MATERIAL SELECTION IN

MACHINE DESIGN
How to Design a Pen ?
Introduction:Materials in design
• Design is the process of translating a new idea or a market need into the
detailed information from which a product can be manufactured.
• Each of its stages requires decisions about the materials of which the
product is to be made and the process for making it.
• Normally, the choice of material is dictated by the design.
• But sometimes it is the other way round: the new product, or the evolution
of the existing one, was suggested or made possible by the new material.
• The number of materials available to the engineer is vast: something over
1,20,000 .
• And although standardization strives to reduce the number, the continuing
appearance of new materials with novel, exploitable, properties expands
the options further.
Introduction:Materials in design
• How does the engineer choose, from this vast menu, the material best suited to
his purpose?
• Must he/she rely on experience?
• In the past material selection: in-house materials guru who knows all about the
things the company makes.
• But many things have changed in the world of engineering design, and all of them
work against the success of this model.
• There is job mobility, meaning that the guru who is here today is gone tomorrow.
• And there is the rapid evolution of materials information.
• We need a systematic procedure—one with steps that can be taught quickly, that
is robust in the decisions it reaches, that allows of computer implementation, and
with the ability to interface with the other established tools of engineering
design.
Introduction:Materials in design
• The choice of material cannot be made independently of the choice of
process by which the material is to be formed, joined, finished, and
otherwise treated. Cost enters, both in the choice of material and in the
way the material is processed.
• And it must be recognized that good engineering design alone is not
enough to sell products.
• In almost everything from home appliances through automobiles to
aircraft, the form, texture, feel, color, decoration of the product—the
satisfaction it gives the person who owns or uses it—are important.
• This aspect, known confusingly as ‘‘industrial design’’, is one that, if
neglected, can lose the manufacturer his market. Good designs work;
excellent designs also give pleasure.
EVOLUTION OF MATERIALS WITH TIME
• What the user want?
STEPS IN DESIGNING
• Input and output functionality. Problem definition
• Tension, compression, moment, shear, torsion, etc
• Governing equations, Constitutive laws.
Analysis of forces and
• Bending, shear, axial stresses
• Failure, FOS stresses
• Mechanism, Linkages
• Feasibility. Generating ideas and
• Design simplicity/complexity planning

• Which material can handle the stresses?

• How to decide? Properties involved. Selection of material
• Which properties should one look for?
• Which material out of 16,000 to choose?
• Availability, Cost.
Implementation and
• Manufacturing the prototype. Fabrication
• Scaled model. NO
• Testing against artificial conditions.
• Linear, Kinematic, Dynamic scaling Testing and Simulation
• Why simulation?

Evaluation and review

• Check for effectiveness.
• Is it market ready?

Product development
DESIGN ASPECTS
DESIGN ASPECTS
 INTRODUCTION TO FORCES
B
A

• Which is my longitudinal axis?

• Which is my transverse axis? A: CONCENTRIC (TENSILE/COMPRESSIVE)
• Why should I care? B: ECCENTRIC (PURE BENDING)

WHY DO WE NEED TO
y axis STUDY DIFFERENT FORCES D C
IN DESIGNING?

X axis

C: CONCENTRIC (SHEAR+BENDING)
z axis
D: ECCENTRIC (TORQUE)
 STRESSES AND MATERIALS
A: (TENSILE/COMPRESSIVE)

B: BENDING

MATERIAL IS MORE WHERE STRESSES ARE MORE

 STRESSES AND MATERIALS cont.
C: (SHEAR)

D:TORQUE

Manufacturing by Centrifugal casting (varying density)

MATERIAL IS MORE WHERE STRESSES ARE MORE

INTERDEPENDENCY OF DESIGN PARAMETERS
• Function mainly decides the choice of material and the
dimension or shape formed.
• Shape generally refers to macro structural internal or
internal view. In the exterior one sees dimensions or
geometry whereas in the interior of the body structures
like honeycomb can be produced to impart more
strength.
• To fabricate the desired shape the component is
undergone various manufacturing processes(e.g
casting, forging, machining, polishing and joining
processes)
• The mfg. processes are greatly influenced by the
choice of material, their strength, hardness,
machinability index, etc.
• Ductile material and brittle material undergoes different
processes to form the same part as discusses earlier.
• Process interacts with shape — the process
determines the shape, the size, the precision and, the
cost.
DESIGN PARAMETERS (SUB-GROUPS)
• a cheap screw to transmit a prescribed load to the cork.
• a light lever (i.e. a beam) to carry a prescribed bending
moment.
• a slender elastic blade that will not buckle when driven
between the cork and bottle-neck.
• a thin, hollow needle, stiff and strong enough to
penetrate a cork.
 ADAPTIVE DESIGNING (case study)
NEED: Problems:
• Carrying goods • Stones are too heavy
• Reduce contact area • Difficult to maneuver
• Easier to move (Rolling better than pushing) • Difficult to surpass obstacles

NEED:
• Lighter material Problems:
• Better control • Difficult to maneuver
• Reduce Moment of Inertia • Failure or crack in wooden spokes
• Difficult to surpass large obstacles

NEED:
• More traction and drive control
• Flexible material (Adjust forces)
• Able to overcome obstacles
• Cheap and durable Further research to improve performance…
IMPORTANCE OF MATERIAL SELECTION

Material behavior
Crystal Packing against operating
Density structure efficiency condition

Size of
Bond strength microstructural
WHY DO MATERIAL grains
BEHAVE DIFFERENT?

Grain
Slip system Boundary
Orientation
 WHY DO MATERIAL BEHAVE DIFFERENTLY

• Crystalline imperfection: defects in metals and ceramics

• Often organized by dimensionality: point defects

(vacancies, impurities – substitutional, interstitial),
dislocations, grain boundaries

• Real materials are riddled with imperfections (with few

exceptions) and these defects explain diffusion,
strength, conductivity, …

• Vacancies do not influence strength, others do

• For strength, dislocations are the key players

• Dislocations and plastic flow

SLIP SYSTEM- INDEX OF DUCTILITY
CLASSIFICATION OF MATERIALS
1. METALS-
PROPERTIES OF DIFFERENT MATERIALS
Hardness – metals tend to be hard and resistant to deformation
Malleability & Ductility – metals can bend and change shape without breaking
Conductivity – metals tend to be good conductors of heat and electricity
Luster – metals have a unique, shiny visual appearance
Magnetism – Many metals are ferromagnetic or paramagnetic

2. CERAMICS
Bond- The ceramics possess both Ionic and Covalent bonds.
Brittleness - The ceramics are brittle in nature.
Conductivity - The ceramics possess bad electrical conductivity because of the absence of free electrons.
Thermal Conductivity - The Ceramics possess bad thermal conductivity but they can sustain at high temperatures easily.
Density - The Density of Metal is greater than the Density of Ceramics and that is greater than the Density of Polymers.
Corrosiveness - The Ceramics are Anti-Corrosive to the environment because they are already in corrosive form.

3. GLASS
Transparency - creates a visual connect with the outside world.
Colour and Shape Varieties - t can be blown, drawn and pressed to any colour, shape, and variety and is available in the
market depending upon their use, dimensional requirements, and safety requirement.
Chemical Resistance - it can withstand the effect of the chemical reaction under different environment conditions or acidic
effects.
Insulation - It is an excellent insulator against heat, electricity and electromagnetic radiation because of its good insulating
response against visible light transmission.
 PROPERTIES OF DIFFERENT MATERIALS cont.
4. POLYMERS-
• As chain length and cross-linking increases, the tensile strength of the polymer increases.
• Polymers do not melt, they change state from crystalline to semi-crystalline.
• Compared to conventional molecules with different side molecules, the polymer is enabled with hydrogen bonding and
ionic bonding resulting in better cross-linking strength.
• Due to their ability to change their refractive index with temperature as in the case of PMMA and HEMA: MMA, they are
used in lasers for applications in spectroscopy and analytical applications.
• Polymers with Van der waals forces linking chains are known to be weak, but give the polymer a low melting point.

5. ELASTOMERS
• High amorphous materials
• High randomly orientated structure
• Large reversible extension
• Low intermolecular forces allowed for flexibility
• A spaghetti and meatball structure with meatballs signifying cross-links.
• Glass transition temperature
• They can revert back into their original shape.
SPECIFICATION OF MATERIAL GROUP
MECHANICAL PROPERTIES
 BEHAVIOR OF MECHANICAL PROPERTIES

Yield properties and ductility are measured with

standard tensile tests taken to failure.

• The yield stress σy (or elastic limit, σel) requires

careful definition. In metals the onset of plasticity
is not distinct – define the 0.2% proof (or offset
yield) stress.

• Beyond the yield point most metals work harden

causing the rise to the maximum called the tensile
strength.

• Followed by non-uniform deformation (necking)

and fracture.
For polymers, σy is the stress at which the stress-
strain curve becomes markedly nonlinear;
typically, a strain of 1%; beyond yielding behavior
depends on T.

• Well below Tg – brittle

• Approaching Tg – some plasticity

• At Tg – cold drawing (large extension at constant

stress, molecules gradually align, harden, and then
fracture.

• Higher T – viscous flow, moldable (thermosets

become rubbery then decompose).

• σy for a polymer matrix composite defined by a

set deviation, often 0.5%.
• Ceramics and glasses are brittle at RT – they
have yield strengths but they are never reached
as they fracture first due to the presence of
micro-cracks; even in compression, they crush
before they yield.

• Sometimes a practical measure, the

compressive crushing strength, is used. It is not
a true yield – called the elastic limit, σel.

• Typical stress-strain diagrams for a ceramic

material under tension and compression are
shown.

• Crack develops vertically during compression.

Serrations during compression are associated
with spalling of the test piece.

• The modulus of elasticity of ceramic materials is

quite high, for example, SiC has a modulus of
elasticity of around 450 GPa which is
comparable to metals like Tungsten (406 GPa).
• Hardness test: pyramidal diamond or hardened
steel ball pressed into surface; the size of the
permanent indent is a measure of resistance to
plastic deformation. Often more convenient
than compression or tensile test (destructive).

• H = F/A; A is the area of the indent projected

onto a plane perpendicular to the load.

• The indented region is constrained by the

surrounding material and thus H > σy.
Expect H ~ 3σy in Mpa.
BEHAVIOUR OF MECHANICAL PROPERTIES cont.
COST ANALYSIS OF DIFFERENT MATERIALS
MATERIAL SELECTION PROCEDURE
Any engineering component has one or more functions:
• to support a load
• to contain a pressure
• to transmit heat.

This must be achieved subject to constraints:

• that certain dimensions are fixed,
• that the component must carry the design loads or pressures without failure,
• that it insulates or conducts,
• that it can function in a certain range of temperature and in a given
environment.

In designing the component, the designer has an objective:

• to make it as cheap as possible, or as light, or as safe, or perhaps some
combination of these.

Certain parameters can be adjusted in order to optimize the objective:

• the designer is free to vary dimensions that have not been constrained by design
requirements.
• free to choose the material for the component.
Taxonomy of the kingdom of materials and their
attributes

The taxonomy of the kingdom of materials and their attributes

 SELECTION OF COOLING FINS (Case study)

Screen :
Rank :
Resistivity ρe > 1019 μΩ.cm.
Maximum thermal conductivity.
 SELECTION BY ASHBY CHART

Result :
Aluminium Oxide
SELECTION OF MATERIAL FOR BEAM (Case study)
SELECTION OF MATERIAL FOR BEAM (Case study)
 NEED FOR DESIGNING
Objectives…
F • Design a structural beam so that it wont fail.
• Will be able to resist forces without failure.
• Weight is to be minimized.

Density Planning…
Strength
• Material to be selected.
• Dimensions and tolerances.
VARIABLES • Service conditions

FREE VARIABLES (Dimension, Cross-section, density, Strength)

CONSTRAINT VARIABLES(Forces, Budget) IS THERE ANY
GENERALISED WAY TO
SELECT MATERIAL?

CONCEPT OF IDLE DESIGN

FORCE RESISTED WEIGHT OF BODY

F σ𝑓 . 𝐴 σ𝑓
ρ can only be changed..
𝐹 =
is needed to be maximized. 𝑊 𝐴. 𝐿. ρ. g
𝑊
 FACTORS AFFECTING MATERIAL SELECTION
Properties
There are literally dozens of properties that a material could have.
• Mechanical: Strength, stiffness, ductility, fracture toughness, fatigue strength, creep strength, etc
• Thermophysical: Density, thermal conductivity, color, transparency, electrical conductivity, magnetic susceptibility,
etc.
• Chemical: Corrosion resistance, bonding, composition, etc.
• Other: Cost.

Availability
An issue that is taken into consideration in material selection is the availability of the material.
• is it available at hand
• does it need to be ordered from a warehouse,
• does it need to be specially made for the application
FACTORS AFFECTING MATERIAL SELECTION Cont.
Economics
How many parts are to be made?
• a few, a few hundred or millions per year
• The economy of scale may dictate one material over another, or one process over another.

Business and Environmental Issues

• Is recyclability an issue?
• Are the materials hazardous or subject to environmental and other regulations?
• Is there a liability issue related to a particular material?

❑ In summary, a designer assumes certain properties when creating a new design or modifying an existing one.

❑ There are thousands of materials, each of which has a specific set of attributes or properties.

❑ Materials selection is the process of identifying the optimum material for a particular design or application.
1. A house in Dehradun, Uttarakhand has recently constructed a swimming pool. The residents have hired you for
constructing a springboard or diving board, which is essentially a cantilever beam of square cross-section. The board is
installed to a predefined pole of steel having a height of 6 meters and it is to be made having a length of 1 meter. The
family has 4 members a man, his wife, and their two kids have weights of 90, 65, 40, 55 kg respectively. The
permissible deflection of the plank is restricted to 10 mm and the weight should not exceed 100kg. Neglect the self-
weight of the plank while calculating deflection.
a) Find which material is best suited to make the springboard and why?
b) Considering a factor of safety of 1.8, will the material remain the same or some other material is to be used? Justify.
Also, find the cross-sectional dimension of the plank.
Note- Use the table given below for reference
Take g=10 m/s^2
Material Density(g/cm^3) Young’s modulus Shear modulus (GPa)
(GPa)

Steel 7.85 7.8 79.3

Flinched wood 1.5 0.8 4

Concrete 2.243 1.4 21

Aluminium 2.6 2.7 25.5

CFRP 1.6 1.6 22.43

2. A bridge is to be constructed having hinge support at both the ends, which is used to carry armed reinforcements for
military training, in a truck. The truck weighs 1 ton and is passed through the bridge. The cross-section is rectangular
having a breadth to depth ratio of 5. As a designer, which material is best suited to construct the bridge provided that the
permissible yield strength be 210MPa and the weight must not exceed 2 ton for the bridge.
Length of the bridge- 2.26m.

a) Which material is to be selected for design against stiffness.

b) Which material is to be selected for design against strength.
Take g=9.81 m/s^2

Material Density(g/cm^3) Yield strength (MPa) Young’s modulus (GPa)

A 1.3 8 7.8

B 7.85 12.3 2.5

C 7.1 15.5 1.4

D 1.77 14.5 2.6

E 2.6 9.8 2.7

Thank You