Design of Machine Elements

Class 2 : Material Selection

Books to refer

• Shigley's Mechanical Engineering Design

• Design of Machine Elements third edition by V B Bhandari
• Machine Design: An Integrated Approach by R L Norton

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Recap
Major criteria for machine components :
Design is a decision-making process. 1. Minimum dimension and weight
2. Conformance to standards
3. Reliability
Depends upon the designer.
4. Strength
5. Rigidity Material
6. Wear resistance Selection

7. Maintainability
Out of
8. Manufacturability
scope
9. Min life cycle cost
Criteria for the decisions
Factors to be considered in machine design
Among various other factors
• Forces on the elements
Depend upon the need of the product. • Static
• Dynamic

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Types of materials
• Properties (mechanical)
• Manufacturing Cost
• Availability of the material
• Cast iron
• Wrought iron
Ferrous • Steel

Metals • Light metal group

Engineering
• Aluminium
Materials
• Magnesium
Non-ferrous • Manganese
• Their alloys
Non-metals • Copper based alloys
• Brass (cu-zn)
Leather • Bronze (cu-sn)
Rubber
Plastic

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Mechanical properties of common engineering materials
Not evident for all ductile materials
Mild steel, Low strain rate material

Engineering Stress and True stress

are almost equal up to yield point

Depends upon the load on the

machine element
• Static load
• Variable load
• Sudden impact
• Constant load at elevated temp.

0.1 – 0.2 %
Elasticity
• This is the property of a material to regain its original shape after
deformation when the external forces are removed.
• All materials are plastic to some extent but the degree varies, for example,
both mild steel and rubber are elastic materials but steel is more elastic
than rubber.
Introduction to Stress-Strain Curve (With PDF) – What Is Piping
https://www.mtu.edu/materials/k12/experiments/tensile/
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Mechanical properties of common engineering materials
Plasticity
• This is associated with the permanent
deformation of material when the
stress level exceeds the yield point.
• Under plastic conditions, ideal plastic
materials deform without any increase
in stress.
• A typical stress-strain diagram for an
elastic-perfectly plastic material is Ductile Material
shown below.
• Mises-Henky criterion gives a good
starting point for plasticity analysis.

Elastic-perfectly plastic
Idealized figure

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Mechanical properties of common engineering materials
Mises-Henky criterion

𝜎1 − 𝜎2 2 + 𝜎2 − 𝜎3 2+ 𝜎3 − 𝜎1 2 = 𝜎𝑦2

𝜎1 , 𝜎2, 𝜎3 , 𝜎𝑦 are the three principal stresses at a point and the tensile yield strength
respectively.

𝜎2

𝜎1
𝜎3

M28- Mohr's circle (part2 3D Mohr's circle, maximum absolute and maximum in-
plane shear stress) - YouTube

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Mechanical properties of common engineering materials
Condition for plastic flow (simplified model) 𝑃
𝑃
2 > 𝑃𝑚
𝜋𝑎
𝑃𝑚 is the flow pressure

Hardness
Property of the material that enables it to resist
• Permanent deformation
• Penetration
• Indentation

Size of indentations by various types of indenters

are the measure of hardness
• Brinnel hardness test,
• Rockwell hardness test,
• Vickers hardness (diamond pyramid) test.
(1524) Shear Stress and Shear Strain |
These tests give hardness numbers which are Mechanical Properties of Solids | Don't
Memorise - YouTube
related to Yield pressure (MPa).
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Mechanical properties of common engineering materials
Ductility How much the material
• Property that enables it to be drawn out or goes into the plastic zone
elongated to an appreciable extent before
rupture occurs. R
• The percentage elongation or percentage
reduction in area before rupture of a test R
specimen is the measure of ductility.
• percentage elongation > 15% the material is
ductile
• percentage elongation < 5% the material is
brittle
• Lead, copper, aluminium, mild steel are
typical ductile materials. 0.1 – 0.2 %
Malleability
• It is a special case of ductility
• It can be rolled into thin sheets
• Not necessarily to be so strong.
• Lead, soft steel, wrought iron, copper and
aluminium are some materials in order of Less reduction Large reduction
diminishing malleability. in area in area
File:Stress strain comparison brittle ductile.svg - Wikimedia Commons
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Mechanical properties of common engineering materials
Brittleness
• This is opposite to ductility.
• Brittle materials show little deformation before fracture
• Failure occur suddenly without any warning
• Poor resistance to shocks
• percentage elongation < 5%
• Cast iron, glass, ceramics

Resilience
• This is the property of the material that enables it
to resist shock and impact by storing energy.
• The measure of resilience is the strain energy
absorbed per unit volume.
• For a rod of length L subjected to tensile load P
and deflection is 𝛿𝐿
1 1 𝑃 𝛿𝐿 1
• Strain energy = 𝑃𝛿𝐿 = A𝐿 = 𝜎𝜖𝑉
2 2𝐴 𝐿 2
1
• Strain energy/V (volume) = 2 𝜎𝜖

Resiliency and Toughness | MATSE 81:

Materials In Today's World (psu.edu)
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Mechanical properties of common engineering materials
Toughness
• This is the property which enables a
material to be twisted, bent or stretched
under impact load or high stress before
rupture.
• Ability of the material to absorb energy in
the plastic zone.
• Energy absorbed after being stressed up
to the point of fracture.
• Test: Charpy, Izod test

Creep
• When a member is subjected to a constant
load over a long period of time
• It undergoes a slow permanent
deformation
• This is dependent on temperature.
• Usually at elevated temperatures creep is
high

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Ferrous materials
Cast iron Types
• Alloy of iron, carbon and silicon 1. Grey cast iron
• Hard and brittle (limited stretching) 2. White cast iron
• Carbon: 1.7% to 3% 3. Malleable cast iron
• Free carbon or iron carbide Fe3C 4. Spheroidal or nodular cast iron
5. Abrasion resistant cast iron.
In general, but not
always

Brittle Ductile

3. Stress strain diagram for a brittle material. | Download

Scientific Diagram (researchgate.net)

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Ferrous materials
Grey cast iron :

• Brittle however easily machinable

• Carbon in form of graphite
• High compressive strength
• Inexpensive
• Graphite : excellent solid lubricant
• Nomenclature: FG20, FG35 or FG35Si15
• The numbers : ultimate tensile strength MPa
• 15 indicates 0.15% silicon.
Grey Cast Iron - Brechmann Guss
(brechmann-guss.de)
White cast iron :

• Hard, brittle and difficult to machine

• Also called abrasion resistant cast iron
• Carbon in of iron carbide (Fe3C)
• Iron carbide increases hardness
• Inexpensive

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Ferrous materials
Malleable cast iron

• Made from white cast iron by annealing process

• Have plastic zone (certain ductility)
• Tougher than grey cast iron (strength and
ductility, Area under the stress-strain curve till
fracture)
• Can be twisted or bent without fracture
• Excellent machining properties
• Inexpensive Malleable Cast Iron Threaded Fittings - Standard
• Malleable cast iron are used for making parts products catalogue IFRC ICRC (redcross.int)
where forging is expensive
Ductile
Annealing is a heat treatment process that changes
the physical and/or chemical properties of a
material to increase ductility and reduce the
hardness to make it more workable. By heating and Toughness
slowly cooling it.
Forging is a manufacturing process involving the
Resilience
shaping of a metal through hammering, pressing, or
rolling.
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Ferrous materials
Spheroidal or nodular graphite cast iron
• Graphite : form of spheres or
nodules.
• This form of graphite gives it high
tensile strength
• Good elongation properties.
• SG50/7, SG80/2
• The first number gives the tensile
strength in MPa and the second
number indicates percentage
elongation.
27-09-2022 biswajitb@mech.iitkgp.ac.in
Tensile strength of
Grey cast iron up to 45 MPa
Elongation of
Ductile material : Mild steel 10 %
Abrasion resistant cast iron
• Wear resistance
• These are alloy cast iron
• The alloying elements render
abrasion resistance.
• A typical designation is ABR33 Ni4
Cr2
• 33 tensile strength in MPa
• 4% nickel and 2% chromium.
15
Ferrous materials
Wrought iron

• This is a very pure iron

• Iron content is of the order of 99.5%.
• It is produced by re-melting pig iron
• Tough
• Malleable
• Ductile
• Small amount of Silicon, Sulphur, or
phosphorus (may be).
• Can easily be forged or welded
• Cannot take sudden shock
• Chains, crane hooks s k modern art Wrought Iron Black Powder Coated Bed
(5 X 6 Feet, Design 3) : Amazon.in: Home & Kitchen
Toughness
• Ability of the material to absorb energy in Malleability
the plastic zone. Ability to be rolled into thin sheets but
• Energy absorbed after being stressed up it is not necessary to be so strong.
to the point of fracture

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Ferrous materials : Steel
Steel
• By far the most important engineering material
• Large variety of steel to meet the wide variety
of engineering requirements
• Steel is basically an alloy
• iron
• carbon less than 1.7% (Iron carbide)
• Good hardness and strength.
• Two main categories
• Plain carbon steel (inexpensive)
• Alloy steel
Plain carbon steel
• Inexpensive
• Mainly dependent on the carbon
percentages
• Other alloying elements : 0.5% Si or
1% Mn
Carbon contents in the steel is
lower than the cast iron
Lesser carbon content
Larger Plasticity
Types of plain carbon steel
• Dead mild steel- upto 0.15% C
• Low carbon steel or mild steel- 0.15 to
0.46% C (widely used)
• Medium carbon steel- 0.45 to 0.8% C
• High carbon steel- 0.8 to 1.5% C
• Higher carbon percentage indicates higher
strength and hardness

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Ferrous materials : Steel
Alloy steel
• Elements other than carbon are added in sufficient quantities
• wear resistance
• corrosion resistance
• electric or magnetic properties

Examples

• Nickel for strength and toughness

• Chromium for hardness and strength
• Tungsten for hardness at elevated temperature
• Vanadium for tensile strength
• Manganese for high strength in hot rolled and heat treated condition
• Silicon for high elastic limit
• Cobalt for hardness
• Molybdenum for extra tensile strength

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 Thank you !!!

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