The University of Derby

Faculty of Arts, Design and Technology

School of Technology

Module Title: Structural Analysis and Materials

Module Code:

Assignment No: 01a

Assignment Title: Material Analysis/Selection

Submitted By:

Programme Title: BEng (Hons) Mechanical

Engineering

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Answer No: 01

Given Data:

𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 40𝑚𝑚 = 0.04𝑚

𝐼𝑛𝑛𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 30𝑚𝑚 = 0.03𝑚
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 25𝑚𝑚 = 0.025𝑚
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 18°𝐶
𝐹𝑖𝑛𝑎𝑙 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 88°𝐶
𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝐸𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑆𝑡𝑟𝑒𝑒𝑙 = 𝐸𝑠 = 210 𝐺𝑃𝑎
𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝐸𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝐵𝑟𝑎𝑠𝑠 = 𝐸𝑏 = 80 𝐺𝑃𝑎
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑒𝑥𝑝𝑎𝑛𝑠𝑡𝑖𝑜𝑛 𝑓𝑜𝑟 𝑆𝑡𝑒𝑒𝑙 = 𝛼𝑠 = 11 𝜇𝑠𝑡𝑟𝑎𝑖𝑛⁄°𝐶
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑒𝑥𝑝𝑎𝑛𝑠𝑡𝑖𝑜𝑛 𝑓𝑜𝑟 𝐵𝑟𝑎𝑠𝑠 = 𝛼𝑏 = 17 𝜇𝑠𝑡𝑟𝑎𝑖𝑛⁄°𝐶

To Find:

1. Stresses in two material when the temperature is raised to 88°C.

𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 𝜎𝑠 =?

𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 𝜎𝑏 =?

2. Stresses at tensile load of 30KN when the temperature is raised to 88°C.

𝑇ℎ𝑒𝑟𝑚𝑎𝑙 + 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 𝜎𝑠 =?

𝑇ℎ𝑒𝑟𝑚𝑎𝑙 + 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 𝜎𝑏 =?

Solution (a):

𝜋𝐷 2 𝜋(0.025)2
∴ 𝐴𝑟𝑒𝑎 𝑜𝑓 𝐵𝑟𝑎𝑠𝑠 = 𝐴𝑏 = =
4 4

Therefore,

𝐴𝑏 = 4.908 × 10−4 𝑚

𝜋𝐷 2 𝜋𝑑2 𝜋(0.04)2 𝜋(0.03)2

∴ 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 𝐴𝑠 = − = −
4 4 4 4

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Therefore,

𝐴𝑠 = 5.497 × 10−4 𝑚

Thus,

𝐴𝑏 𝐸𝑏 = 4.908 × 10−4 × 80 × 109

𝐴𝑏 𝐸𝑏 = 39269908.17 𝑁

Therefore,

1
= 2.546 × 10−8
𝐴𝑏 𝐸𝑏

𝐴𝑠 𝐸𝑠 = 5.497 × 10−4 × 210 × 109

𝐴𝑠 𝐸𝑠 = 115453530 𝑁

Therefore,

1
= 8.661 × 10−9
𝐴𝑠 𝐸𝑠

∴ 𝑇 = 𝐹𝑖𝑛𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 88 − 18 = 70°𝐶

𝑇(𝛼𝑏 − 𝛼𝑠 ) = 70 × (17 − 11) × 10−6

𝑇(𝛼𝑏 − 𝛼𝑠 ) = 4.2 × 10−4

Since,

1 1
𝐹[ + ] = 𝑇(𝛼𝑏 − 𝛼𝑠 )
𝐴𝑠 𝐸𝑠 𝐴𝑏 𝐸𝑏

Therefore,

𝐹[8.661 × 10−9 + 2.546 × 10−8 ] = 4.2 × 10−4

𝐹[3.412 × 10−8 ] = 4.2 × 10−4

𝑭 = 𝟏𝟐𝟑𝟎𝟕. 𝟐𝟐𝟗𝟎𝟗 𝑵

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Since,

𝐹
𝑆𝑡𝑟𝑒𝑠𝑠 = 𝜎 =
𝐴

Therefore,

𝐹
𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 𝜎𝑏 =
𝐴𝑏

12307.22909
𝜎𝑏 =
4.908 × 10−4

𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 𝜎𝑏 = 25072081.22 𝑁 ⁄ 𝑚2

𝑺𝒕𝒓𝒆𝒔𝒔 𝒊𝒏 𝑩𝒓𝒂𝒔𝒔 𝒕𝒖𝒃𝒆 = 𝝈𝒃 = 𝟐𝟓. 𝟎𝟕𝟐 𝑴𝑵 ⁄ 𝒎𝟐 (𝑪𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒊𝒐𝒏)

𝐹
𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 𝜎𝑠 =
𝐴𝑠

12307.22909
𝜎𝑠 =
5.497 × 10−4

𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 𝜎𝑠 = 22385786.8 𝑁⁄𝑚2

𝑺𝒕𝒓𝒆𝒔𝒔 𝒊𝒏 𝑩𝒓𝒂𝒔𝒔 𝒕𝒖𝒃𝒆 = 𝝈𝒔 = 𝟐𝟐. 𝟑𝟖𝟓 𝑴𝑵 ⁄ 𝒎𝟐 (𝑻𝒆𝒏𝒔𝒊𝒐𝒏)

Note:

As 𝛼𝑏 > 𝛼𝑠 ,so with increase in temperature brass expands more than steel, however both ends of
the both tubes are fixed with compound bar, so free expansion cannot occurs, therefore compound
bar are supplying force which decreasing the length of Brass and increasing the length of Steel unit it
reaches to the equilibrium at common length.

Solution (b):

Stress due to Tensile Force,

𝐹𝐸𝑏
𝜎𝑏 =
𝐸𝑠 𝐴𝑠 + 𝐸𝑏 𝐴𝑏

30000 × 80 × 109
𝜎𝑏 =
115453530 + 39269908.17

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 𝜎𝑏 = 15511547.76 𝑁⁄𝑚2

𝝈𝒃 = 𝟏𝟓. 𝟓𝟏𝟏 𝑴𝑵 ⁄ 𝒎𝟐 (𝑻𝒆𝒏𝒔𝒊𝒐𝒏)

𝐹𝐸𝑠
𝜎𝑠 =
𝐸𝑠 𝐴𝑠 + 𝐸𝑏 𝐴𝑏

30000 × 210 × 109

𝜎𝑠 =
115453530 + 39269908.17

𝜎𝑠 = 40717812.86 𝑁⁄𝑚2

𝝈𝒔 = 𝟒𝟎. 𝟕𝟏𝟕 𝑴𝑵 ⁄ 𝒎𝟐 (𝑻𝒆𝒏𝒔𝒊𝒐𝒏)

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝐵𝑟𝑎𝑠𝑠 𝑡𝑢𝑏𝑒 = 15.511 − 25.072

𝑹𝒆𝒔𝒖𝒍𝒕𝒂𝒏𝒕 𝑺𝒕𝒓𝒆𝒔𝒔 𝒊𝒏 𝑩𝒓𝒂𝒔𝒔 𝒕𝒖𝒃𝒆 = 𝟗. 𝟓𝟔𝟏 𝑴𝑵⁄𝒎𝟐 (𝑪𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒊𝒐𝒏)

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑆𝑡𝑒𝑒𝑙 𝑡𝑢𝑏𝑒 = 40.717 + 22.385

𝑹𝒆𝒔𝒖𝒍𝒕𝒂𝒏𝒕 𝑺𝒕𝒓𝒆𝒔𝒔 𝒊𝒏 𝑺𝒕𝒆𝒆𝒍 𝒕𝒖𝒃𝒆 = 𝟔𝟑. 𝟏𝟎𝟐 𝑴𝑵⁄𝒎𝟐 (𝑻𝒆𝒏𝒔𝒊𝒐𝒏)

Answer No: 02

A suitable ceramic material required for heat and wear resistance for titanium alloy. Material must
have the similar properties and suitable process for coating in order to get better adhesive and non-
destructive for titanium surface.

Following are the some important properties of titanium alloy that can help to choose suitable
material:

Density 4.4 × 103 − 4.8 × 103 𝐾𝑔⁄𝑚3

Young Modulus 110 − 120 Gpa

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Hardness − Vickers 267 − 380 HV
Melting Point 1.48 × 103 − 1.68 × 103 °C
Maximum Service Temperature 450 − 500 °C
Thermal expansion coefficient 8.9 − 9.6 μ strain⁄°C

Titanium has low density which is about 60% density of iron, which can be highly strengthened by
deformation process and alloying. The coefficient of thermal expansion is very low with compare to
steel and aluminium which made titanium itself a very good heat resistant can be used between 450
and 500 °C working temperature. As titanium has between 267 and 380 HV Vickers hardness it is
also a very good friction and wear resistant, these properties can be increased by using suitable
coating to make titanium more heat and wear resistant.

In order to choose right ceramic CES 2013 level 2 software has been used provided by the University
of Derby. By using this software a graph can be produce which can filter the suitable required
material. As, in this case suitable ceramics required for heat and wear resistant coating , so below a
graph has been produce in terms of Hardness-Vickers to Maximum service temperature.

As from the above graph it can be seen there are three different types of ceramics (Technical
Ceramics, Glass and Non-technical Ceramics). Technical ceramics can be use for required coating as
they have maximum hardness and service temperature by comparing others. As on the top right

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corner materials have got the highest Vickers hardness and service temperature, so that top right
corner has been selected by using box selection tool.

This selection gives three ceramics which are;

 Alumina
 Boron carbide
 Silicon carbide

Comparison Between Above Materials

Alumina (Aluminium oxide-𝐀𝐥𝟐 𝐎𝟑 )

 Technical Ceramic
 Electrical Insulator
 High mechanical Strength
 Temperature resistance up to 650°C
 High Thermal abrasion resistance
 Good abrasion resistance

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  Excellent chemical stability

Important properties:
Density 3.8 × 103 − 3.98 × 103 𝐾𝑔⁄𝑚3
Young Modulus 343 − 390 GPa
Hardness − Vickers 1.2 × 103 − 2.06 × 103 HV
Melting Point 2 × 103 − 2.1 × 103 °C
Maximum Service Temperature 1.08 × 103 − 1.3 × 103 °C
Thermal expansion coefficient 7 − 7.9 μ strain⁄°C

Boron Carbide (𝐁𝟒 𝐂)

 Nearly hard as diamond
 Low density
 High hardness

Important properties:
Density 2.35 × 103 − 2.55 × 103 kg⁄m3
Young Modulus 440 − 472 GPa
Hardness − Vickers 3.2 × 103 − 4 × 103 HV
Melting Point 2.37 × 103 − 2.51 × 103 °C
Maximum Service Temperature 727 − 1.7 × 103 °C
Thermal expansion coefficient 3.2 − 3.4 μ strain⁄°C

Silicon Carbide (Carborundum-SiC)

 Very Hard
 High temperature 2200°C
 Good thermal shock resistance
 Abrasion Resistance
 Brittle
 Corrosion resistance

Important properties:
Density 3.1 × 103 − 3.21 × 103 𝐾𝑔⁄𝑚3
Young Modulus 400 − 460 GPa
Hardness − Vickers 2.3 × 103 − 2.6 × 103 HV
Melting Point 2.15 × 103 − 2.5 × 103 °C
Maximum Service Temperature 1.4 × 103 − 1.7 × 103 °C
Thermal expansion coefficient 7 − 7.9 μ strain⁄°C

Selection
As from the above it is concluded that alumina has the closer properties to the titanium alloy and
process of alumina coating is much better than the other two as they required very high
temperature in process which can damage the titanium surface.

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Answer No: 03

A light stiff material required to select for automotive connecting rod by using appropriated
material indices which has the best performance in terms of

(a)
 Stiffness to density ratio
 As above per material cost
 As above with regard to environmental impact
(b)
 Strength to density ratio
 As above per material cost
 As above with regard to environmental impact

(a) CES 2013 software has been used in order to select the appropriate material which
has the properties as described above.

Below is the graph of Stiffness to Density ratio:

Note: Metals in RED are Non-ferrous and in GREEN are Ferrous.

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As from the above graph mostly all of the ferrous metal have got the highest ratio in terms
of stiffness to density, where non-ferrous are ranging from low to high. Following is another
graph produce by the ratio of above per material.

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Above graph shows that most of the ferrous metals are much cheaper than non-ferrous in
terms of stiffness to density ratio. Below is another graph has been produced in terms of
above per environmental impact.

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It can be seen above the metals are in left and top side have high stiffness to density, low
price and low environmental impact by comparing metals right and bottom side. Suitable
material can be filter by using the slope line as below.

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As from the above slope selection following three ferrous metals suggest by the CES which
matched with the require properties.

 High carbon steel

 Medium carbon steel
 Low carbon steel

(b) Below is the graph between Fatigue strength to density ratio

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As above graph shows that the most of the non-ferrous have got high ratio in terms of
strength to density and mostly ferrous metal have got medium to high ratio. Another graph
has been produce in terms of above per price.

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Above graph shows that ferrous metals are on left and non-ferrous are increasing on right
side which shows that ferrous metals are cheaper than non-ferrous in terms of strength to
density ratio. Following is another graph in terms of as above per Environmental impacts.

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Above graph shows that most of the ferrous metal are on top left corner which means them
have highest strength to density with respect to price and low carbon footprint. Top
material has been select by using slope line selection method as shown below.

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By using slope line three metals have been selected which matched to the required
properties are below:

 High carbon steel

 Medium carbon steel
 Low alloy steel

Selection:
According to the CES software it suggest the two types of steel with respect to required properties

 Plain Carbon Steel (Low, Medium and High Carbon Steel)

 Low Alloy Steel

High carbon steel has more carbon than medium carbon steel so, it is stronger and typically used in
cutting tools and bearings, where medium carbon steel has more carbon than low carbon steel
which makes it stronger and it is typically used in connecting rods (production engine) general
construct and other tools, however low carbon steel have got the less carbon than other two but still
it is stronger though and typically used in construction.

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Alloy steels are made by adding one or more other elements in order to get more properties which
cannot found in plain carbon it is typically used in connecting rods, ball bearings and other tools.

It is concluded that plain carbon and alloy steel can be used in connected rods, however medium
carbon steel is more likely to suitable in connecting rod as it can be manufacture easily by forging
process.

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