MECH4301 2008 Lecture 3 Charts 1/19

Lecture 3
Understanding Material Selection Charts (2/2)
MECH4301 2008
Materials Selection in Mechanical Design
Fracture Toughness - Elastic Modulus Chart (p. 59)
Fracture Toughness - Strength Chart (p. 61)
MECH4301 2008 Lecture 3 Charts 2/19
Fracture toughness vs Youngs modulus: stiffness is
important provided the material does not crack or snap under load.
Tough
and
stiff
Deflects a lot
without breaking
(hinges, snap-on lids)
Stiff
but
brittle
E
(GPa)
K
Ic
(MPa m
1/2
)


a K t o
*
IC
=
MECH4301 2008 Lecture 3 Charts 3/19
Fracture toughness vs Youngs modulus:
c
EG K
IC
=
a K t o
*
IC
=
Metals:
K
IC
> 15 MPa m
1/2
(Minimum for safe design, p.136)
Contours
of equal
G
c
=K
2
Ic
/E
(slope 0.5)
Lower limit
for K
IC

Contours
of equal
K
Ic
/E
(slope 1)

E
K
G
Ic
c
2
=
MECH4301 2008 Lecture 3 Charts 4/19
Contour/Selection Lines in K
Ic
- E chart
4 lines of interest in the K
Ic
- E chart:
Lower limit for K
Ic
?
Contour lines of constant K
Ic
?
Contour lines at constant K
Ic
2
/E ?
Contour lines at constant K
Ic
/E ?
Next slide
3 Case studies
MECH4301 2008 Lecture 3 Charts 5/19
r
o
= 2 x 10
-10
m (interatomic spacing)





Lower limit for perfectly brittle materials
Ceramics & glasses nearly touch the boundary
Lower limit to K
Ic

E m x
r
E K
o
Ic
2 / 1 6
2 / 1
10 3
10

=
(

=
c
EG K
IC
=
2 / 1
o
2 / 1
o
c
10
r
20
2r
2 2 G
(

=
(

= = > E E E K
Ic

20
o
Er
=
a K t o
*
IC
=
MECH4301 2008 Lecture 3 Charts 6/19
Contour lines: Case studies involving K
Ic
-E
Three case studies (textbook, p. 136; Question 3.11,
Tute 1, p. 561):
1. Load limited design (component should take specified load
w/o failure, e.g.: tension members in cantilever bridge)
2. Displacement limited design (Component must deflect a
given amount w/o failure, e.g.: bottle snap-on lids)
3. Energy absorption controlled design (component must
absorb specified amount of energy prior to failure, e.g.: car bumper)
MECH4301 2008 Lecture 3 Charts 7/19
Case study 1: Load limited design (component should take
specified load without failure, trivial case) (p. 137)
a
K
Ic
t
o =
*
To increase o
*

for given a,
increase K
Ic

a K t o
*
IC
=
Application: anything
supporting a tensile load
MECH4301 2008 Lecture 3 Charts 8/19
Case study 2: Displacement limited design
(Component must deflect a given amount without failure) (p.138)
a
K
Ic
t
o =
*
(

= = =
E
K
const
a
K
E E
Ic Ic
.
1
*
*
t
o
c
To increase c
*

for given a,
increase K
Ic
/E
F
F
a
Elastic strain at failure?
o
*
= E c
*
(Hookes law)
c
(

E
K
Ic
*
c
MECH4301 2008 Lecture 3 Charts 9/19
Case study 2 (contd.) : Displacement limited design
(p. 138) Component must deflect a given amount without failure)
To increase c
*

for given a,
increase
K
Ic
/E
(

E
K
Ic
*
c
Application: hinges, plastic snap-on lids
Question 3.11, Tute 1
MECH4301 2008 Lecture 3 Charts 10/19
Process
zone
Case study 3: Energy absorption controlled design (p. 137)
(component must absorb specified amount of energy prior to failure)
E
K
G
Ic
c
2
=
To increase energy
absorption prior to
fracture, pick
materials with high
values of (K
Ic
)
2
/E
F
F
a
c
EG K
IC
=
Application: car bumper
Also called J- integral
MECH4301 2008 Lecture 3 Charts 11/19
Conclusion: Fracture toughness vs. Youngs modulus
Load limited
design (K)
K K/E K
2
/E
M
etal
s

P
olym

C
era
m

Displacement limited
design (K/E)
Energy limited
design (K
2
/E)
Polymers beat ceramics despite their low
K because of their high G
c
and low E
(K/E=G
c
/E
1/2
; K
2
/E=G
c
)
MECH4301 2008 Lecture 3 Charts 12/19
Fracture toughness vs strength: strength is important provided
the material does not crack under load.
Tough and
strong
Yield before
fracture (ductile
materials)
Fracture
before yield
(brittle materials)
YS
(MPa)
K
Ic
(MPa m
1/2
)


Yield before fracture
Leak before fracture
MECH4301 2008 Lecture 3 Charts 13/19
Fracture toughness vs strength: strength is important provided
the material does not crack under load.
Contours of equal
process zone or
crack size
a K t o
*
IC
=
2
1
(
(

=
y
Ic
K
a
o t
MECH4301 2008 Lecture 3 Charts 14/19
Case studies in K
Ic
- o: Pressure vessels
Two case studies (p. 140 in textbook, Question 3.12,
Tute 1, p 561):
1. Yield before break, or why you can forget you coke/beer can in the
freezer and nothing happens. Small vessels.
2. Leak before break, or why nuclear reactors dont go bust (most of
of the time, anyway.) Large vessels.
MECH4301 2008 Lecture 3 Charts 15/19
Small pressure vessels: Yield before break
y
t
PR
o o < =
2
a
K
Ic
t
o =
*
P
a < t
crack
a K t o
*
IC
=
Y.B.B. => o
y
< o
*

2
1
(
(

=
y
Ic
K
a
o t
To maximise size of safe
crack, pick materials with
high K/o
y
ratio
t
MECH4301 2008 Lecture 3 Charts 16/19
Crack size
increases this way
Small pressure vessels: Yield before break
2
1
(
(

=
y
Ic
K
a
o t
MECH4301 2008 Lecture 3 Charts 17/19
Large pressure vessels: Leak before break
R
t
P
y
o 2
=
2
*
t
K
a
K
Ic Ic
t
t
o = =
y
PR
t
o 2
=
Set 2a = t
(vessel leaks)
2
* *
IC
t a K t o t o = =
2
2
2
*
t
K
Ic
t
o =
PR
K
y Ic
t
o
o
2
2
*
4
=
y
Ic
R
K
P
o t
2
4
=
y
o o =
*
set
To maximise operating pressure,
pick materials with high K
2
/o
y
ratio
Crack still stable at yield
Maximum
pressure
Eliminate
t
To minimise wall
thickness, maximise o
y

MECH4301 2008 Lecture 3 Charts 18/19
Operating pressure
increases this way
Large pressure vessels: Leak before break
y
Ic
K
P
o
2

y
PR
t
o 2
=
Wall thickness
decreases this way
Pressure
vessel steels
MECH4301 2008 Lecture 3 Charts 19/19
End of Lecture 3
MECH4301 2008 Lecture 3 Charts 20/19
Question 3.21 : production energy is
embodied energy * density => q* (MJ/m
3
)
MaterialUniverse:\Metals and alloys
MaterialUniverse:\Hybrids: composites, foams, natural materials

MaterialUniverse:\Polymers and elastomers


MaterialUniverse:\Metals and alloys MaterialUniverse:\Hybrids: composites, foams, natural materials MaterialUniverse:\Polymers and elastomers
D
e
n
s
i
t
y

*

E
m
b
o
d
i
e
d

e
n
e
r
g
y
,

p
r
i
m
a
r
y

p
r
o
d
u
c
t
i
o
n

1000
10000
100000
1e6
1e7
1e8
1e9
Cast aluminum alloy,
ABS (High-impact, Injection Molding)
GFRP Why do we plot *q
instead of just q

?
MECH4301 2008 Lecture 3 Charts 21/19
Modulus - Density chart
E


E

C
R

Modulus- Relative Cost chart
(relative to iron)
Why do we plot
C
R
instead of
just C
R
?
MECH4301 2008 Lecture 3 Charts 22/19
Modulus - Production energy chart (Embodied energy)
Why do we plot H
q

instead of just H
q
?
E

H
q

MECH4301 2008 Lecture 3 Charts 23/19
Mass m (kg) proportional to density, (kg/m
-3
)
COST: Cost per unit mass c ($/kg)
Total cost, C ($), for mass m
The Total Cost C is proportional to c ($/m
3
)
( c = cost density)

H
q
= production energy per unit mass (MJ/kg)
The total production energy Q
The total Q is proportional to Hq (MJ/ m
3
)
( H
q
= density of production energy)


c c V c m C = =
= V m
q
H H V H m Q = =
q q

Tute 1, Exercises 19 and 21)
Why do we plot C
R
and H
q
instead of just C
R
or H
q
?