Material Selection

Function dictates the choice of material and shape. Shape restricts the choice of material and process.

Function

Material

Shape

Process is influenced by material

Process

Process interacts with shape.

Material selection and process cannot be separated from the shape and the function of the product, two way interaction.
Ken Youssefi SJSU, ME dept.

Engineering Materials
Materials
Metals

Plastics

Ferrous

Non-ferrous

Thermoplastics

Thermosets

Elastomers

Steel Stainless steel

Aluminum Copper

Acrylic Nylon

Phenolic Polymide

Rubber Polyurethane

Die & tool steel

Cast iron

Zinc
Titanium Tungsten

ABS
Polyethylene Polycarbonate PVC
SJSU, ME dept.

Epoxies
Polyester

Silicone

Ken Youssefi

Engineering Materials
Materials

Metals

Plastics

Ceramics Glass

Composites

Carbides Nitrides Graphite Diamond Glasses Glass ceramics

Ken Youssefi SJSU, ME dept.

Reinforced plastics

Metal-Matrix
Ceramic-Matrix Laminates

Most Commonly Used Materials

The following 25 materials are the most commonly used materials in the design of mechanical products; in themselves they represent the broad range of other materials.

Steel and Cast Iron

1. 2. 3. 4. 5. 6. 7. 8. 1020 1040 4140 4340 S30400 S316 O1 ASTM20-60 (plain carbon steel, hot-rolled or cold-drawn) (plain carbon steel, hot-rolled or cold-drawn) (heat-treated alloy steel, chromium-molybdenum) (heat-treated alloy steel, nickel-chromium-molybdenum) (stainless steel) (stainless steel) (tool steel) (gray cast iron)

Ken Youssefi

SJSU, ME dept.

Most Commonly Used Materials

Aluminum and Copper Alloys
9. 10. 11. 12. 13. 2024 3003 6061 7075 C268 (aluminum, O, T3, T4 or T6) (aluminum, H12 or H16) (aluminum, T6) (aluminum, T6) (copper)

Other metals
14. Titanium 6-4 15. AZ63A (magnesium)

Ken Youssefi

SJSU, ME dept.

Most Commonly Used Materials

Plastics
16. 17. 18. 19. 20. ABS Polycarbonate Nylon 6/6 Polypropylene Polystyrene

Ceramics
21. Alumina 22. Graphite

Composite materials
23. Douglas fir 24. Fiberglass 25. Graphite/epoxy
Ken Youssefi SJSU, ME dept.

Application of Most Commonly Used Materials

Component Material

Ken Youssefi

SJSU, ME dept.

Application of Most Commonly Used Materials

Component Material

Ken Youssefi

SJSU, ME dept.

Application of Most Commonly Used Materials

Component Material

Ken Youssefi

SJSU, ME dept.

Properties of Most Commonly Used Materials

Ultimate Strength in tension

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SJSU, ME dept.

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Properties of Most Commonly used Materials

Yield strength

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SJSU, ME dept.

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Properties of Most Commonly used Materials

Fatigue endurance limit (strength under cyclic loading)

Ken Youssefi

SJSU, ME dept.

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Properties of Most Commonly used Materials

Density

Ken Youssefi

SJSU, ME dept.

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Cost of Most Commonly used Materials

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SJSU, ME dept.

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Example Materials for table legs

Luigi Tavolino, furniture designer, conceives of a lightweight table of daring simplicity: a flat sheet of toughened glass supported on slender, unbraced, cylindrical legs. The legs must be solid and as light as possible (to make the table easier to move). They must support the table top and whatever is placed upon it without buckling. What materials could one recommend.

Ken Youssefi

SJSU, ME dept.

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Example Materials for table legs

The Model

The leg is a slender column of density and modulus E. The load P and its length l are determined by design (fixed). The radius r of the leg is a variable. We wish to minimize the mass m of the leg. Objective function
Ken Youssefi SJSU, ME dept.

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Example Materials for table legs

The constraint is that the legs must support a design load without buckling. Eulers buckling equation

where I = r4/4
Solving for the free variable , r, and substituting it into the equation for m gives,

=
Material properties

The weight is minimized by selecting the subset of materials with the greatest value of the material index.

Ken Youssefi

SJSU, ME dept.

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Example Materials for table legs

Solving the Eulers formula for r, gives an equation for the thinnest leg which will not buckle:

Material properties

The thinnest leg is that made of the material with the largest value of the material index.

Two material indices,

To minimize the weight, both have to be maximize.

Ken Youssefi SJSU, ME dept.

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Procedure for deriving material indices

Ken Youssefi

SJSU, ME dept.

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Modulus of Elasticity (E) vs. Density () Charts

Constant guidelines

Ken Youssefi

SJSU, ME dept.

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Modulus of Elasticity (E) vs. Density () Charts

Ken Youssefi

SJSU, ME dept.

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Modulus of Elasticity (E) vs. Density () Charts

Ken Youssefi

SJSU, ME dept.

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Ken Youssefi

SJSU, ME dept.

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Summary of materials for table legs

Ken Youssefi

SJSU, ME dept.

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