Materials Selection in Mechanical Design, Third Edition

Front Matter......Page 2
Acknowledgements......Page 11
Features of the Third Edition......Page 12
Preface......Page 10
Table of Contents......Page 4
1. Introduction......Page 14
1.2 Materials in Design......Page 15
1.3 The Evolution of Engineering Materials......Page 17
1.4 Case Study: The Evolution of Materials in Vacuum Cleaners......Page 19
1.5 Summary and Conclusions......Page 21
2. The Design Process......Page 24
2.2 The Design Process......Page 25
2.3 Types of Design......Page 29
2.4 Design Tools and Materials Data......Page 30
2.5 Function, Material, Shape, and Process......Page 32
2.6 Case Study: Devices to Open Corked Bottles......Page 33
2.7 Summary and Conclusions......Page 37
3. Engineering Materials and their Properties......Page 40
3.2 The Families of Engineering Materials......Page 41
3.3 The Definitions of Material Properties......Page 43
3.4 Summary and Conclusions......Page 56
4. Material Property Charts......Page 58
4.2 Exploring Material Properties......Page 59
4.3 The Material Property Charts......Page 63
4.4 Summary and Conclusions......Page 90
5. Materials Selection - The Basics......Page 92
5.1 Introduction and Synopsis......Page 93
5.2 The Selection Strategy......Page 94
5.3 Attribute Limits and Material Indices......Page 98
5.4 The Selection Procedure......Page 106
5.5 Computer-Aided Selection......Page 112
5.6 The Structural Index......Page 115
5.7 Summary and Conclusions......Page 116
6. Materials Selection - Case Studies......Page 118
6.2 Materials for Oars......Page 119
6.3 Mirrors for Large Telescopes......Page 123
6.4 Materials for Table Legs......Page 127
6.5 Cost: Structural Materials for Buildings......Page 130
6.6 Materials for Flywheels......Page 134
6.7 Materials for Springs......Page 139
6.8 Elastic Hinges and Couplings......Page 143
6.9 Materials for Seals......Page 146
6.10 Deflection-Limited Design with Brittle Polymers......Page 149
6.11 Safe Pressure Vessels......Page 153
6.12 Stiff, High Damping Materials for Shaker Tables......Page 157
6.13 Insulation for Short-Term Isothermal Containers......Page 160
6.14 Energy-Efficient Kiln Walls......Page 164
6.15 Materials for Passive Solar Heating......Page 167
6.16 Materials to Minimize Thermal Distortion in Precision Devices......Page 170
6.17 Nylon Bearings for Ships\' Rudders......Page 173
6.18 Materials for Heat Exchangers......Page 176
6.19 Materials for Radomes......Page 181
6.20 Summary and Conclusions......Page 185
7. Processes and Process Selection......Page 188
7.1 Introduction and Synopsis......Page 189
7.2 Classifying Processes......Page 190
7.3 The Processes: Shaping, Joining, and Finishing......Page 193
7.4 Systematic Process Selection......Page 208
7.5 Ranking: Process Cost......Page 215
7.6 Computer-Aided Process Selection......Page 222
7.8 Summary and Conclusions......Page 228
8. Process Selection Case Studies......Page 232
8.2 Forming a Fan......Page 233
8.3 Fabricating a Pressure Vessel......Page 236
8.4 An Optical Table......Page 240
8.5 Economical Casting......Page 243
8.6 Computer-Based Selection: A Manifold Jacket......Page 245
8.7 Computer-Based Selection: A Spark Plug Insulator......Page 248
8.8 Summary and Conclusions......Page 250
9. Multiple Constraints and Objectives......Page 252
9.1 Introduction and Synopsis......Page 253
9.2 Selection with Multiple Constraints......Page 254
9.3 Conflicting Objectives, Penalty-Functions, and Exchange Constants......Page 258
9.4 Summary and Conclusions......Page 267
Appendix: Traditional Methods of Dealing with Multiple Constraints and Objectives......Page 269
10. Case Studies - Multiple Constraints and Conflicting Objectives......Page 274
10.2 Multiple Constraints: Con-Rods for High-Performance Engines......Page 275
10.3 Multiple Constraints: Windings for High-Field Magnets......Page 279
10.4 Conflicting Objectives: Casings for a Mini-Disk Player......Page 285
10.5 Conflicting Objectives: Materials for a Disk-Brake Caliper......Page 289
10.6 Summary and Conclusions......Page 294
11. Selection of Material and Shape......Page 296
11.1 Introduction and Synopsis......Page 297
11.2 Shape Factors......Page 298
11.3 Microscopic or Micro-Structural Shape Factors......Page 309
11.4 Limits to Shape Efficiency......Page 314
11.5 Exploring and Comparing Structural Sections......Page 318
11.6 Material Indices that Include Shape......Page 320
11.7 Co-Selecting Material and Shape......Page 325
11.8 Summary and Conclusions......Page 327
12. Selection of Material and Shape: Case Studies......Page 330
12.1 Introduction and Synopsis......Page 331
12.2 Spars for Man-Powered Planes......Page 332
12.3 Ultra-Efficient Springs......Page 335
12.4 Forks for a Racing Bicycle......Page 339
12.5 Floor Joists: Wood, Bamboo or Steel?......Page 341
12.6 Increasing the Stiffness of Steel Sheet......Page 344
12.7 Table Legs Again: Thin or Light?......Page 346
12.8 Shapes that Flex: Leaf and Strand Structures......Page 348
12.9 Summary and Conclusions......Page 350
13. Designing Hybrid Materials......Page 352
13.1 Introduction and Synopsis......Page 353
13.2 Filling Holes in Material-Property Space......Page 355
13.3 The Method: \"A + B + Configuration + Scale\"......Page 359
13.4 Composites: Hybrids of Type 1......Page 361
13.5 Sandwich Structures: Hybrids of Type 2......Page 371
13.6 Lattices: Hybrids of Type 3......Page 376
13.7 Segmented Structures: Hybrids of Type 4......Page 384
13.8 Summary and Conclusions......Page 389
14. Hybrid Case Studies......Page 392
14.2 Designing Metal Matrix Composites......Page 393
14.3 Refrigerator Walls......Page 395
14.4 Connectors that do not Relax their Grip......Page 397
14.5 Extreme Combinations of Thermal and Electrical Conduction......Page 399
14.6 Materials for Microwave-Transparent Enclosures......Page 402
14.7 Exploiting Anisotropy: Heat Spreading Surfaces......Page 404
14.8 The Mechanical Efficiency of Natural Materials......Page 406
15. Information and Knowledge Sources for Design......Page 414
15.1 Introduction and Synopsis......Page 415
15.2 Information for Materials and Processes......Page 416
15.3 Screening Information: Structure and Sources......Page 420
15.4 Supporting Information: Structure and Sources......Page 422
15.5 Ways of Checking and Estimating Data......Page 424
15.6 Summary and Conclusions......Page 428
16. Materials and the Environment......Page 430
16.2 The Material Life Cycle......Page 431
16.3 Material and Energy-Consuming Systems......Page 432
16.4 The Eco-Attributes of Materials......Page 435
16.5 Eco-Selection......Page 440
16.6 Case Studies: Drink Containers and Crash Barriers......Page 446
16.7 Summary and Conclusions......Page 448
17. Materials and Industrial Design......Page 452
17.2 The Requirements Pyramid......Page 453
17.3 Product Character......Page 455
17.4 Using Materials and Processes to Create Product Personality......Page 458
17.5 Summary and Conclusions......Page 467
18. Forces for Change......Page 470
18.2 Market-Pull and Science-Push......Page 471
18.3 Growing Population and Wealth, and Market Saturation......Page 477
18.4 Product Liability and Service Provision......Page 478
18.5 Miniaturization and Multi-Functionality......Page 479
18.6 Concern for the Environment and for the Individual......Page 480
18.7 Summary and Conclusions......Page 482
Appendix A: Useful Solutions to Standard Problems......Page 484
Introduction and Synopsis......Page 486
A.1 Constitutive Equations for Mechanical Response......Page 487
A.2 Moments of Sections......Page 489
A.3 Elastic Bending of Beams......Page 491
A.4 Failure of Beams and Panels......Page 493
A.5 Buckling of Columns, Plates, and Shells......Page 495
A.6 Torsion of Shafts......Page 497
A.7 Static and Spinning Disks......Page 499
A.8 Contact Stresses......Page 501
A.9 Estimates for Stress Concentrations......Page 503
A.10 Sharp Cracks......Page 505
A.11 Pressure Vessels......Page 507
A.12 Vibrating Beams, Tubes, and Disks......Page 509
A.13 Creep and Creep Fracture......Page 511
A.14 Flow of Heat and Matter......Page 513
A.15 Solutions for Diffusion Equations......Page 515
Appendix B: Material Indices......Page 520
B.2 Uses of Material Indices......Page 521
Appendix C: Data and Information for Engineering Materials......Page 526
C.1 Names and Applications: Metals and Alloys......Page 527
C.2 Names and Applications: Polymers and Foams......Page 528
C.3 Names and Applications: Composites, Ceramics, Glasses, and Natural Materials......Page 529
C.4 Melting Temperature, T_m, and Glass Temperature, T_g^l......Page 531
C.5 Density, Rho......Page 533
C.6 Young\'s Modulus, E......Page 535
C.7 Yield Strength, Sigma_y, and Tensile Strength, Sigma_ts......Page 537
C.8 Fracture Toughness (Plane-Strain), K_1C......Page 539
C.9 Thermal Conductivity, Lambda......Page 541
C.10 Thermal Expansion, Alpha......Page 543
C.11 Approximate Production Energies and CO_2 Burden......Page 545
C.12 Environmental Resistance......Page 547
Appendix D: Information and Knowledge Sources for Materials and Processes......Page 550
D.2 Information Sources for Materials......Page 551
D.3 Information for Manufacturing Processes......Page 565
D.4 Databases and Expert Systems in Software......Page 566
D.5 Additional Useful Internet Sites......Page 567
D.6 Supplier Registers, Government Organizations, Standards and Professional Societies......Page 568
Appendix E: Exercises......Page 570
E.1 Introduction to the Exercises......Page 571
E.3 Use of Material Selection Charts......Page 572
E.4 Translation: Constraints and Objectives......Page 575
E.5 Deriving and Using Material Indices......Page 578
E.6 Selecting Processes......Page 587
E.7 Multiple Constraints and Objectives......Page 592
E.8 Selecting Material and Shape......Page 600
E.9 Hybrid Materials......Page 607
D......Page 612
J......Page 613
M......Page 614
P......Page 615
W......Page 616