Materials and process selection for engineering design

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1. Verfasser: Farag, Mahmoud M. 1937- (VerfasserIn)
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Veröffentlicht: Boca Raton, Fla. u.a. CRC Press 2014
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adam_text Titel: Materials and process selection for engineering design Autor: Farag, Mahmoud M Jahr: 2014 Contents Preface to the Third Edition...................................................................................xix Preface to the Second Edition.................................................................................xxi Author..................................................................................................................xxiii Chapter 1 Product Design and Development in the Industrial Enterprise............1 1.1 Introduction...............................................................................1 1.2 Feasibility Study, Identification of Needs, and Concept Selection....................................................................................2 1.2.1 Market Research...........................................................2 1.2.2 Customer Needs and Product Specifications...............2 1.2.3 Concept Generation, Screening, and Selection............5 1.2.4 Economic Analysis.......................................................5 1.2.5 Selecting an Optimum Solution...................................5 1.3 System-Level Design.................................................................9 1.4 Detail Design and Selection of Materials and Processes........12 1.4.1 Configuration (Embodiment) Design.........................12 1.4.2 Final Detail Design....................................................13 1.4.3 Design Reviews..........................................................13 1.5 Testing and Refinement...........................................................13 1.6 Launching the Product............................................................14 1.6.1 Project Planning and Scheduling...............................14 1.6.2 Manufacturing............................................................15 1.6.3 Quality Control...........................................................16 1.6.4 Packaging...................................................................17 1.6.5 Marketing...................................................................17 1.6.6 After-Sales Service.....................................................17 1.7 Selling the Product..................................................................17 1.7.1 Cost of Product Engineering......................................18 1.7.2 Actual Manufacturing Cost........................................18 1.7.3 Sales Expense and Administrative Cost.....................20 1.7.4 Selling Price...............................................................20 1.8 Planning for Retirement of the Product and Environmental Considerations................................................20 1.8.1 Recycling of Materials...............................................20 1.8.2 Sources of Materials for Recycling............................21 1.8.3 Infrastructure for Recycling Packaging Materials.....22 1.8.4 Sorting........................................................................22 1.8.5 Scrap Processing........................................................23 1.8.6 Recyclability of Materials..........................................24 1.9 Product Market Cycle..............................................................24 viii Contents 1.10 Summary.................................................................................25 Review Questions...............................................................................26 Bibliography and Further Readings...................................................27 PART I Performance of Materials in Service Chapter 2 Failure under Mechanical Loading....................................................33 2.1 Introduction.............................................................................33 2.2 Types of Mechanical Failures..................................................33 2.3 Fracture Toughness and Fracture Mechanics..........................34 2.3.1 Flaw Detection...........................................................35 2.3.2 Fracture Toughness of Materials................................36 2.4 Ductile and Brittle Fractures...................................................40 2.4.1 Ducti Íe Fractures........................................................40 2.4.2 Brittle Fractures..........................................................41 2.4.3 Ductile-Brittle Transition..........................................43 2.4.4 Design and Manufacturing Considerations................45 2.5 Fatigue Failures.......................................................................45 2.5.1 Types of Fatigue Loading...........................................48 2.5.2 Fatigue Strength.........................................................49 2.5.3 Crack Initiation...........................................................50 2.5.4 Crack Propagation......................................................51 2.6 Elevated-Temperature Failures................................................52 2.6.1 Creep..........................................................................53 2.6.2 Combined Creep and Fatigue.....................................55 2.6.3 Thermal Fatigue.........................................................55 2.7 Failure Analysis: Experimental Methods................................56 2.8 Failure Analysis: Analytical Techniques.................................57 2.8.1 Root Cause Analysis..................................................57 2.8.2 Fault Tree Analysis.....................................................58 2.8.3 Failure Logic Model...................................................63 2.8.4 Failure Experience Matrix.........................................64 2.8.5 Expert Systems...........................................................65 2.9 Failure Prevention at the Design Stage....................................65 2.10 Failure Mode Effect Analysis..................................................66 2.11 Summary.................................................................................68 Review Questions...............................................................................68 Bibliography and Further Readings...................................................69 Chapter 3 Corrosion, Wear, and Degradation of Materials................................71 3.1 Introduction.............................................................................71 3.2 Electrochemical Principles of Metallic Corrosion..................72 Contents ix 3.3 Types of Metallic Corrosion....................................................73 3.3.1 General Corrosion......................................................76 3.3.2 Galvanic Corrosion....................................................76 3.3.3 Crevice Corrosion.......................................................77 3.3.4 Pitting Corrosion........................................................78 3.3.5 Intergranular Corrosion..............................................78 3.3.6 Selective Leaching.....................................................80 3.4 Combined Action of Stress and Corrosion..............................80 3.4.1 Stress Corrosion Cracking..........................................80 3.4.2 Corrosion Fatigue.......................................................81 3.4.3 Erosion Corrosion.......................................................82 3.4.4 Cavitation Damage.....................................................82 3.4.5 Fretting Corrosion......................................................82 3.5 Corrosion of Plastics and Ceramics.........................................82 3.5.1 Corrosion of Plastics..................................................83 3.5.2 Corrosion of Ceramics...............................................84 3.6 Oxidation of Materials............................................................84 3.6.1 Oxidation of Metals....................................................84 3.6.2 Oxidation of Plastics..................................................87 3.6.3 Oxidation of Ceramics...............................................87 3.7 Corrosion Control....................................................................87 3.7.1 Galvanic Protection....................................................87 3.7.2 Inhibitors....................................................................89 3.8 Wear Failures...........................................................................89 3.8.1 Adhesive Wear............................................................90 3.8.2 Abrasive, Erosive, and Cavitation Wear.....................92 3.8.3 Surface Fatigue...........................................................92 3.8.4 Lubrication.................................................................92 3.9 Radiation Damage...................................................................94 3.9.1 Radiation Damage by Electromagnetic Radiation.....94 3.9.2 Radiation Damage by Particles..................................95 3.10 Summary.................................................................................95 Review Questions...............................................................................96 Bibliography and Further Readings...................................................96 Chapter 4 Selection of Materials to Resist Failure.............................................99 4.1 Introduction.............................................................................99 4.2 Grouping and Identifying Engineering Materials...................99 4.2.1 Classification and Designation of Engineering Materials.....................................................................99 4.2.2 Considerations in Material Selection.......................100 4.3 Selection of Materials for Static Strength.............................100 4.3.1 Aspects of Static Strength........................................100 4.3.2 Level of Strength......................................................101 4.3.3 Load-Carrying Capacity..........................................101 Contents 4.4 Selection of Materials for Stiffness.......................................104 4.4.1 Effect of Material Stiffness on Deflection under Load..........................................................................104 4.4.2 Specific Stiffness......................................................107 4.4.3 Effect of Material Stiffness on Buckling Strength......108 4.5 Selection of Materials for Higher Toughness........................110 4.5.1 Metallic Materials....................................................110 4.5.2 Plastics and Composites...........................................114 4.5.3 Ceramics...................................................................115 4.6 Selection of Materials for Fatigue Resistance.......................115 4.6.1 Steels and Cast Irons................................................117 4.6.2 Nonferrous Alloys....................................................118 4.6.3 Plastics......................................................................118 4.6.4 Composite Materials................................................118 4.7 Selection of Materials for High-Temperature Resistance......119 4.7.1 Creep Resistance of Metals......................................119 4.7.2 Performance of Plastics at High Temperatures........120 4.7.3 Widely Used Materials for High-Temperature Applications..............................................................120 4.7.3.1 Room Temperature to 150°C (300°F).......120 4.7.3.2 150°C-400°C (300°F-750°F)..................121 4.7.3.3 400°C-600°C (750°F-1100°F).................121 4.7.3.4 600°C-1000°C (1100°F-1830°F).............122 4.7.3.5 1000°C (1830°F) and Above.....................123 4.7.4 Niobium, Tantalum, and Tungsten...........................123 4.7.5 Ceramics...................................................................123 4.8 Selection of Materials for Corrosion Resistance...................126 4.8.1 Corrosive Medium Parameters.................................126 4.8.2 Design Parameters....................................................127 4.8.3 Material Parameters.................................................127 4.8.4 Carbon Steels and Cast Irons...................................127 4.8.5 Stainless Steel...........................................................127 4.8.6 Nickel.......................................................................129 4.8.7 Copper......................................................................130 4.8.8 Tin............................................................................130 4.8.9 Lead..........................................................................130 4.8.10 Aluminum................................................................130 4.8.11 Titanium...................................................................131 4.8.12 Tantalum and Zirconium..........................................132 4.8.13 Metallic Glasses.......................................................132 4.8.14 Plastics and Fiber-Reinforced Plastics.....................132 4.8.15 Ceramic Materials....................................................133 4.8.16 Other Means of Resisting Corrosion........................133 4.9 Coatings for Protection against Corrosion............................133 4.9.1 Metallic Coatings.....................................................134 Contents xi 4.9.2 Organic Coatings......................................................134 4.9.3 Vitreous Enamels.....................................................134 4.10 Selection of Materials for Wear Resistance...........................136 4.10.1 Wear Resistance of Steels........................................137 4.10.2 Wear Resistance of Cast Irons..................................138 4.10.3 Nonferrous Alloys for Wear Applications................138 4.10.4 Wear Resistance of Plastics......................................139 4.10.5 Wear Resistance of Ceramics...................................140 4.11 Wear-Resistant Coatings........................................................140 4.12 Summary...............................................................................141 Review Questions.............................................................................142 Bibliography and Further Readings.................................................144 PART II Relationships between Design, Materials, and Manufacturing Processes Chapter 5 Nature of Engineering Design..........................................................149 5.1 Introduction...........................................................................149 5.2 General Considerations in Engineering Design....................150 5.2.1 Human Factors.........................................................150 5.2.2 Industrial Design, Esthetic, and Marketing Considerations..........................................................151 5.2.3 Environmental Considerations.................................151 5.2.4 Functional Requirements.........................................152 5.3 Design for Six Sigma.............................................................152 5.4 Major Phases of Design.........................................................153 5.4.1 Preliminary and Conceptual Design........................155 5.4.2 Configuration (Embodiment) Design.......................155 5.4.3 Detail (Parametric) Design.......................................156 5.5 Environmentally Responsible Design...................................157 5.6 Design Codes and Standards.................................................157 5.7 Effect of Component Geometry............................................158 5.7.1 Stress-Concentration Factor.....................................158 5.7.2 Stress Concentration in Fatigue................................159 5.7.3 Guidelines for Design...............................................159 5.8 Factor of Safety......................................................................162 5.9 Reliability of Components.....................................................164 5.10 Product Reliability and Safety...............................................167 5.11 Product Liability....................................................................169 5.12 Summary...............................................................................170 Review Questions.............................................................................170 Bibliography and Further Readings.................................................171 xii Contents Chapter 6 Effect of Material Properties on Design..........................................173 6.1 Introduction...........................................................................173 6.2 Designing for Static Strength................................................173 6.2.1 Designing for Simple Axial Loading.......................173 6.2.2 Designing for Torsional Loading.............................174 6.2.3 Designing for Bending.............................................175 6.3 Designing for Stiffness..........................................................176 6.3.1 Design of Beams......................................................177 6.3.2 Design of Shafts.......................................................179 6.3.3 Design of Columns...................................................179 6.4 Designing with High-Strength, Low-Toughness Materials...............................................................................180 6.4.1 Fail-Safe Design.......................................................181 6.4.2 Guidelines for Design...............................................182 6.4.3 Leak-before-Burst.....................................................183 6.5 Designing against Fatigue.....................................................184 6.5.1 Factors Affecting Fatigue Behavior.........................184 6.5.1.1 Endurance-Limit-Modifying Factors.......185 6.5.2 Effect of Mean Stress...............................................189 6.5.3 Cumulative Fatigue Damage....................................190 6.5.4 Other Fatigue Design Criteria..................................191 6.6 Designing under High-Temperature Conditions....................191 6.6.1 Design Guidelines....................................................192 6.6.2 Larson-Miller Parameter.........................................194 6.6.3 Life under Variable Loading....................................196 6.6.4 Life under Combined Fatigue and Creep Loading..............................................................196 6.7 Designing for Hostile Environments.....................................196 6.7.1 Design Guidelines....................................................196 6.8 Designing with Specific Materials (Material-Specific Design Features)....................................................................197 6.8.1 Designing with Metallic Materials..........................197 6.8.2 Designing with Polymers.........................................199 6.8.3 Designing with Ceramics.........................................200 6.8.4 Designing with Composites.....................................201 6.9 Summary...............................................................................203 Review Questions.............................................................................204 Bibliography and Further Readings.................................................206 Chapter 7 Effect of Manufacturing Processes on Design.................................209 7.1 Introduction...........................................................................209 7.2 Product Manufacture in the Industrial Enterprise.................209 7.3 Classification of Manufacturing Processes...........................210 7.3.1 Processing of Metallic Materials.............................210 7.3.2 Processing of Plastic Parts.......................................212 Contents xiii 7.3.3 Processing of Ceramic Products..............................212 7.3.4 Manufacture of Reinforced Plastic Components.....212 7.3.5 Manufacture of Reinforced Metal Components.......213 7.4 Selection of Manufacturing Processes..................................213 7.5 Design for Manufacture and Assembly.................................218 7.6 Design Considerations for Cast Components........................220 7.6.1 Guidelines for Design...............................................223 7.6.2 Effect of Material Properties....................................223 7.7 Design Considerations for Molded Plastic Components.......224 7.7.1 Guidelines for Design...............................................225 7.7.2 Accuracy of Molded Parts........................................227 7.8 Design Considerations for Forged Components....................227 7.8.1 Guidelines for Design...............................................228 7.9 Design Considerations for Powder Metallurgy Parts............229 7.9.1 Guidelines for Design...............................................229 7.10 Design of Sheet Metal Parts..................................................231 7.10.1 Guidelines for Design...............................................231 7.11 Designs Involving Joining Processes....................................232 7.11.1 Welding....................................................................232 7.11.1.1 Weldability of Materials...........................234 7.11.1.2 Tolerances in Welded Joints......................235 7.11.1.3 Guidelines for the Design of Weldments.....235 7.11.1.4 Types of Welded Joints.............................236 7.11.1.5 Strength of Welded Joints.........................236 7.11.2 Adhesive Bonding....................................................238 7.11.2.1 Design of Adhesive Joints.........................239 7.12 Designs Involving Heat Treatment........................................239 7.13 Designs Involving Machining Processes...............................240 7.13.1 Machinability Index.................................................240 7.13.2 Guidelines for Design...............................................241 7.14 Automation of Manufacturing Processes..............................246 7.15 Computer-Integrated Manufacturing.....................................246 7.16 Summary...............................................................................247 Review Questions.............................................................................248 Bibliography and Further Readings.................................................251 PART III Selection and Substitution of Materials and Processes in Industry Chapter 8 Economics and Environmental Impact of Materials and Processes......................................................................................255 8.1 Introduction...........................................................................255 8.2 Elements of the Cost of Materials.........................................256 8.2.1 Cost of Ore Preparation............................................256 xiv Contents 8.2.2 Cost of Extraction from the Ore...............................256 8.2.3 Cost of Purity and Alloying.....................................257 8.2.4 Cost of Conversion to Semifinished Products..........258 8.2.5 Cost of Conversion to Finished Products.................258 8.3 Factors Affecting Material Prices.........................................258 8.3.1 General Inflation and Price Fluctuations.................259 8.3.2 Supply and Demand.................................................259 8.3.3 Order Size.................................................................259 8.3.4 Standardization of Grades and Sizes.......................259 8.3.5 Inventory Costs.........................................................260 8.3.6 Cost Extras for Special Quality................................260 8.3.7 Geographic Location................................................260 8.4 Comparison of Materials on Cost Basis................................260 8.5 Value Analysis of Material Properties..................................263 8.6 Economics of Material Utilization........................................264 8.7 Economic Competition in the Materials Field......................268 8.7.1 Legislation................................................................268 8.7.2 Cost Saving...............................................................268 8.7.3 Superior Performance...............................................269 8.8 Processing Time....................................................................269 8.8.1 Elements of Processing Time...................................269 8.9 Processing Cost.....................................................................270 8.9.1 Rules of Thumb........................................................270 8.9.2 Standard Costs..........................................................270 8.9.3 Technical Cost Modeling.........................................272 8.10 Economics of Time-Saving Devices.....................................272 8.11 Cost-Benefit and Cost-Effectiveness Analyses.....................275 8.12 Environmental Impact Assessment of Materials and Processes...............................................................................277 8.12.1 Environmental Considerations.................................277 8.12.2 Energy Content of Materials....................................279 8.12.3 Life Cycle Assessment.............................................281 8.13 Recyclability of Engineering Materials and Recycling Economics.............................................................................283 8.14 Life Cycle Cost......................................................................285 8.15 Summary...............................................................................287 Review Questions.............................................................................288 Bibliography and Further Readings.................................................290 Chapter 9 Materials Selection Process.............................................................291 9.1 I ntroduction...........................................................................291 9.2 Nature of the Selection Process.............................................292 9.3 Analysis of the Material Performance Requirements and Creating Alternative Solutions..............................................294 9.3.1 Functional Requirements.........................................294 Contents xv 9.3.2 Processability Requirements....................................295 9.3.3 Cost...........................................................................295 9.3.4 Reliability Requirements..........................................297 9.3.5 Resistance to Service Conditions.............................297 9.3.6 Creating Alternative Solutions.................................297 9.4 Initial Screening of Solutions................................................298 9.4.1 Rigid Materials and Process Requirements.............298 9.4.2 Cost per Unit Property Method................................298 9.4.3 Ashby s Method........................................................300 9.4.4 Dargie s Method.......................................................301 9.4.5 Esawi and Ashby s Method......................................303 9.5 Comparing and Ranking Alternative Solutions....................304 9.5.1 Weighted Property Method......................................304 9.5.2 Digital Logic Method...............................................304 9.5.3 Performance Index...................................................305 9.5.4 Limits on Property Method......................................313 9.5.5 Analytic Hierarchy Process......................................318 9.6 Selecting the Optimum Solution...........................................322 9.7 Computer Assistance in Making Final Selection..................328 9.7.1 CAD/CAM Systems.................................................328 9.7.2 Expert Systems.........................................................329 9.8 Using MATLAB® in Materials and Process Selection.........330 9.8.1 Multicriteria Decision Making.................................330 9.8.2 MATLAB® Programming Environment..................331 9.9 Sources of Information for Materials Selection....................333 9.9.1 Locating Material Property Data.............................333 9.9.2 Types of Material Information.................................333 9.9.3 Computerized Materials Databases.........................334 9.10 Summary...............................................................................335 Review Questions.............................................................................336 Bibliography and Further Readings.................................................340 Chapter 10 Materials Substitution......................................................................343 10.1 Introduction...........................................................................343 10.2 Materials Audit......................................................................343 10.3 Considerations in Materials Substitution...............................345 10.4 Screening of Substitution Alternatives..................................346 10.5 Comparing and Ranking of Alternative Substitutes.............347 10.5.1 Cost of Performance Method of Substitution...........347 10.5.2 Compound Performance Function Method..............348 10.6 Reaching a Final Decision.....................................................352 10.6.1 Cost-Benefit Analysis..............................................352 10.6.2 Economic Advantage of Improved Performance.....352 10.6.3 Total Cost of Substitution.........................................353 10.7 Using MATLAB® in Materials Substitution.........................362 xvi Contents 10.8 Summary...............................................................................365 Review Questions.............................................................................366 Bibliography and Further Readings.................................................368 Chapter 11 Case Studies in Material Selection and Substitution........................371 11.1 Introduction...........................................................................371 11.2 Design and Selection of Materials for a Turnbuckle.............371 11.2.1 Introduction..............................................................371 11.2.2 Factors Affecting Performance in Service...............372 11.2.3 Design Calculations..................................................373 11.2.4 Design for Static Loading........................................373 11.2.5 Design for Fatigue Loading......................................375 11.2.6 Candidate Materials and Manufacturing Processes...............................................................376 11.2.7 Sample Calculations.................................................377 11.3 Design and Selection of Materials for Surgical Implants......380 11.3.1 Introduction..............................................................380 11.3.2 Main Dimensions and External Forces....................381 11.3.3 Fatigue-Loading Considerations..............................383 11.3.4 Wear Considerations................................................383 11.3.5 Analysis of Implant Material Requirements............384 11.3.5.1 Tissue Tolerance.......................................384 11.3.5.2 Corrosion Resistance................................384 11.3.5.3 Mechanical Behavior................................385 11.3.5.4 Elastic Compatibility................................385 11.3.5.5 Weight.......................................................385 11.3.5.6 Cost...........................................................385 11.3.6 Classification of Materials and Manufacturing Processes for the Prosthesis Pin...............................386 11.3.7 Evaluation of Candidate Materials...........................387 11.3.8 Results......................................................................387 11.4 Design and Selection of Materials for Lubricated Journal Bearings.................................................................................387 11.4.1 Introduction..............................................................387 11.4.2 Design of the Journal Bearing..................................390 11.4.3 Analysis of Bearing Material Requirements............392 11.4.4 Classification of Bearing Materials..........................394 11.4.5 Selection of the Optimum Bearing Alloy................397 11.4.6 Conclusion................................................................398 11.5 Analysis of the Requirements and Substitution of Materials for Tennis Rackets.................................................399 11.5.1 Introduction..............................................................399 11.5.2 Analysis of the Functional Requirements of the Tennis Racket...........................................................399 11.5.3 Design Considerations..............................................400 Contents xvii 11.5.4 Classification of Racket Materials............................402 11.5.5 Material Substitution................................................402 11.5.6 Ranking of Alternative Substitutes..........................402 11.5.7 Conclusion................................................................402 11.6 Material Substitution in the Automotive Industry.................405 11.6.1 Introduction..............................................................405 11.6.2 Materials and Manufacturing Processes for Interior Panels..........................................................405 11.6.3 Performance Indices of Interior Panels....................406 11.6.3.1 Technical Characteristics..........................406 11.6.3.2 Cost Considerations for Interior Panel......408 11.6.3.3 Esthetics and Comfort..............................409 11.6.3.4 Environmental Considerations.................410 11.6.4 Comparison of Candidate Materials........................411 11.6.5 Performance/Cost Method of Substitution...............411 11.6.6 Compound Objective Function Method...................413 11.6.7 Conclusion................................................................414 Bibliography and Further Readings.................................................417 PART IV Appendices Appendix A: Metallic Materials—Classification, General Characteristics, and Properties....................................425 Appendix B: Polymers—Classification, General Characteristics, and Properties...............................................................................447 Appendix C: Ceramic Materials—Classification, General Characteristics, and Properties....................................463 Appendix D: Composite Materials—Classification and Properties...............471 Appendix E: Semiconductors and Advanced Materials..................................477 Appendix F: Conversion of Units and Hardness Values..................................479 Appendix G: Glossary.........................................................................................483 Index......................................................................................................................495
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id DE-604.BV041569374
illustrated Illustrated
indexdate 2024-12-24T03:59:30Z
institution BVB
isbn 9781466564091
language English
oai_aleph_id oai:aleph.bib-bvb.de:BVB01-027014802
oclc_num 869875320
open_access_boolean
owner DE-573
DE-862
DE-BY-FWS
owner_facet DE-573
DE-862
DE-BY-FWS
physical XXIII, 513 S. Ill., graph. Darst.
publishDate 2014
publishDateSearch 2014
publishDateSort 2014
publisher CRC Press
record_format marc
spellingShingle Farag, Mahmoud M. 1937-
Materials and process selection for engineering design
Engineering design
Materials
Manufacturing processes
Werkstoffwahl (DE-588)4136338-3 gnd
Fertigung (DE-588)4016899-2 gnd
subject_GND (DE-588)4136338-3
(DE-588)4016899-2
title Materials and process selection for engineering design
title_auth Materials and process selection for engineering design
title_exact_search Materials and process selection for engineering design
title_full Materials and process selection for engineering design Mahmoud M. Farag
title_fullStr Materials and process selection for engineering design Mahmoud M. Farag
title_full_unstemmed Materials and process selection for engineering design Mahmoud M. Farag
title_short Materials and process selection for engineering design
title_sort materials and process selection for engineering design
topic Engineering design
Materials
Manufacturing processes
Werkstoffwahl (DE-588)4136338-3 gnd
Fertigung (DE-588)4016899-2 gnd
topic_facet Engineering design
Materials
Manufacturing processes
Werkstoffwahl
Fertigung
url http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=027014802&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
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