| Preface | xi |
| Acknowledgements | xiii |
1 | Introduction | 1 |
1.1 | Introduction and synopsis | 1 |
1.2 | Materials in design | 1 |
1.3 | The evolution of engineering materials | 3 |
1.4 | The evolution of materials in vacuum cleaners | 4 |
1.5 | Summary and conclusions | 6 |
1.6 | Further reading | 7 |
2 | The design process | 8 |
2.1 | Introduction and synopsis | 8 |
2.2 | The design process | 8 |
2.3 | Types of design | 10 |
2.4 | Design tools and materials data | 11 |
2.5 | Function, material, shape and process | 13 |
2.6 | Devices to open corked bottles | 14 |
2.7 | Summary and conclusions | 18 |
2.8 | Further reading | 19 |
3 | Engineering materials and their properties | 20 |
3.1 | Introduction and synopsis | 20 |
3.2 | The classes of engineering material | 20 |
3.3 | The definitions of material properties | 22 |
3.4 | Summary and conclusions | 31 |
3.5 | Further reading | 31 |
4 | Materials selection charts | 32 |
4.1 | Introduction and synopsis | 32 |
4.2 | Displaying material properties | 32 |
4.3 | The material property charts | 36 |
4.4 | Summary and conclusions | 63 |
4.5 | Further reading | 64 |
5 | Materials selection - the basics | 65 |
5.1 | Introduction and synopsis | 65 |
5.2 | The selection strategy | 65 |
5.3 | Deriving property limits and material indices | 69 |
5.4 | The selection procedure | 77 |
5.5 | The structural index | 82 |
5.6 | Summary and conclusions | 83 |
5.7 | Further reading | 83 |
6 | Materials selection - case studies | 85 |
6.1 | Introduction and synopsis | 85 |
6.2 | Materials for oars | 85 |
6.3 | Mirrors for large telescopes | 89 |
6.4 | Materials for table legs | 93 |
6.5 | Cost - structural materials for buildings | 97 |
6.6 | Materials for flywheels | 100 |
6.7 | Materials for high-flow fans | 105 |
6.8 | Golf-ball print heads | 108 |
6.9 | Materials for springs | 111 |
6.10 | Elastic hinges | 116 |
6.11 | Materials for seals | 119 |
6.12 | Diaphragms for pressure actuators | 122 |
6.13 | Knife edges and pivots | 125 |
6.14 | Deflection-limited design with brittle polymers | 129 |
6.15 | Safe pressure vessels | 133 |
6.16 | Stiff, high damping materials for shaker tables | 137 |
6.17 | Insulation for short-term isothermal containers | 140 |
6.18 | Energy-efficient kiln walls | 143 |
6.19 | Materials for passive solar heating | 147 |
6.20 | Materials to minimize thermal distortion in precision devices | 151 |
6.21 | Ceramic valves for taps | 154 |
6.22 | Nylon bearings for ships' rudders | 157 |
6.23 | Summary and conclusions | 160 |
6.24 | Further reading | 161 |
7 | Selection of material and shape | 162 |
7.1 | Introduction and synopsis | 162 |
7.2 | Shape factors | 162 |
7.3 | The efficiency of standard sections | 172 |
7.4 | Material limits for shape factors | 175 |
7.5 | Material indices which include shape | 180 |
7.6 | The microscopic or micro-structural shape factor | 182 |
7.7 | Co-selecting material and shape | 186 |
7.8 | Summary and conclusions | 188 |
7.9 | Further reading | 190 |
Appendix | Geometric constraints and associated shape factors | 190 |
8 | Shape - case studies | 194 |
8.1 | Introduction and synopsis | 194 |
8.2 | Spars for man-powered planes | 194 |
8.3 | Forks for a racing bicycle | 198 |
8.4 | Floor joists: wood or steel? | 200 |
8.5 | Increasing the stiffness of steel sheet | 204 |
8.6 | Ultra-efficient springs | 206 |
8.7 | Summary and conclusions | 209 |
9 | Multiple constraints and compound objectives | 210 |
9.1 | Introduction and synopsis | 210 |
9.2 | Selection by successive application of property limits and indices | 210 |
9.3 | The method of weight-factors | 212 |
9.4 | Methods employing fuzzy logic | 214 |
9.5 | Systematic methods for multiple constraints | 215 |
9.6 | Compound objectives, exchange constants and value-functions | 218 |
9.7 | Summary and conclusions | 226 |
9.8 | Further reading | 227 |
10 | Case studies: multiple constraints and compound objectives | 228 |
10.1 | Introduction and synopsis | 228 |
10.2 | Multiple constraints - con-rods for high-performance engines | 228 |
10.3 | Multiple constraints - windings for high field magnets | 232 |
10.4 | Compound objectives - materials for insulation | 237 |
10.5 | Compound objectives - disposable coffee cups | 241 |
10.6 | Summary and conclusions | 245 |
11 | Materials processing and design | 246 |
11.1 | Introduction and synopsis | 246 |
11.2 | Processes and their influence on design | 246 |
11.3 | Process attributes | 261 |
11.4 | Systematic process selection | 262 |
11.5 | Screening: process selection diagrams | 264 |
11.6 | Ranking: process cost | 274 |
11.7 | Supporting information | 279 |
11.8 | Summary and conclusions | 279 |
11.9 | Further reading | 280 |
12 | Case studies: process selection | 281 |
12.1 | Introduction and synopsis | 281 |
12.2 | Forming a fan | 281 |
12.3 | Fabricating a pressure vessel | 284 |
12.4 | Forming a silicon nitride micro-beam | 289 |
12.5 | Forming ceramic tap valves | 290 |
12.6 | Economical casting | 292 |
12.7 | Computer-based selection - a manifold jacket | 293 |
12.8 | Computer-based selection - a spark plug insulator | 298 |
12.9 | Summary and conclusions | 301 |
12.10 | Further reading | 301 |
13 | Data sources | 303 |
13.1 | Introduction and synopsis | 303 |
13.2 | Data needs for design | 303 |
13.3 | Screening: data structure and sources | 305 |
13.4 | Further information: data structure and sources | 307 |
13.5 | Ways of checking and estimating data | 309 |
13.6 | Summary and conclusions | 312 |
13.7 | Further reading | 313 |
Appendix | Data sources for material and process attributes | 313 |
14 | Case studies: use of data sources | 334 |
14.1 | Introduction and synopsis | 334 |
14.2 | Data for a ferrous alloy - type 302 stainless steel | 334 |
14.3 | Data for a non-ferrous alloy - Al-Si die-casting alloys | 335 |
14.4 | Data for a polymer - polyethylene | 338 |
14.5 | Data for a ceramic - zirconia | 340 |
14.6 | Data for a glass-filled polymer - nylon 30% glass | 342 |
14.7 | Data for a metal-matrix composite (MMC) - Ai/SiC[subscript p] | 344 |
14.8 | Data for a polymer-matrix composite - CFRP | 345 |
14.9 | Data for a natural material - balsa wood | 347 |
14.10 | Summary and conclusions | 349 |
14.11 | Further reading | 350 |
15 | Materials, aesthetics and industrial design | 351 |
15.1 | Introduction and synopsis | 351 |
15.2 | Aesthetics and industrial design | 351 |
15.3 | Why tolerate ugliness? The bar code | 354 |
15.4 | The evolution of the telephone | 355 |
15.5 | The design of hair dryers | 357 |
15.6 | The design of forks | 359 |
15.7 | Summary and conclusions | 361 |
15.8 | Further reading | 361 |
16 | Forces for change | 363 |
16.1 | Introduction and synopsis | 363 |
16.2 | The market pull: economy versus performance | 363 |
16.3 | The science-push: curiosity-driven research | 366 |
16.4 | Materials and the environment: green design | 367 |
16.5 | The pressure to recycle and reuse | 373 |
16.6 | Summary and conclusions | 373 |
16.7 | Further reading | 374 |
Appendix A | Useful solutions to standard problems | 375 |
A.1 | Constitutive equations for mechanical response | 376 |
A.2 | Moments of sections | 378 |
A.3 | Elastic bending of beams | 380 |
A.4 | Failure of beams and panels | 382 |
A.5 | Buckling of columns and plates | 384 |
A.6 | Torsion of shafts | 386 |
A.7 | Static and spinning discs | 388 |
A.8 | Contact stresses | 390 |
A.9 | Estimates for stress concentrations | 392 |
A.10 | Sharp cracks | 394 |
A.11 | Pressure vessels | 396 |
A.12 | Vibrating beams, tubes and discs | 398 |
A.13 | Creep and creep fracture | 400 |
A.14 | Flow of heat and matter | 402 |
A.15 | Solutions for diffusion equations | 404 |
A.16 | Further reading | 406 |
Appendix B | Material indices | 407 |
Appendix C | Material and process selection charts | 413 |
C.1 | Introduction | 413 |
C.2 | The materials selection charts | 418 |
Chart 1 | Young's modulus, E against density, [rho] | 418 |
Chart 2 | Strength, [sigma][subscript f], against density, [rho] | 420 |
Chart 3 | Fracture toughness, K[subscript Ic], against density, [rho] | 422 |
Chart 4 | Young's modulus, E, against strength, [sigma][subscript f] | 424 |
Chart 5 | Specific modulus, E/[rho], against specific strength, [sigma][subscript f]/[rho] | 426 |
Chart 6 | Fracture toughness, K[subscript Ic], against Young's modulus, E | 428 |
Chart 7 | Fracture toughness, K[subscript Ic], against strength, [sigma][subscript f] | 430 |
Chart 8 | Loss coefficient, [eta], against Young's modulus, E | 432 |
Chart 9 | Thermal conductivity, [lambda], against thermal diffusivity, a | 434 |
Chart 10 | T-Expansion coefficient, [alpha], against T-conductivity, [lambda] | 436 |
Chart 11 | Linear thermal expansion, [alpha], against Young's modulus, E | 438 |
Chart 12 | Normalized strength, [sigma][subscript t]/E, against linear expansion coeff., [alpha] | 440 |
Chart 13 | Strength-at-temperature, [sigma](T), against temperature, T | 442 |
Chart 14 | Young's modulus, E, against relative cost, C[subscript R][rho] | 444 |
Chart 15 | Strength, [sigma][subscript f], against relative cost, C[subscript R][rho] | 446 |
Chart 16 | Dry wear rate against maximum bearing pressure, P[subscript max] | 448 |
Chart 17 | Young's modulus, E, against energy content, q[rho] | 450 |
Chart 18 | Strength, [sigma][subscript f], against energy content, q[rho] | 452 |
C.3 | The process-selection charts | 454 |
Chart P1 | The material-process matrix | 454 |
Chart P2 | Hardness, H, against melting temperature, T[subscript m] | 456 |
Chart P3 | Volume, V, against slenderness, S | 458 |
Chart P4 | The shape classification scheme | 460 |
Chart P5 | The shape-process matrix | 462 |
Chart P6 | Complexity against volume, V | 464 |
Chart P7 | Tolerance range, T, against RMS surface roughness, R | 466 |
Appendix D | Problems | 469 |
D1 | Introduction to the problems | 469 |
D2 | Use of materials selection charts | 469 |
D3 | Deriving and using material indices | 472 |
D4 | Selection with multiple constraints | 480 |
D5 | Selecting material and shape | 483 |
D6 | Selecting processes | 488 |
D7 | Use of data sources | 490 |
D8 | Material optimization and scale | 491 |
| Index | 495 |