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3.
Chart 1
Young's modulus/Density
Chart P1
Chart 2
Strength/Density
Chart P2
Chart 3
Young's modulus/Strength
Chart P3
Process/Mass
Chart 4
Chart P4
Process/Section thickness
Chart 5
Fracture toughness/Modulus
Chart P5
Process/Dimensional tolerance
Chart 6
Fracture toughness/Strength
Chart P6
Process/Surface roughness
Chart 7
Chart P7
Chart 8
Chart 9
Chart 10
Chart 11
Table 1
Chart 12
Table 2
Chart 13
Coefficient of friction
Table 3
Chart 14
Table 4
Vibration-limited design
Chart 15a,b
Table 5
Chart 16
Table 6
Chart 17
Strength/Relative cost
Chart 18a,b
Chart 19
Chart 20
Strength/Energy content
Family
Metals
(The metals and alloys of
engineering)
Polymers
(The thermoplastics and
thermosets of engineering)
Classes
Family
Al alloys
Cu alloys
Lead alloys
Mg alloys
Ni alloys
Steels
Stainless steels
Tin alloys
Ti alloys
W alloys
Pb alloys
Zn alloys
ABS
CA
Ionomers
Epoxy
Phelonics
PA
PC
Polyester
PEEK
PE
PET or PETE
PMMA
POM
PP
PS
PTFE
PVC
Short name
Butyl rubber
EVA
Isoprene
Natural rubber
Neoprene
PU
Silicones
Alumina
Aluminum nitride
Boron carbide
Silicon Carbide
Silicon Nitride
Tungsten carbide
Al203
AlN
B4C
SiC
Si3N4
WC
Brick
Concrete
Stone
Brick
Concrete
Stone
Soda-lime glass
Borosilicate glass
Silica glass
Glass ceramic
Soda-lime glass
Borosilicate
Silica glass
Glass ceramic
CFRP
GFRP
Al-SiC
Hybrids: foams
Flexible foams
Rigid foams
Cork
Bamboo
Wood
Cork
Bamboo
Wood
Elastomers
(Engineering rubbers,
natural and synthetic)
Short name
Aluminum alloys
Copper alloys
Lead alloys
Magnesium alloys
Nickel alloys
Carbon steels
Stainless steels
Tin alloys
Titanium alloys
Tungsten alloys
Lead alloys
Zinc alloys
Classes
Butyl rubber
EVA
Isoprene
Natural rubber
Polychloroprene (Neoprene)
Polyurethane
Silicone elastomers
Glasses
Hybrids: composites
You will not find specific material grades on the charts. The aluminum alloy 7075 in the T6
condition (for instance) is contained in the property envelopes for Al-alloys; the Nylon 66 in
those for nylons. The charts are designed for the broad, early stages of materials selection, not
for retrieving the precise values of properties needed in the later, detailed design, stage.
Material properties
The charts that follow display the properties listed here. The charts let
you pick off the subset of materials with a property within a specified range:
materials with modulus E between 100 and 200 GPa for instance; or
materials with a thermal conductivity above 100 W/mK.
Class
General
Property
Density
Price
(kg/m3 or Mg/m3)
Cm
($/kg)
E ,G , K (GPa)
Yield strength
(MPa)
Ultimate strength
(MPa)
Compressive strength
(MPa)
K11c/ 2 / f , and so on. The Charts are designed to display these groups or
Failure strength
(MPa)
Mechanical
"material indices", and to allow you to pick off the subset of materials which
maximize them. The Appendix of this document lists material indices.
Details of the method, with worked examples, are given in "Materials
Selection in Mechanical Design", cited earlier.
Multiple criteria can be used. You can pick off the subset of materials
with both high E 1 / 2 / and high E (good for light, stiff beams) from
Chart 1; that with high 2f / E 3 and high E (good materials for pivots)
from Chart 4. Throughout, the goal is to identify from the Charts a subset of
materials, not a single material. Finding the best material for a given
application involves many considerations, many of them (like availability,
appearance and feel) not easily quantifiable. The Charts do not give you the
final choice - that requires the use of your judgement and experience. Their
power is that they guide you quickly and efficiently to a subset of materials
worth considering; and they make sure that you do not overlook a promising
candidate.
Thermal
(Vickers)
Elongation
(--)
(MPa)
Fracture toughness
K1c
(MPa.m1/2)
Toughness
G1c
(kJ/m2)
(--)
Melting point
Tm
Tg
(C or K)
Glass temperature
(C or K)
Thermal conductivity
Tmax (C or K)
(W/m.K)
Specific heat
Cp
(J/kg.K)
Ts
-1
(K )
(C or K)
Electrical resistivity
( .m or .cm))
Dielectric constant
(--)
Electrical
Hardness
Eco-properties
Ef
(MJ/kg)
Environmental
resistance
KA
MPa-1
or 0.5 ; G E / 3 ; K 10 E (elastomers,
rubbery polymers)
where is Poisson's ratio, G the shear modulus and K
the bulk modulus.
(b)
2/3
/ = C (minimum weight design of strong
1/2
/ = C (minimum weight design of strong
plates)
The value of the constant C increases as the lines are
displaced upwards and to the left. Materials offering the
greatest strength-to-weight ratio lie towards the upper left
corner.
f /E
(b)
f /E
= C
(elastic hinges)
= C
3/2
/E = C
f /E = C
2f / 3 / E 1 / 2 = C
(c)
f /E = C
2
KIc /E = C (lines of constant toughness, Gc;
energy-limited failure)
(a)
10
KIc/f
(b)
2
KIc /f = C
= C
(yield-before-break)
(leak-before-break)
11
12
13
(b) /a1/2 = C
energy storage)
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15
E = C MPa/K
o
(constant thermal stress per K)
16
f .
The chart gives a birds-eye view of the regimes of
stress and temperature in which each material class, and
material, is usable. Note that even the best polymers have
little strength above 200oC; most metals become very soft
by 800oC; and only ceramics offer strength above
1500oC.
17
F
= s
Fn
18
W =
and thus has units of m2. A more useful quantity, for our
purposes, is the specific wear-rate
W
An
ka =
W
=
Fn
P
19
20
C v ,R
C v ,R =
E / Cv ,R = C
E 1 / 2 / Cv ,R = C
(minimum cost
E 1 / 3 / Cv ,R = C
(minimum cost
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strong plates)
The value of the constants C increase as the lines are
displaced upwards and to the left. Materials offering the
greatest strength per unit cost lie towards the upper left
corner.
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23
E / H p = C
E1 / 2 / H p = C
E1 / 3 / H p = C
of stiff plates)
The value of the constant C increases as the lines are
displaced upwards and to the left. Materials offering the
greatest stiffness per energy content lie towards the upper
left corner.
Other moduli are obtained approximately from E
using
or 0.5 ; G E / 3 ; K 10 E (elastomers,
rubbery polymers)
where is Poisson's ratio, G the shear modulus and K
the bulk modulus.
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strong plates)
The value of the constant C increases as the lines are
displaced upwards and to the left. Materials offering the
greatest strength per unit energy content lie towards the
upper left corner.
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Each process is characterised by a set of attributes: the materials it can handle, the
shapes it can make and their precision, complexity and size and so forth. Process
Selection Charts map the attributes, showing the ranges of size, shape, material,
precision and surface finish of which each class of process is capable. They are used in
the way described in "Materials Selection in Mechanical Design". The procedure does
not lead to a final choice of process. Instead, it identifies a subset of processes which
have the potential to meet the design requirements. More specialised sources must then
be consulted to determine which of these is the most economical.
The hard-copy versions, shown here, are necessarily simplified, showing only a limited
number of processes and attributes. Computer implementation, as in the CES Edu
software, allows exploration of a much larger number of both.
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Maximize
E/
Maximize
f /
G1 / 2 /
G /
G1 / 3 /
f /
1f / 2 /
E1 / 2 /
E /
E1 / 3 /
f /
1f / 2 /
E1 / 2 /
E1 / 3 /
E1 / 3 /
E /
E /( 1 )
2f / 3 /
2f / 3 /
f /
1f / 2 /
1f / 2 /
f /
f /
f /
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Maximize
2f / E
2f / E
f /E
3f / E 2 and H
3f / 2 / E and 1 / E
Maximize
E /
E /
E1 / 2 /
E /
E1 / 3 /
3f / 2 / E
E /
E1 / 2 /
f /
E1 / 3 /
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Maximize
K1c and f
K1c / E and f
K12c / E and f
K1c and f
K1c / E and f
K12c / E and f
K1c and f
K1c / E and f
K12c / E and f
K1c / f
K12c / f
1/
1/ a = Cp /
a / = 1/ Cp
C p / Cm
/ a = Cp
/a
f / E
HEAT SINKS
maximum heat flux per unit volume; expansion limited
maximum heat flux per unit mass; expansion limited
/
/
Maximize
f
f /
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Maximize
1 / e Cm
ELECTRO-MAGNET WINDINGS
maximum short-pulse field; no mechanical failure
maximize field and pulse-length, limit on temperature rise
C p / e
e / e
1 / e
RELAY ARMS
minimum response time; no fatigue failure
minimum ohmic losses; no fatigue failure
e / E e
e2 / E e
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Length, l
1 rad
1 lb/ft3
1cm3/s
See opposite
1 kgf
1 lbf
1 dyne
1 ft
1 inch
1
Mass, M
Power, P
Stress,
Specific Heat, Cp
Stress Intensity, K1c
Surface Energy
Temperature, T
Thermal Conductivity
Volume, V
Viscosity,
1 tonne
1 short ton
1 long ton
1 lb mass
See opposite
See opposite
1 cal/gal.oC
Btu/lb.oF
1 ksi in
1 erg/cm2
1oF
1 cal/s.cm.oC
1 Btu/h.ft.oF
1 Imperial gall
1 US gall
1 poise
1 lb ft.s
57.30o
16.03 kg/m3
1.0 x 10-4m2/s
9.807 N
4.448 N
1.0 x 10-5N
304.8 mm
25.40 mm
0.1 nm
1000 kg
908 kg
1107 kg
0.454 kg
4.188 kJ/kg.oC
4.187 kg/kg.oC
1.10 MN/m3/2
1 mJ/m2
0.556oK
418.8 W/m.oC
1.731 W/m.oC
4.546 x 10-3m3
3.785 x 10-3m3
0.1 N.s/m2
0.1517 N.s/m2
MPa
lb.in2
kgf/mm2
bar
long ton/in2
0.102
10
6.48 x 10-2
MPa
10
1.45 x 10
dyn/cm2
10-7
1.45 x 10-5
1.02 x 10-8
10-6
6.48 x 10-9
lb/in2
6.89 x 10-3
6.89 x 104
703 x 10-4
6.89 x 10-2
4.46 x 10-4
kgf/mm2
9.81
9.81 x 107
1.42 x 103
98.1
63.5 x 10-2
bar
0.10
106
14.48
1.02 x 10-2
6.48 x 10-3
15.44
1.54 x 108
2.24 x 103
1.54
1.54 x 102
erg
7
cal
eV
Btu
18
ft lbf
-4
10
0.239
erg
10-7
2.39 x 10-8
6.24 x 1011
9.48 x 10-11
7.38 x 10-8
cal
4.19
4.19 x 107
2.61 x 1019
3.97 x 10-3
3.09
-19
-12
6.24 x 10
-20
9.48 x 10
0.738
-22
1.18 x 10-19
eV
1.60 x 10
Btu
1.06 x 103
1.06 x 1010
2.52 x 102
6.59 x 1021
7.78 x 102
ft lbf
1.36
1.36 x 107
0.324
8.46 x 1018
1.29 x 10-3
1.60 x 10
3.38 x 10
1.52 x 10
erg/s
10
-10
hp
ft lbf/s
1.34
7.38 x 102
kW (kJ/s)
erg/s
10-10
1.34 x 10-10
7.38 x 10-8
hp
7.46 x 10-1
7.46 x 109
15.50 X 102
Ft lbf/s
1.36 X 10-3
1.36 X 107
1.82 X 10-3
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