Updated: Dec 2013

ME 770

MATERIALS SELECTION IN MECHANICAL DESIGN

Department of Mechanical Engineering Indian Institute of Technology Kanpur Course instructor: Sujeet Kumar SINHA Office location: Level 2, Northern Laboratories-1, Department of Mechanical Engineering Meeting time: Normally anytime. E-mails are welcome E-mail: sujeet@iitk.ac.in Tel. (Office): 0512-259 6679 Course website: All teaching materials will be provided through e-mails. Re-requisite: Prior background in Materials and Mechanical Design is essential Rationale for introducing this course: All mechanical engineers need sound knowledge of engineering materials and how the materials can be used in mechanical design. Fundamental understanding of this field of engineering will be essential for mechanical engineers to carry out their professional work in design, performance evaluation, maintenance, quality control, failure analysis, re-design, safety assessment of engineering component etc and in solving similar practical engineering problems. Course Description: This module highlights various properties of engineering materials that are of paramount importance to a design engineer along with various design philosophies that are commonly practiced. It develops the analytical ability of students in choosing the most appropriate material from a design engineer's perspective. The topics covered are: Introduction of engineering materials; The evolution of engineering materials; Materials and the design process; Functional requirements of engineering materials; Materials selection based on properties alone; Materials selection for weight-critical applications; Materials for stiffness-based designs; Materials for strength-based designs; Materials for damage tolerant designs; Materials and fatigue-based designs; Materials and design against corrosion; Materials for wear critical applications; Materials for thermal applications; Materials for biomedical applications; Materials selection based on properties & shape; Processing, materials & design; Materials property data; latest developments in the use of materials; new materials; Case studies. This module will be useful to students who want to acquire an in-depth knowledge and understanding of the mechanical properties of materials used in many mechanical engineering applications. Emphasis is given on the application of the knowledge to design through various case studies. Learning Outcomes: On successful completion of this module, the student will be able to: 1. Describe important mechanical properties (strength, toughness, fatigue, wear resistance, corrosion resistance etc) and attributes (e.g. cost, processability) of engineering materials that are important for engineering design. 2. Explain the mechanisms underlying different mechanical properties of materials such as strength, fatigue, wear, friction, corrosion, thermal etc. 2. Use mathematical (materials and performance indices) and mapping tools (Ashbys map) for selecting right material for a given design situation. 3. Explain the requirements of simple engineering design such as stress, stiffness, environment, stress concentration and then predict performances of given materials using analytical tools. 4. Outline important engineering materials for mechanical design and assess their performances based on various properties and processing. Materials include metals, alloys, plastics, composites and ceramics.

5. Devise a plan for materials selection for a given mechanical design using various materials properties, design requirements and performance indicators

Detailed topics : 1. Introduction of engineering materials: Survey of engineering materials such as metals, metal alloys, ceramics, polymers, semi-conductors, nano-materials and different types of composites, Introduction to design concepts. classroom video/case discussion. 2. Materials for stiffness based designs: Concept of stiffness of materials. Defining stiffness, Stress-Strain Diagram. Examples of stiff materials and their applications in engineering designs, Case study on stiffness based design, selection criteria for stiffness based design. 3. Materials for strength-based designs: Strength of materials. Strength vs. stiffness. Criterion for strength critical design, Survey of the strength of materials, Case study material for pressure vessels, Materials for high strength and high stiffness, Material selection chart, Tensile strength vs. compressive strength, Concept of ideal strength and real strength, Ceramics, polymers and metals, Strengthening mechanisms for materials, Different types of strengthening such as precipitation hardening and fiber strengthening, Examples of high strength materials. 4. Materials for damage tolerant designs: Types of material damage. Fracture mechanics and fracture toughness. Toughness vs. fracture toughness, Energy approach to fracture, Modes of fracture, Mechanism of fracture, Standard tests for fracture toughness, Examples of improved damage tolerant materials. 5. Materials and fatigue-based designs: Case study Failure of lifting eye, Defining fatigue failure. Cyclic loading. Fatigure test and data presentation, The S-N curve. High cycle and Low-Cycle fatigue. Fatigue behaviour for materials with existing crack, Material design for fatigue resistance avoiding fatigue failure, Fatigue design criteria. 6. Materials and design against corrosion and environmental degradation: Oxidation, Rate of oxidation, Pilling-Bedworth ratio, Corrosion - aqueous, Polarization, Passivity, Environmental effects on corrosion, Common types of corrosion. Corrosion prevention, Design considerations for corrosion control, corrosion resistant materials. 7. Materials for wear critical applications: Wear critical applications, What is wear, Types of wear, Wear resistance of materials, Wear mechanisms and wear maps, Prevention of wear, Liquid and solid lubricants, Factors affecting wear, Wear resistant materials, coatings and surface engineering for wear resistance. 8. Materials and design for high temperatures

Subject to minor changes as the course progresses

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Limiting factors for materials and design for high temperatures; Mechanisms of creep, stress relaxation and creep fracture; thermal fatigue; materials selection for creep resistant designs. 8. Materials for biomedical applications: Defining biomaterials, biocompatibility and biostability. Important medical use of biomaterials, Selection criteria for biomaterials, Biomaterial classes, Polymers as biomaterials, Metals as biomaterials, BioCeramics, Current research trends in biomaterials. Teaching and Learning Methods: This module will be conducted through lectures, tutorials and case discussions. The lecture notes in the form of PowerPoint slides will be given out to students after each lecture via e-mail. Students are expected to check e-mails regularly for this course. I encourage students to participate in classroom discussion by raising questions, answering questions or challenging any topic that are being discussed. Tutorial problems will be discussed/solved in conjunction with lectures. Students are expected to bring their calculators to the class as we will solve tutorial problems after each topic discussed. Learning does not end in the classroom. Therefore, you are welcome to discuss with me any topic relevant to this course through e-mail or in person. Assessment: The assessment for this module is designed as follows: 2 Quizzes: Class contribution & Attendance Mid-term exam (closed book) Final Exam (closed-book) 2x10% 10% 35% 35%

Quiz: 2 quizzes (closed-book) will be conducted during the course of this module. The questions will be MCQ, True/False or very minor calculation type. The purpose of the quizzes is to encourage students to study the topics throughout the semester and not just before the final exam. You must take the quiz tests for obtaining quiz marks. Make-up quiz will be given for a student who is on medical leave only. Hence, for any unfortunate reason if you needed medical leave on the quiz day, please get the medical certificate (MC) from your doctor. Class contribution: Every student is highly encouraged to participate and contribute to the class in whatever positive way he/she can. Please participate in the class (lecture or tutorial) by asking questions, answering questions, raising new ideas or topics etc. You are expected to participate whenever we have case discussions. Finally, only positive contribution that helps in the learning process will be considered. Recommended books:
Engineering Materials in Mechanical Design by S. K. Sinha, 2nd Edition, 2014, Research Publishing Engineering Materials 1 An Introduction to their properties & Applications by M. F. Ashby and D. R. H. Jones, 2nd Edition, 2000, Butterworth-Heinemann Materials Science for Engineers by J. F. Shackelford, 5th Edition, 2000, Prentice Hall International Engineering Materials: Properties and Selection by K. G. Budinski and M. K. Budinski, 7th Edition, 2002, Prentice Hall Engineering Design by G. E. Dieter, 3rd Edition, 2000, McGraw-Hill International Editions Mechanical Behavior of Materials by N. E. Dowling, 2nd Edition, 1999, Prentice Hall International Materials Selection in Mechanical Design by M. F. Ashby, 2nd Edition, Butterworth Heinemann, ISBN: 0750643579 Textbook Concise knowledge of engineering materials and their common properties; has many case studies. Good book for a deep study on materials; includes chapters on semiconductors and magnetic materials and their properties This book provides some general ideas on the materials, selection, properties. Does not provide much in-depth. An excellent reference book. Good book from design aspects Excellent book. More mathematical orientation This book contains some simple design tips on how to select engineering materials. A good guide book for engineers.

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