Professional Documents
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MFA 2009
Outline
Background: the motivation
Materials and their attributes The CES EduPack and its use Hands-on session 1, with exercises
Resources: Materials: engineering, science, processing and design by M.F. Ashby, H.R. Shercliff and D. Cebon, Butterworth Heinemann, Oxford 2007, Chapters 1 and 2 Materials Selection in Mechanical Design, 3rd edition by M.F. Ashby, Butterworth Heinemann, Oxford, 2006, Chapters 1 - 3. Callister, Budinski, Askeland and others recommended reading in records CES EduPack 2009 software ( Grantadesign.com)
MFA 2009
Engineers make things. They make them out of materials, using processes. What do they need to know to do this successfully? A perspective of the world of materials and processes
An understanding material properties and their origins An ability to select those that best meet requirements of a design Access to information and tools for comparison and selection
The CES EduPack provides the resources to achieve this and gives
students a tool they can use in their later profession (like CAD or FE tools)
MFA 2009
Mechanical engineering
Metals, alloys
Polymers, elastomers
Ceramics, glasses
Hybrids, composites
MFA 2009
Metals, alloys
Polymers, elastomers
Ceramics, glasses
Hybrids, composites
MFA 2009
Metals, alloys
Polymers, elastomers
Ceramics, glasses
Hybrids, composites
MFA 2009
Bio-engineering
Metals, alloys
Polymers, elastomers
Ceramics, glasses
Hybrids, composites
MFA 2009
Metals, alloys
Polymers, elastomers
Ceramics, glasses
Hybrids, composites
MFA 2009
The database
DATA FOR
Links
DATA FOR
Materials
data-table
Links
Processes
data-table
Hybrids
Suppliers
data-table
Select on links
MFA 2009
Universe
Family
Ceramics & glasses
Class
Member
Attributes
Al 6463 Al 6060 Density Al 6061
Steels
Cu-alloys Al-alloys Ti-alloys
Materials
data-table
Ni-alloys
Zn-alloys
Density Mechanical Densityprops. Mechanical props. Thermal props. props. Mechanical Thermal props. Electrical props. Thermal props. Electrical props. Optical props. props. Electrical Optical props. Corrosion props. Optical props. Corrosion props. Documentation Corrosion props. Documentation -- specific Documentation -- specific -- general -- specific -- general -- general
Structured information
Unstructured information
Material records
MFA 2009
Electrical Properties
Conductor or insulator? Good insulator
Thermal Properties
Max Service temp Thermal expansion Specific heat Thermal conductivity 350 70 1500 0.17 370 75 1510 0.24 K 10-6/K J/kg.K W/m.K
+
*Using the CES Level 2 DB
Links to Processes
MFA 2009
Design guidelines.
ABS has the highest impact resistance of all polymers. It takes color well. Integral metallics are possible (as in GE Plastics' Magix.) ABS is UV resistant for outdoor application if stabilizers are added. It is hygroscopic (may need to be oven dried before thermoforming) and can be damaged by petroleum-based machining oils. ABS can be extruded, compression moulded or formed to sheet that is then vacuum thermoformed. It can be joined by ultrasonic or hot-plate welding, or bonded with polyester, epoxy, isocyanate or nitrile-phenolic adhesives.
Technical notes. ABS is a terpolymer - one made by copolymerising 3 monomers: acrylonitrile, butadiene and syrene. The
acrylonitrile gives thermal and chemical resistance, rubber-like butadiene gives ductility and strength, the styrene gives a glossy surface, ease of machining and a lower cost. In ASA, the butadiene component (which gives poor UV resistance) is replaced by an acrylic ester. Without the addition of butyl, ABS becomes, SAN - a similar material with lower impact resistance or toughness. It is the stiffest of the thermoplastics and has excellent resistance to acids, alkalis, salts and many solvents.
Typical Uses.
Safety helmets; camper tops; automotive instrument panels and other interior components; pipe fittings; homesecurity devices and housings for small appliances; communications equipment; business machines; plumbing hardware; automobile grilles; wheel covers; mirror housings; refrigerator liners; luggage shells; tote trays; mower shrouds; boat hulls; large components for recreational vehicles; weather seals; glass beading; refrigerator breaker strips; conduit; pipe for drain-waste-vent (DWV) systems.
The environment.
The acrylonitrile monomer is nasty stuff, almost as poisonous as cyanide. Once polymerized with styrene it
becomes harmless. ABS is FDA compliant, can be recycled, and can be incinerated to recover the energy it contains.
*Using the CES Level 2 DB
MFA 2009
Mould
Primary shaping
Heater Screw
Secondary shaping
Injection moulding
No.8-CMYK-5/01
Machining
Joining
Surface treating
Welding
Painting
MFA 2009
Universe
Family
Class
Member
Attributes
RTM Blow molding Material Injection molding Material
Shape Material Shape Size Range Shape Size Range Min. section Size Range Min. section Tolerance Min. section Tolerance Roughness Tolerance Roughness Economic batch Roughness Economic batch Documentation Economic batch Documentation -- specific Documentation -- specific -- general -- specific -- general -- general
Processes
data-table
Shaping
Structured information
Rapid prototyping
Unstructured information
Process records
MFA 2009
PowerPoint lectures
Software
White papers
Elementary text
Advanced text
Eco text
MFA 2009
Level 1
1st year students: Engineering, Materials Science, Design
Level 2
2nd - 4th year students of Engineering and Materials Science and Design.
Level 3
4th year, masters and research students.
2916 materials, 233 processes
67 materials, 77 processes
Materials science
Polymer engineering
Aeronautical engineering
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CES Help
Table:
MaterialUniverse
MaterialUniverse
+ + + +
Ceramics and glasses Hybrids: composites etc Metals and alloys Polymers and elastomers
When you think of PMMA, thinkbe transparency. ABS (Acrylonitrile-but can now Acrylic, or PMMA, the thermoplastic that transparent, and it is can be given vivid colors. most closely resembles glass than in transparency ABS-PVC alloys are tougher standard and resistance to weathering. The material adiene-styrene) is tough, resilient, and easily has a long history: discovered in 1872, some first molded. It is usually opaque, although commercialized inin 1933, its first major grades, grades ABS and, self-extinguishing application was cockpit for fighter are used for theas casings ofcanopies power tools. aircraft during the second World War. Composition : (CH2-CH-C6H4)n Composition (CH3-CH2-C-CO-OCH3)n General properties Image Density _ Price
Find what
Look in table
Class
Member
1010 2.33 1210 2.56
kg/m^3
General properties
Elastomers
Thermoplastics
Thermosets
Density Mechanical properties Price Young's modulus Yield strength (elastic limit) Mechanical properties Tensile strength Young's modulus Elongation Yield strength (elastic limit) Hardness - Vickers Tensile strength Fatigue strength at 10^7 cycles Compressive strength Fracture toughness Elongation Hardness - Vickers Thermal properties Fatigue strength at 10^7 cycles Maximum service temperature Fracture toughness Thermal conductor or insulator? Thermal conductivity Thermal properties Specific heat capacity Glass temperature Thermal expansion coefficient Maximum service temperature etc
ABS 1.2e3
kg/m^3 USD/kg
Polycarbonate
2.9 USD/kg GPa 18.5 - 51 MPa 27.6 - 55.2 MPa 2.2 3.8 GPa 1.5 - 100 % 54 72 MPa 5.6 - 15.3 HV 48 80 MPa 11.04 - 22.08 MPa 72 1.3e2 MPa 1.186 - 4.289 MPa.m^1/2 2 10 % 16 22 HV * 15 33 MPa 335 K 0.7 1.6 - 350 MPa.m^1/2 Good insulator 0.188 - 0.335 W/m.K - 1919 J/kg.K 3.6e2 1386 4.4e2 K - 234 strain/C 3.2e2 84.6 3.3e2 K
Etc ..
MFA 2009
Youngs modulus
Electrical properties
Electrical resistivity 3.8 6 ohm.cm
MFA 2009
Toolbar
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Eco audit
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Sheet
Graph
Units
Number
Labels
Preferred Currency
US dollar Metric
'Teaching Engineering Materials', M.F. Ashby, D. Cebon (PDF, 5.5 MB) 'Teaching Materials and Processes to First and Second Year Students', M.F. Ashby (PDF, 400 KB) 'Materials and Product Design', M.F. Ashby (PDF, 800 KB) 'The CES EduPack Database of Natural and Man-Made Materials', M.F. Ashby (PDF, 1.7 MB) 'The CES Database for Architecture and the Built Environment - background reading', M.F. Ashby, J. Fernandez, and A. Gray (PDF, 680 KB) 'The CES Eco-selector - background reading', M.F. Ashby, A. Miller, F. Rutter, C. Seymour, and U.G.K. Wegst (PDF, 1.5 MB) 'The CES Eco Audit tool a white paper', M.F. Ashby, N. Ball, and C. Bream (PDF)
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MFA 2009
The data take two broad forms: (a) numeric, non-numeric data that can be structured in a uniform way for all materials (b) documentation, usually in the form of text and images
MFA 2009
MFA 2009
Exercises: Browsing
1.1 Find, by browsing, the Level 1 record for Titanium alloys in Metals and alloys: Non-ferrous
File Edit View Select Tools Window
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Select
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1.2 Find the Level 1 record for Phenolics in Polymers and elastomers: Thermosets
Table: Subset:
1.3 Find the Level 1 record for Alumina in Ceramics and and elastomers: Technical ceramics
+ + + +
Ceramics and glasses Hybrids: composites etc Metals and alloys Polymers and elastomers
1.4 Find the Level 2 record for Age-hardening wrought aluminum alloys in in Metals and alloys: Non-ferrous: Aluminum alloys
1.5 Find the Level 2 record for Plywood in in Hybrids: Natural materials
MFA 2009
Exercises: Searching
1.6 Find, by searching, the record for Polylactide: what is it?
Answer: Polylactide, PLA, is a biodegradable thermoplastic derived from corn.
File Edit View Select Tools Window
Browse
Search
Select
1.7 Find records for materials that are used for Lenses: what are they?
Answer: Silicon, Polyamides (PA), Polycarbonate (PC) and Acrylic (PMMA).
Find what:
Polylactide
MFA 2009
CO 2 PET
Mass of CO 2 directly ari sin g from PET production per year Mass of PET shipped per year
MFA 2009
End of Unit 1
MFA 2009