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    Part - 1: Wrap Up Shape Selection Part 2: Introduction To Process Selection Jayant Jain

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    Tarun Gupta
    MATERIAL SCIENCE LECTURE SERIES

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    Download as PDF, TXT or read online from Scribd

    Part - 1: Wrap Up Shape Selection Part 2: Introduction To Process Selection Jayant Jain

    Uploaded by

    Tarun Gupta
    20 views17 pages
    MATERIAL SCIENCE LECTURE SERIES

    Original Title

    Lecture 30

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    MATERIAL SCIENCE LECTURE SERIES

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    20 views17 pages

    Part - 1: Wrap Up Shape Selection Part 2: Introduction To Process Selection Jayant Jain

    Uploaded by

    Tarun Gupta
    MATERIAL SCIENCE LECTURE SERIES

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    Lecture 30:

    Part -1: Wrap up shape


    selection
    Part 2: Introduction to
    process selection

    Jayant Jain

    Assistant Professor,
    Department of Applied Mechanics,
    IIT Delhi, Hauz Khas, 110016

    Presentation Schedule
    Monday morning group

    Wednesday, 22/04/2015, 8:00-8:20

    Monday afternoon group

    Wednesday, 22/04/2015, 8:20-8:40

    Tuesday morning group

    Wednesday, 22/04/2015, 8:40-9:00

    Tuesday afternoon group

    Friday, 24/04/2015, 8:00-8:20

    Wednesday morning group

    Friday, 24/04/2015, 8:20-8:40

    Wednesday afternoon group

    Friday, 24/04/2015, 8:40-9:00

    Thursday morning group

    Tuesday, 28/04/2015, 8:00-8:20

    Thursday afternoon group

    Tuesday, 28/04/2015, 8:20-8:40

    Friday morning group

    Tuesday, 28/04/2015, 8:40-9:00

    Note: All the discussions, questions and key concepts will be


    the part of your final exam

    Recap
    Shape factors (SF), significance of SF, derived SFs for
    common loading conditions
    Microscopic shape factors, derived SFs for common shapes
    Combined Macro and microscopic shape factors
    Graphical approach of solving problem: 4 Q approach,
    limitations were also highlighted
    Calculated Materials Indices that includes shape, this can be
    used for any material selection problem that involves shape
    as a variable

    Material-Shape co-selection
    The indices can be used to allow comparison and
    selection of best material-shape combinations:
    will seek maximum of Material indices
    The co-selection of Material and Shape can be
    carried by two ways:

    1. Calculations
    2. Graphical

    Problem: By calculations
    Your task would be is to select best material from the
    choices given below in the table for a stiff beam of
    minimum mass. Note that you have to propose your choice
    for both when shape is variable and when it is not.

    Fixed shape
    Shape as a variable

    Solve the same problem by graphical approach:


    How to utilise shape factors in graphical
    selection

    Introduction of shape
    has moved material
    below the line to above
    the line

    The structured material behaves like a new material with a


    modulus and a density, moving it from a position below the
    broken selection line to one above.

    A similar procedure can be adopted for other


    cases e.g. Failure in bending

    The material with strength and density, when shaped,


    behaves in bending like a new material of strength and
    density

    Introduction to process selection

    Processes
    What is a process?
    A process is a method of shaping, joining and finishing a
    material
    Examples of various processes
    1) Sand casting
    2) Injection molding
    3) Fusion welding
    4) Electro polishing

    There can be hundreds other...............

    Processes
    It is important to choose the right process-route at an early
    stage in the design before the cost-penalty of making
    changes becomes large.
    What could be the factors on which the choice of a process
    for a given component depends?
    1) Material
    2) Shape
    3) Size, required precision, quantity.......

    Process
    attributes

    Each process is characterized by a set of attributes

    Process selection means finding the best match between


    process attributes and design requirements

    Material-Process-Shape Interaction
    Included process now
    Processing selection
    depends on material
    and shape.
    The process
    attributes can be
    used as criteria for
    selection

    Material properties, shape and


    processes
    Materials properties and shape limit the choice of process

    How does a choice of material affects the process selection?


    Example: Ductile materials vs. Brittle materials

    How does a shape affects the process selection?


    Example: Slender shape vs. Hollow shapes

    How does the processing affects the materials properties


    Example: Rolling, forging of metals

    Process-property Interaction
    Processing has dual functions
    Soft, stretchy rubber becomes hard and
    brittle when vulcanized
    Annealing a metal increases its ductility
    Glass becomes bullet-proof through a
    specific heat treatment
    Electroplating improves corrosion
    resistance

    It is imp to understand the relationship


    between process and property
    Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David
    Cebon

    Effect of processing on properties

    Strengthening
    mechanisms and the
    consequent drop in
    ductility, here shown for
    copper alloys. The
    mechanisms are
    frequently combined. The
    greater the strength, the
    lower the ductility.

    Materials Selection in Mechanical Design, 4th Edition, 2010 Michael Ashby

    Thermal conductivity and


    strength for aluminum
    alloys.

    Copper cables

    The best choice of material


    for a cable is one with high
    strength and low
    resistivity, but
    strengthening mechanisms
    increase resistivity.
    Materials Selection in Mechanical Design, 4th Edition, 2010 Michael Ashby

    The changes in fracture toughness


    and yield strength for a plain
    carbon steel on heat treatment.
    Materials Selection in Mechanical Design, 4th Edition, 2010 Michael Ashby

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