Machine Design: An Integrated Approach Chapter Two Objectives

Machine Design: An Integrated
Approach Chapter Two Objectives

Sixth Edition
1. Material Property Definitions
2. Hardness and Heat Treatment
3. Coatings and Surfaces
4. General Properties of Metals (mostly) and Non-metals (quick mention)

Chapter 2
5. Selecting Materials - Considerations
Materials and Processes
Copyright © 2020 Pearson Education, Inc. All Rights Reserved Copyright © 2020 Pearson Education, Inc. All Rights Reserved
1 2
Material Property Definitions Material Tests

ASTM Standards
• Modulus of Elasticity (Young’s Modulus) • Tensile Test
https://www.astm.org/Standard
• Yield Strength • Ductility and Brittleness s/physical-and-mechanical-
• Ultimate Tensile strength • Compression
testing-standards.html
Material Properties
• Modulus of rigidity 101 by Real • Bending
• Fatigue strength Engineering • Torsion

https://youtu.be/BHZA
• Toughness • Fatigue Strength and Endurance Limits
LtqAjeM
• Hardness • Impact Resistance
• Fracture Toughness
• Creep and Temperature Effects
3 4
What are the differences between

ASTM Introduction stress and strength?
• Stress (σ) is defined as the resistance force when we apply a force on a specimen.
Video: ASTM International: Connecting the Dots • Stress = load/area (force per unit of area) applied as tensile or compression or shear
• https://youtu.be/LacuO9Z7_QE
• Strength (S) is the ability of the specimen to withstand failure.
• Strength is the resistance to maximum stress at the time of failure, it does not depend on
area. Strength is an extrinsic property of the materials.
Website: From toys to jet fuel, over 12,800 standards support quality, safety, and
performance.
• https://www.astm.org/
5 6
1
What are the differences between
stress and strength? Strength (S): Units and Values
• English units: lbf/in2 = psi ksi (=1,000 psi)
• Metric Units: N/m 2 = Pa (Pascals) MPa (=1,000,000), Gpa (= 1,000,000,000)
Strength is Inherent Material Property

• Atomic Structure
• Processing and treatment.
7 8
Also called Young’s

Modulus, measures Elastic Behavior
material resistance to F
elastic (recoverable)
deformation under
load. stress
ultimate
tensile
strength
The steeper the slope fracture
neck yield stress
E, the stiffer the
stress
material.
steel
tensile
specimen
tensile load elastic plastic
strain
direction range range
F
9 10
Modulus of Elasticity
Understanding E = σ/ε Understanding
the Stress-Strain Curve the Stress-Strain Curve
• elastic range – • yield stress –
The linear portion of The minimum stress stress
stress
the stress-strain curve. that causes permanent
When the force is ultimate
deformation.
ultimate
tensile
tensile
released, the material strength fracture strength fracture
yield
returns to its original yield
stress
stress • ultimate tensile stress
stress
dimensions. strength –
The maximum stress
• plastic range –
The region of strain
that the material can elastic plastic strain
elastic plastic
permanent range range withstand. range range
deformation. Also defines the

Copyright © 2020 Pearson Education, Inc. All Rights Reserved beginning of necking. Copyright © 2020 Pearson Education, Inc. All Rights Reserved
11 12
2
13 14
Figure 2.4 Stress-Strain Curve of a

Brittle Material Heat Treatment
• Quenching **Heat Treatment – The Science of
• Tempering Forging by Real Engineering
https://youtu.be/6jQ4y0LK1kY
• Annealing
• Normalizing
• Surface (Case Hardening)
Heat Treatment – Types, Process

and Structures
https://youtu.be/skQRLfU3plM
15 16
Figure 2.12 Stress-Strain Curves for

Annealed, Quenched, and Tempered Mechanical Forming
Steel • Cold Working
• Hot Working
https://makezine.com/2015/03/20/
• Forging 18-lessons-smart-prototyping-self-
• Extrusion made-billionaire/
Dan Gelbert – 18 Lessons in

Smart Prototyping from a Self-
Made Billionaire
https://youtu.be/RopgrECLSJc
17 18
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Figure 2.13 Strain Hardening a
Ductile Material by Cold Working (a) Ashby Plots
First Working (b) Second Working • Material selection is critical. Typically, engineers use a systematic approach depending
on their application/industry:
– In depth: research, testing, qualification
– Heritage based on success of previous designs
• M. F. Ashby (Cambridge University developed powerful method for material selection

using material selection charts.
• Ashby plots show the relation between two material properties across a number of
materials.
19 20
21 22
Other Considerations in Material Figure 2.16 Coating Methods

Selection Available for Metals
• Operating environment
• Shipping and storage environment
• Cost
• Manufacturing processes
• Aesthetics/Decoration
• Raw material accessibility
• Vendor relationships
23 24
4
AISI/SAE steel numbers Major classifications of steel
• AISI – American Iron and Steel Institute SAE designation Type
1xxx Carbon steels
• SAE – Society of Automotive Engineers
2xxx Nickel steels
• Alloy steels and carbon steels can be designated with specific grades by a four-digit
AISI/SAE numerical index system based on the chemical composition of the steels and 3xxx Nickel-chromium steels
alloys. 4xxx Molybdenum steels
5xxx Chromium steels
6xxx Chromium-vanadium steels
Example AISI/SAE No. 1020
The first digit indicates that it is plain carbon steel 7xxx Tungsten steels
The second digit indicates there are no alloying elements 8xxx Nickel-chromium-molybdenum
The last two digits indicates that the steel contains approximately 0.20 percent carbon steels
9xxx Silicon-manganese steels
25 26
Carbon and alloy steel grades Everything you want to know about
SAE designation Type and composition by weight metals….(for free)
Carbon steels • MIL-HDBK-5J, Department of Defense Handbook: Metallic Materials and Elements for
10xx Plain carbon (Mn 1.00% max) Aerospace Vehicle Structures (31 Jan 2003).
– Contains design information on the strength properties of metallic materials and
11xx Resulfurized
elements for aerospace vehicle structures.
12xx Resulfurized and rephosphorized – All info coordinated with Air Force, Army, Navy, Federal Aviation Administration
15xx Plain Carbon (Mn 1.00-1.65% max.) (FAA), and industry prior to publication. Maintained by FAA and Department of
Defense (DOD).
Manganese steels
– Superseded by MMPDS Handbook ($739 Digital, Published by Battelle Memorial
13xx Mn 1.75%. Institute)
Nickel steels
23xx Ni 3.50%
25xx Ni 5.00%
Nickel-chromium steels
31xx Ni 1.25%; Cr 0.65%, or 0.80%
…and so on……
27 28
A simple worksheet to read a stress-

strain curve…. Test Lab Demos
• Tensile Testing https://youtu.be/lqR5cp2v1eQ
• Bending Test https://youtu.be/jGjZujHOuho
• Torsion Test https://youtu.be/qPIug2sewFA
• Charpy Impact Test https://youtu.be/tpGhqQvftAo
• Fatigue Test https://youtu.be/LhUclxBUV_E
29 30
5
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Machine Design: An Integrated

Approach Chapter Two Objectives

2. Hardness and Heat Treatment

3. Coatings and Surfaces

4. General Properties of Metals (mostly) and Non-metals (quick mention)

Material Property Definitions Material Tests

• Fatigue strength Engineering • Torsion

• Creep and Temperature Effects

What are the differences between

• Strength (S) is the ability of the specimen to withstand failure.

• Metric Units: N/m 2 = Pa (Pascals) MPa (=1,000,000), Gpa (= 1,000,000,000)

Strength is Inherent Material Property

Also called Young’s

deformation. Also defines the

Figure 2.4 Stress-Strain Curve of a

• Surface (Case Hardening)

Heat Treatment – Types, Process

Figure 2.12 Stress-Strain Curves for

Dan Gelbert – 18 Lessons in

• M. F. Ashby (Cambridge University developed powerful method for material selection

Other Considerations in Material Figure 2.16 Coating Methods

• Shipping and storage environment

• Raw material accessibility

A simple worksheet to read a stress-

• Bending Test https://youtu.be/jGjZujHOuho

• Torsion Test https://youtu.be/qPIug2sewFA

• Charpy Impact Test https://youtu.be/tpGhqQvftAo

• Fatigue Test https://youtu.be/LhUclxBUV_E

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