1. What are materials property charts can be used for?

2. What are the major sources for supporting information?

3. What are the design requirements for a component or a product specify them briefly?
4. What are the boundary conditions for selecting a material and what does they mean?
5. What are the major problems that have to be solved during material selection process?
6. Draw a flow-chart showing the main steps for material selection process?
7. What does we mean by Local conditions?
8. Draw a flow chart showing the the steps of materials selection procedure?
9. The performance P of the element is described by an equation state it?
10. When we talk about choosing materials for a component, we take into account many
different factors. What are they?

Give a meaning to five of the following:

1- Material selection 2- Translation task 3- Material property charts 4- Material index
5-Design 6- screemng 7- Ranking CE

Ex/1
E4.5 An acrylic (PMMA) window is clamped in a low carbon steel Answer. Th
frame at T = 20 C. The temperature falls to T = -20 C, putting the window, so t
window under tension because the thermal expansion coefficient of instability is
PMMA is larger than that of steel. If the window was stress-free at
20C, what stress does it carry at -20 C? Use the result that the bi-axial Cσ
stress caused by a bi-axial strain difference ∆ε is
Inserting the
E∆ε unstable:
σ =
1 −ν

where E is Young’s modulus for PMMA and Poisson’s ratio ν = 0.33 . 2a =

You will find data for expansion coefficients in Table A7, and for moduli
in UASSP, 5. Use mean values. Thus the 0.5

Answer. The strain difference caused by difference in thermal E4.7 A flywh

expansion, α , when the temperature changes by ∆T is 8000 rpm. It
( )
∆ε = α PMMA − α Low C steel ∆T
shop can gua
than 2a = 2 m
From the CES EduPack, stress in a sp
small enclos
α PMMA = 117x 10-6/C and α Low C steel = 12.3 x 10-6/C CES EduPac
-3
ν for cast iro
giving ∆ε = 4.2 x 10 . The modulus of PMMA from the CES
EduPack is E = 3.0 GPa. The equation given in the question then
Answer. Th
predicts a tensile stress in the window of σ = 19 MPa.
σ max =
Page 1 of 5
for a contain
the rotationa
E4.6 The PMMA window described in Exercise 4.5 has a contained the mean va
 CES EduPack – Exercises with Worked Solutions

Ex/2E4.3 A thick-walled tube has an inner radius r = 10 mm and an outer

i
ASSP) is a radius ro = 15 mm. It is made from polycarbonate, PC. What is the
Teaching maximum torque that the tube can carry without the onset of yield?
e used to Retrieve the (mean) yield strength σ y of PC, the expression for the
torque at onset of yield from UASSP, 6 and that for the polar moment of a
thick walled tube from UASSP, 2 to find out.
b = 5 mm and
y how much
from the CES Answer. The torque at the onset of yield for a thick walled tube is
minum alloys,
UASSP, 3 Kσ y π
find out. Tf = with K = ( ro4 − ri4 )
2 ro 2
oad F is, from The mean yield strength of σ y of PC from the CES EduPack is 65 MPa.
Inserting the data from the question gives a torque at the onset of yield of
T f = 138 N.m.

Inserting the Ex/3

7 mm. E4.4 A round bar, 20 mm in diameter, has a shallow circumferential
notch with a depth c = 1 mm with a root radius r = 10 microns. The bar
is made of a low carbon steel with a yield strength of σ y = 250 MPa. It is
e diameter
loaded axially with a nominal stress, σ nom (the axial load divided by the
much will it
e shear un-notched area). At what value of σ nom will yield first commence at the
ung’s modulus root of the notch? Use the stress concentration estimate of UASSP, 9 to
sion for the find out.

Answer. The stress concentration caused by notch of depth c and root

Pg = 9.81 N radius r is
1/ 2
σ max c
= 1 + α  with α ≈ 2 for tension
σ nom r
Yield first starts when σ max = σ y . Inserting the data from the question
gives a nominal stress for first yield of 11.9 MPa. Stress concentrations
modulus can be very damaging – in this example, a cyclic stress of only ± 12 MPa
0.4 mm. will ultimately initiate a fatigue crack at the notch root.

7 www.grantadesign.com/education/resources

Page 2 of 5
 for a contain
Ex/4 the rotationa
E4.6 The PMMA window described in Exercise 4.5 has a contained the mean va
crack of length 2a = 0.5 mm. If the maximum tensile stress that is from the CE
anticipated in the window is σ = 20 MPa, will the crack propagate? velocity that
Choose an appropriate equation for crack propagation from UASSP, 10 or 41,600 rp
and data for the fracture toughness K 1c of PMMA from the CES
CES EduPack – Exercises with Worked Solutions
EduPack to calculate the length of crack that is just unstable under this
tensile stress.
steel Answer. The crack length is small compared with the width of the
ng the window, so the appropriate choice of equation describing crack
cient of instability is
free at M.F. Ashby 2010 8
the bi-axial Cσ π a ≥ K 1c with C = 1 .0

Inserting the data we find the length of the shortest crack that is just
unstable:
2
2K 
ν = 0.33 . 2a =  1c  = 2.1 mm, using (K 1c ) PMMA = 1.15 MPa.m1/2
π σ 
d for moduli
Thus the 0.5mm crack will not propagate.
Ex/5
E5.4 Use a E-ρ chart to identify metals with both E > 100 GPa and E5.5 U
mal E4.7 E/
A ρflywheel with a radius
> 0.02 GPa/(kg/m 3). R = 200 mm is designed to spin up to
and
8000 rpm. It is proposed to make it out of cast iron, but the casting
takin
shop can guarantee only that it will have no crack-like flaws greater
Answer. The chart shows the selection. The metals that lie in the
than 2search
a = 2 mm areain are
length.
listedUse thetable.
in the expression for the maximum
stress in a Material
spinning disk in UASSP, 7, that for the stress intensity at a
Comment
and
throu
small enclosed crack from UASSP, 10 and data for cast iron from the
-6 Steels Cheap, widely used. Stiff structural material.
/C CES EduPack to establishMore
Nickel alloys if theexpensive
flywheel than
is safe.
steelTake Poisson’s ratio Answer.
ν for cast iron to
Titanium be 0.33. Titanium alloys are very expensive.
alloys search ar
ES
CF
on then
Answer. The maximum tensile stress in a spinning disk is
(3 +ν ) ρ ω 2 R 2 , and K = σ
Bor

σ max = 1 max πa ≤ K 1c
8 ρ=
E/ρ
for a contained crack. Here ω = 2 π W / 60 radians/sec when W is 0.02
the rotational velocity in rpm. Inserting the data from the question and
ontained Search area 3
the mean values for density ρ = 7150 kg/m and K 1c = 38 MPa.m E = 100
1/2

that is from the CES EduPack, we find the maximum that the rotational
agate? velocity that will just cause the cracks to propagate is 4350 radians/s,
UASSP, 10 or 41,600 rpm. The flywheel is safe.
CES
e under this

8 www.grantadesign.com/education/resources
Page 3 of 5

M.F. Ashby 2010

 CES EduPack – Exercises with Worked Solutions

00 GPa and Ex/6

E5.5 Use a E-ρ chart to identify materials with both E > 100 GPa
1/3
and E 1 / 3 / ρ > 0.003 (GPa) /(kg/m3). Remember that, on
taking logs, the index M = E 1 / 3 / ρ becomes
lie in the Log ( E ) = 3 Log ( ρ ) + 3 Log ( M )
and that this plots as a line of slope 3 on the chart, passing
through the point E = 27 when ρ = 1000 in the units on the chart.
material.
Answer. The chart shows the selection. The materials that lie in the
search area are listed in the table. No metals survive.
Material Comment
CFRP Carbon-fiber composites excel in stiffness
at low weight.
Boron carbide, B4C Boron carbide is exceptionally stiff, hard
and light; it is used for body armour.

E1/3/ρ
ρ = 0.003
ρ=
E/ρ
0.02

Search area
E = 100 E = 100

Slope 3

11 www.grantadesign.com/education/resources

Page 4 of 5
 C

Ex/7
E6.1 A material is required for the windings of an electric air-furnace Functio
o
capable of temperatures up to 1000 C. Think out what attributes a Constra
material must have if it is to be made into windings and function
properly in a furnace. List the function and the constraints; set the
objective to “minimize cost” and the free variables to “choice of
material”.
CE
Objecti
Free va
Answer. If the material is to be used as windings it must be able to be Functio
E6.1 A material is required for the windings of an electric air-furnace
drawn to wire and wound to a coil. It must o conduct electricity and
capable of temperatureso up to 1000 C. Think out what attributes a Constra
be able to operate at 1000 C in air. The constraints are tabulated E6.3 A
material must have if it is to be made into windings and function
below. from
properly in a furnace. List the function and the constraints; set the
objective to “minimize cost” and the free variables unde
Function • High temperature furnace winding to “choice of to “m
material”.
Constraints • Maximum service temperature, Tmax > 1000 C Objectiv
• Able to be rolled or drawn to wire
Free va
• Good
Answer. If the material is electrical
to be used conductor
as windings it must be able to be Answer.
• Good resistance
drawn to wire and wound to a coil. to oxidation at elevated
It must conduct electricity and temp
temperature o
be able to operate at 1000 C in air. The constraints are tabulated E6.3 wellAa
Objective
below. • Minimize material cost the
fromh
Free variables • Choice of material unde
mate
Function • High temperature furnace winding to “m
ductil
Constraints • Maximum service temperature, Tmax > 1000 C
• toAble to be rolled or drawnscissors.
to wire Functio
E6.2 A material is required manufacture office Paper is an
• Good electrical conductor
abrasive material, and scissors sometimes encounter hard Constra
Answer.
• Good
obstacles like staples. resistanceand
List function to oxidation at elevated
constraints; set the temp
temperature well a
objective to “minimize cost” and the free variables to “choice of
Objective
material”. • Minimize material cost the h
Free variables • Choice of material mate
ductil
Ex/8E6.2 ATo
Answer. resist is
material abrasive
requiredwear the scissors
to manufacture mustscissors.
office have bladesPaperofis an Functio
highabrasive
hardness. material, and scissors sometimes encounter hard a
In cutting, they will sooner or later encounter Constra
staple or otherlike
obstacles hard obstruction
staples. that would
List function chip a brittleset
and constraints; blade
the – Objecti
some toughness is required. These two parameters
objective to “minimize cost” and the free variables to “choice help reduce
of Free va
wear, butCES
there
material”. EduPack
are other – Exercises
factors that with
influence Worked
it, so it is Solutions
sensible
to specify good wear resistance. Finally, the scissors must be
formed – if the handles are integral with the blades, they must be
electric air-furnace Function
forged orTo
stamped • sheet,
from Scissorsrequiring the ability to be processed
Answer. resist abrasive wear the scissors must have blades of
ut what attributes a Constraints
in this way. •
high hardness. In cutting,hardness
High they will sooner or later encounter a
gs and function staple or other hard 1/ 2 –
• obstruction that would
Adequate toughness: K 1chip a brittle
c > 15 MPa.mblade Objectiv
constraints; set the some toughness is required. These two parameters help reduce
es to “choice of • Good wear resistance Free va
wear, but there are other factors that influence it, so it is sensible
• Able to be forged
M.F. Ashby 2010 17
to specify good wear resistance. Finally, the scissors must be
Objective
formed – if the handles• Minimize material
are integral cost
with the blades, they must be
Free variables
forged or stamped • from
Choice of material
sheet, requiring the ability to be processed
must be able to be in this way.
uct electricity and
aints are tabulated E6.3 A material is required for a heat exchanger to extract heat
o
from geo-thermally heated, saline, water at 120 C (and thus
Page 5 of 5M.F. Ashby 2010 17
under pressure). List function and constraints; set the objective
ng to “minimize cost” and the free variables to “choice of material”.
Tmax > 1000 C
e