MTRL 280 MIDTERM 1

CHAPTER 1 & 2
DESIGN The process of translating a new idea or a market need into
the detailed information fro m which a product can be manufactured.
Invention Design Innovation
MECHANICAL/INDUSTRAIL DESIGN Mechanical design: product
function
Industrial design: customer appeal
NEED STATEMENT Must be clearly expressed before starting
process, solution neutral. Ex. A device is required to perform the
following set of design requirements
DESIGN PROCESS Concept, Embodiment, Detail
TECHNICAL SYSTEMSMade up of sub-groups with sub-components.
Must identify all components initially.
TYPES OF DESIGN
**LIST EXAMPLES OF EACH**
Type 1) Original design: New idea, not typical, ex. Pen
Type 2) Adaptive (development) design: Re-design of product,
adaptive to market need, ex. Turbo engine to adaptive to new
materials
Type 3) Variant design: Changes of dimensions or details, no
change to function, ex. Color, size
CHAPTER 3
MATERIALS
1) METALS Stiff, soft and ductile, prone to fatigue failure, prone to
corrosion, low cost, good for large-scale applications. Ex) steels, cast
irons, Al-alloys, Cu-alloys etc.
2) CERAMICS Stiff, strong, brittle, 15x stronger in compression,
sensitive to cracks, good for structural members in compression. Ex)
Alumina, silicon nitrides, concrete

3) GLASSES Stiff, strong, brittle, 15x stronger in compression,

sensitive to cracks, some translucent, metallic glasses used in sports
equipment. Ex) Soda glass, silica glass, glass ceramics
4) POLYMERS Compliant, 50x less stiff then metals, strong, creep at
room temp, properties strongly depend on temp, corrosion resistant,
cheap, easily formed. Ex) Nylon, polyesters,
5) ELASTOMERS Very compliant, very large deformation, properties
highly temp dependent, prone to environmental attack. Ex) Natural
rubber, silicones, isoprene
6) HYBRIDS Combination of materials and shapes, composites,
glass fiber reinforced polymers, wood, sandwiches, segmental
structures, foams, and lattices.
STRUCTURAL PROPORITES Maximize properties, cost, force etc.
Depends on size, shape.
MATERIAL PROPROTIES
1) General Properties: Density, cost
2) Mechanical Properties: Strength, moduli
3) Thermal Properties: Expansion, diffusion, and conduction
ELASTIC MODULI
Tensile Moduli: ***formula
Shear Moduli: ***
Bulk Moduli: ***
STRENGTH/ STIFFNESS
Strength: maximum force/stress to cause material to fail (fracture)
Stiffness: elastic modulus, non-permanent deformation (resistance).
The proportionality between force and displacement. STRUCTURAL
PROPERTY
Elastic Modulus: The proportionality constant in the relationship
between stress and strain. MATERIAL PROPORTY
Failure Stress: Varity of different meaning, Yield stress of a material,
brittle fracture stress, UTS. MATERIAL PROPORTY

STRENGTH
Metals: Yield stress (stress to cause permanent plastic deformation)
Polymers: Proportional limit (stress at which stress/strain is nonlinear)
Ceramics: Fracture strength (difference by factor of 10 in tension and
compression)
TOUGHNESS/FRACTURE TOUGHNESS Inter-related but different
properties measuring the resistance of a material to brittle crack
prolongation
1) Toughness (Gc): Energy needed to break a material
2) Fracture Toughness (Kc): Critical amount of stress increase at sharp
crack needed to cause fracture
ENERGY ABSORBED
Resilience(R): Area under elastic portion of stress-strain curve, spring
like behavior ***formula
Loss Coefficient ( ): Energy dissipated when material is vibrated
MECHANICAL LOADING
1) Tie: Tensile member
2) Beam: Member in bending
3) Shaft: Member in torsion
4) Column: Compression member
THERMAL PROPORTIES
Critical Temp (Tm)
Glass Transition Temp (Tg)
Maximum Service Temp (Ts)
YIELD STRESS Measures the strength of a material (material
property)
FORCE AT FRACTURE Measures the strength of a material
(structural property)
POSSIONS RATIO Is NOT an appropriate measure for strength of a
material. Measures the elastic property (stretching a material)

CHAPTER 4

***READ CHAPTER IN TEXT + SLIDES***

CHAPTER 5

MATERIAL SELECTION STAGES

1) TRANSLATION Converting the design requirements into
constraints and objectives that can be applied to the material
database.
2) SCREENING Eliminating the materials that cannot meet the
constraints. Structural Properties
3) RANKING Ordering the survivors by their ability to meet criterion
of excellence, such as minimizing cost or maximizing impact resistance
using objectives.
4) DOCUMENTATION Explore most promising materials in depth,
history, present. Which materials produce the greatest value of
material index? Describes graphical, descriptive positives or negatives
of material.
ATTRIBUTES Its properties of a certain material including
mechanical, thermal, electrical, optical and chemical properties.
PROPORTY PROFILE Includes attributes of material and processing
characteristics (cost, availability, environment effect)
STRUCTURAL ELEMENTS Components that perform a physical
function. Carry loads, transmit heat, store energy etc.
FUNCTIONAL REQUIRMENTS A tie must carry a specific load, a
spring must provide a given restoring force etc.
PERFORMANCE OF A STRUCTURAL ELEMENT
P=f (F, G, M)
-Where (F= functional requirements, G=geometry parameters,
M=material proprieties, P=performance matric)

-f (F), f (G) are related to: Structural Index

-f (M) is related to: Material Index

**REVIEW TABLE 5.5 & TABLE 5.6**

** REVIEW CHAPTER 6**

CASE STUDY LAYOUT
1) The problem statement: Setting the scene
2) The translation: Identifying function, constraints, objective and
free variables, from which emerge the attribute limits and
material indices.
3) The selection: In which the full menu of materials is reduced by
screening and ranking to a short list of viable candidates.
4) The postscript: Allowing a commentary on results and philosophy.