DAM 21102

ENGINEERING MATERIAL
SELECTION
CHAPTER 2 :
Design Process

En. Muhammad Hanafi Bin

Asril Rajo Mantari
Hanafi,JKM,PPD,2015

CONTENTS (WEEK 2)
2.1
2.2
2.3
2.4
2.5
2.6

Introduction
The Design Process
Types of Design
Design Tools & Materials Data
Function, Materials, Shape & Process
Consideration Factors in Materials
Selection

Hanafi,JKM,PPD,2013

2.1 INTRODUCTION

Design

Mechanical

deals with the physical principles, the proper

functioning and the production of mechanical
system.
Something that could be quantify
(measurable/quantitatively)
Industrial
involves pattern, colour, texture and consumer
appeal (qualitatative)
Main focus ~ mechanical design
# The aim is to develop a methodology for selecting
materials and processes
Hanafi,JKM,PPD,2013

2.2 DESIGN
PROCESS
Design
I. An iterative process
II. Based on market need (keperluan pasaran)
and product specification (spesifikasi
product)

Stages in design process:

i. concept (konsep)
ii. embodiment (penjelmaan)
iii. detail (perincian)
.Refer to Figure 1

Hanafi,JKM,PPD,2013

 Define specification
Determine function structure
Seek working principles
Evaluate and select concepts
Develop layout, scale, form
Model and analyse assemblies
Optimize the functions
Evaluate and select layout

Analyse components in detail

Select processing route
Optimize performance and cost
Prepare detailed drawings

MARKET
NEED

CONCEPT
EMBODIMENT/
MODELLING
DETAIL

PRODUCT
SPECIFICATION

Iterate

Figure 1: Design Flow Chart

Hanafi,JKM,PPD,2013

Let assume desired product as a

technical system that required to
perform task i.e TASK XX

It consists of
assemblies,
subassemblies
and
components,
joint together
to performs
the required
task. Material
and process
selection
at component

Materia
l and
process
selectio
n

Figure 2: Analysis of a Technical System

Hanafi,JKM,PPD,2013

 Previous approach - ok for existing design but

it still not much help in the design process
itself, that is, in the synthesis of new designs.
Another approach where the inputs, outputs,
information, energy and materials are
considered in the system analysis.
The design converts the inputs into the
outputs i.e:
An electric motor converts electrical into
mechanical energy
a forging press takes and reshapes material
Hanafi,JKM,PPD,2013

# What is
SYNTHESIS

In this approach, the system is broken down into

connected subsystems which perform specific
sub-functions.
This resulting
arrangement
is called the
function
structure or
function
decomposition
of the system

Figure 3: Analysis of a Technical System, Seen

as Transformation of Energy, Materials and
Information
Hanafi,JKM,PPD,2013

2.3 TYPES OF
DESIGN

a) Original-Involves a new idea or working principle. New

materials can offer new, unique combinations of
properties which enable original design

High Purity
Glass
Fiber
Optics

High Purity
Silicone
Hanafi,JKM,PPD,2013

Transistor

2.3 TYPES OF
DESIGN (contd)
b) Adaptive/Development- takes an existing concept and
seeks an incremental advance in performance through a
refinement of the working principle possible due to
development in materials technology

Wood base
boat

Carbon fibre boat

Hanafi,JKM,PPD,2013

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2.3 TYPES OF
DESIGN (contd)
c) Variant- involves a change of scale or dimension or detailing
without change of function or the method of achieving it. Change
of scale or range of conditions may require change of material

small boilers are made of

copper
Hanafi,JKM,PPD,2013

Large boiler are made from

steel
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2.4 Design Tools & Materials Data

Design tools are needed in order to implement
the steps in Figure 1
Enable the modeling and optimization of a
design, easing the routine aspects of each phase.
Material selection is very important and enters at
every stage of the design.
Complete and precise information about materials
are required to enable the selection process.

Hanafi,JKM,PPD,2013

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Market
need

Material Selection

Design Tools
1. Function
Concept
1. All Materials
modelling
(low precision data)
2. Viability studies
Embodiment/
3. Approximate
2. Subset of
Modelling
analysis
Materials
4. Geometric
modelling
(higher precision
Detail
5. Simulation
data)
6. Optimization
methods
3. One Material
7. Cost modelling
Product
(best available data
8. Component
Figure
4: The design flow chart. Shows howprecision)
design tools and
modelling
materials
selection enter the procedure information about materials
9. Finite element
is needed
analysis at each stage at very different levels of breadth and

precision.

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2.5 Function, Materials, Shape & Process

The selection of a material and process cannot be separated
from the choice of shape i.e. the macro-shape and micro-shape
To get the shape, the material is subjected to processes
(manufacture) include
i.
ii.
iii.
iv.

Primary forming processes (casting and forging),

Material removal processes (machining, drilling),
Finishing processes (such as polishing)
Joining processes (welding, fastener etc).

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2.5 Function, Materials, Shape & Process

FUNCTION
Function
dictates the
choice of both
material and
shape

Process is
influenced by the
material: by its
formability,
machinability etc

specification
of shape
restricts the
choice of
material and
process.
Specification
of process
limits the
materials you
can
Shape
use and the
shapes they
can take
Process determines
the shape
and COST
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Transmit load, heat

Contain pressure
Store energy, etc,
at minimum mass,
or at minimum cost,
or with minimum
environmental effect

Material
Process
Hanafi,JKM,PPD,2013

2.6 Consideration Factors in Materials Selection

Interrelated constraint (Kekangan Berhubungkait)
1.
2.
3.
4.
5.
6.
7.

Physical factors size, shape & weight of material

Mechanical factors the ability of the materials to withstand
the type of stresses (tensile, compression, bending and cyclic)
imposed on it.
Processing & Fabricability the ability to form or shape the
material (different material different method of processing).
Life of Component factors the length of time the
materials perform their intended function in the environment
to which they are exposed.
Cost and availability market-driven economy, quantity and
standardization.
Code technical requirements that are imposed on the
material or the component (usually set by the customer), eg.
ASTM, ASME, SAE etc.
Statutory & Other Factors relate to local, state and
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federal regulationsHanafi,JKM,PPD,2013
about the materials and processes
used or

......FINISH ......
THank you

Hanafi,JKM,PPD,2013

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