rank materials for the six cases of minimum cost
criteria shown in Table 2. (Fill derived parameter column and Rank (N) column.) Prepare six separate sheets for
six cases. Identify the best and worst materials for each criteria. Do the best and worst materials remain same for
the six criteria? Write your comments on the rankings using various criterions.
Except the table, all calculations and comments should be submitted handwritten on A4 size paper.
Tables to be printed on A4 paper.
Table 1: Material Data

Generic Material Cost Tensile Elastic Compressive Density, Derived

$/kg yield Modulus, yield Kg/m^3 parameter N
strength MN/m^2 strength
MN/m^2 ,MN/m^2
Gray cast iron 2.86E-01 2.93E+02 1.34E+05 2.93E+02 7.21E+03
Ductile iron 3.52E-01 4.48E+02 1.65E+05 3.10E+02 7.13E+03
Malleable iron 4.18E-01 3.45E+02 1.60E+05 3.45E+02 7.38E+03
Mild steel(c.q. annealed) 9.90E-01 2.62E+02 2.07E+05 2.62E+02 7.77E+03
Alloy steel(high strength) 6.16E+00 1.38E+03 2.07E+05 1.38E+03 7.85E+03
Stainless steel 2.75E+00 2.48E+02 1.93E+05 2.48E+02 8.04E+03
Aluminium alloy(high 5.28E+00 1.93E+02 7.10E+04 1.93E+02 2.75E+03
strength)
Beryllium copper 3.85E+01 1.10E+03 1.28E+05 1.01E+03 8.27E+03
Copper, hard 2.86E+00 3.10E+02 1.17E+05 3.10E+02 8.96E+03
Magnesium 7.70E+00 2.34E+02 4.48E+04 2.34E+02 1.80E+03
Titanium 2.68E+01 9.45E+02 1.13E+05 9.45E+02 4.74E+03
Lead 2.86E+00 2.00E+01 1.52E+04 2.00E+01 1.14E+04
Epoxy(Glass reinforced) 5.28E+00 6.55E+01 3.10E+03 2.48E+02 1.91E+03
Polyethylene(high density) 7.48E-01 2.48E+01 8.27E+02 2.48E+01 9.71E+02
Polycarbonate(Glass 3.52E+00 1.59E+02 1.16E+04 1.45E+02 1.53E+03
reinforced)
Rubber( isoprene) 3.48E+00 2.76E+01 4.59E+00 2.76E+01 9.71E+02
Polyurethane foam 1.76E+00 1.52E+01 1.08E+02 1.72E+01 4.99E+02
Particle Board (Medium 3.52E-01 1.55E+01 2.93E+03 1.45E+01 6.02E+02
density)
Pine 2.05E+00 7.93E+01 8.27E+03 3.31E+01 3.61E+02
Diamond 7.26E+02 2.69E+02 1.03E+06 4.00E+03 3.52E+03
Silicon carbide(sintered) 6.60E+01 6.90E+01 3.31E+05 1.03E+03 2.97E+03
Tungsten carbide 2.64E+02 8.96E+02 3.39E+05 4.95E+03 1.33E+04
Glass(soda lime, general 3.30E-01 9.17E+01 7.31E+04 1.38E+03 2.47E+03
purpose)
Pottery 1.32E-01 3.31E+01 7.03E+04 5.00E+02 2.22E+03
Concrete 1.50E+00 1.65E+00 3.00E+04 2.48E+01 2.50E+03
Cork E+01 1.00E+00 2.00E+01 1.00E+00 1.39E+02
Table 2: Derived parameters (Cm = Material cost, Yt = tensile yield stress, Yc = Compressive yield stress, E = Young’s Modulus, ρ = density)

To obtain: Maximum performance Minimum weight Minimum cost

Strongest tension member Yt Yt/ρ Yt/ρCm
Strongest compression member Yc Y c/ ρ Yc/ ρCm
Strongest beam or plate Yt Yt0.5/ ρ Yt0.5/ ρCm
Stiffest structural member E E1/3/ ρ E1/3/ ρCm
Best coil or tension spring Yt2/E Yt2/ (Eρ) Yt2/ (EρCm)
Best diaphragm spring Yt1.5/E Yt1.5/(Eρ) Yt1.5/(EρCm)