Week 3 - Mechanical Behavior and Manufacturing Properties of Materials - Part 2 - With Notes

Mechanical Properties Join at slido.
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#3867986 to ask questions
Shear Elastic Region

• In the elastic region, the relationship is defined as
• G is called shear modulus, or

shear modulus of elasticity
• For most materials, _________,

where E = elastic modulus
Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Copyright ©2019 John Wiley & Sons, Inc.
23
Mechanical Properties Join at slido.com with
Shear Plastic Region

• Relationship similar to flow curve for a tensile test
• Shear stress at fracture =
• Shear strength can be estimated
from tensile strength:
• Since cross-sectional area of

test specimen in torsion test
does not change as in tensile
and compression, engineering
stress-strain curve for shear 
true stress-strain curve
24
Torsion Testing Machine
Source: https://www.youtube.com/watch?v=qPIug2sewFA&ab_channel=EngineersAcademy
25
• So far, we have reviewed the three main types of static

stresses to which materials can be subjected:
o Tensile - stretching the material

o Compressive - squeezing the material
o Shear - causing adjacent portions of the material to
slide against each other
• In addition to the above three tests, there are still many

properties to help us to define the mechanical behavior
of a specific material

26
_______________________
• Resistance to _____________________________
• Good hardness generally means material is resistant to

_____________________________
• Most tooling used in manufacturing must be hard for

scratch and wear resistance
• Commonly used for assessing material properties because
they are quick and convenient (no special specimens
required)
• Variety of testing methods due to differences in hardness

among different materials
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Brinell Hardness Test Rockwell Hardness Test

• Widely used for testing metals and • A cone shaped indenter is pressed
nonmetals of low to medium into specimen using a minor load
hardness of 10 kg, thus seating the indenter
• A hard ball is pressed into in material
specimen surface with a load of
500, 1500, or 3000 kg • Then, a major load of 150 kg is
applied, causing indenter to
penetrate beyond its initial position

Copyright ©2019 John Wiley & Sons, Inc. 28
Rockwell Hardness Test
Source: https://www.youtube.com/watch?v=p-
lu7mdT7ns&ab_channel=SIInstrumentsTV
29
___________________________
• ____________________ may be caused by
fluctuating mechanical loads, e.g. gear and rotating
machine elements
• When a material fails at stresses below its yield point

on subjected to ______________. This mode of
failure is known as _______ as well as ____________
• Fatigue test methods involve testing specimens under

a combination of tension and bending
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
30
Fatigue
• Typical plots are called S–N curves
• Value of stress at which failure

occurs after some specified
number of cycles is called
___________________________
• Maximum stress without fatigue

failure, regardless of the number
of cycles, is known as the
____________________________
Source: https://www.admet.com/products/torsion-
test-machines/rotating-beam-fatigue-test-system/
• Endurance limit for metals can be

related to their ________________
_________________________
Copyright © 2014 Pearson Education South Asia Pte Ltd 31
Fatigue S-N Plots for Different Materials
32
Fatigue Test
Source: https://www.tec-science.com/material-science/material-testing/fatigue-test/
33
Fatigue Test
Source: https://www.youtube.com/watch?v=hASl6d3z3BM&ab_channel=LSPTechnologies
34
Fatigue Test
Source: https://www.youtube.com/watch?v=TH9k9fWaFrs&ab_channel=Boeing
35
Correction Join at slido.com with
Engineering Stress-Strain Plot

F
s=
Ao
36
Stress-Strain Relationships
• Three types of static stresses to which materials can
be subjected:
o Tensile - stretching the material

o Compressive - squeezing the material
o Shear - causing adjacent portions of the material
to slide against each other
• As long as there is a linear region, you “should” be

able to use 0.2% offset method to define the location
of yield point. However, in practice, this 0.2% offset
method is mostly used for tensile test only.
37
Fundamentals of Materials Join at slido.com with
38
Physical Properties of Materials Join at slido.com with
• Properties that define the behavior of materials

in response to physical forces other than
mechanical
• Components in a product must do more than

withstand mechanical stresses
• They must conduct electricity (or prevent its

conduction), allow heat to transfer (or allow its
escape), transmit light (or block its
transmission), and satisfy many other functions

Physical Properties in Manufacturing
• Important in manufacturing because physical properties

often influence process performance
• In machining, thermal properties of the work material

determine cutting temperature, which affects tool life
• In microelectronics, electrical properties of silicon and

how these properties can be altered by chemical and
physical processes is the basis of semiconductor
manufacturing

Volumetric and Melting Properties

• Properties related to the volume of solids and how
these properties are affected by temperature

Density
• Density =
• Typical units are g/cm3 (lbm/in3)
• Strength may also be important, and the two

properties are often related in a _______________
______, which is ___________________________
• Useful ratio in comparing materials for structural

applications in aircraft, automobiles, and other
products where weight and energy are concerns
42
Density
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Thermal Expansion
• Density of a material is a _________________________
• In general, density ________ with increasing temperature
• Volume per unit mass (1/density) increases with

increasing temperature
• Thermal expansion is the name for this effect of

temperature on density
• Measured as ___________________________________

44
Thermal Expansion
• Change in length per degree of temperature, such as
mm/mm/C, often reduced to 1/C (in/in/F or 1/F)
• Length ratio rather than volume ratio because this is

easier to measure and apply
• Change in length for a given temperature change:
 = coefficient of thermal expansion

L1 and L2 are lengths corresponding respectively to temperatures T1 and T2

45
Thermal Expansion in Manufacturing

• Thermal expansion is used in shrink fit and expansion fit
assemblies
• Part is heated to increase size or cooled to decrease size to

permit insertion into another part
• When part returns to ambient temperature, a tightly-fitted

assembly is obtained
• Thermal expansion can be a problem in heat treatment and

welding due to thermal stresses that develop in the metal
during these processes
46
Thermal Expansion in Manufacturing
Source: https://www.youtube.com/watch?v=F5q5JqmFpHk&ab_channel=RayMAKES
47
Example: If a meter long brass scale expands by 0.45 mm in length

then by how much is the temperature has increased (in °C)? The
coefficient of thermal linear expansion  for brass is 1.8x10-5K-1.

48
Melting Point
• Melting point Tm of a pure element =
temperature at which it transforms _________
_____________________________
• The reverse transformation occurs at the same

temperature and is called the ______________
• Heat of fusion = heat energy required at Tm to

accomplish transformation from solid to liquid

49
Melting Point in Manufacturing

• Metal casting - the metal is melted and then poured into
a mold cavity
• Metals with lower melting points are generally easier to

cast
• Plastic molding - melting characteristics of polymers

are important in nearly all polymer shaping processes
• Sintering of powdered metals - sintering does not melt

the metal, but temperatures must approach the melting
point to achieve bonding of the powders
50
Electrical Properties
• Engineering materials exhibit a great variation in
their capability to conduct electricity
• Flow of electrical current involves movement of

charge carriers - infinitesimally small particles
possessing an electrical charge
• In solids, these charge carriers are _______________
• In liquid solutions, charge carriers are ____________

______________________________

51
• Movement of charge carriers is driven by the
presence of electric voltage
• And resisted by the inherent characteristics of the

material, such as atomic structure and bonding
between atoms and molecules
I = current, A,
Ohm's law: E = voltage, V,
R = electrical resistance, 

52
Resistance in a uniform section of material (e.g., a wire)
depends on its length L, cross-sectional area A, and
resistivity of the material r
Resistivity r has units of

 -m2/m or  -m ( -in)
Resistivity
• Property that defines a material’s ___________________________
• Resistivity is not a constant; it varies, as do so many other

properties, with temperature
• For metals, resistivity ________ with temperature

53
Conductivity
• Often more convenient to consider a material as
conducting electrical current rather than resisting its flow
• Conductivity of a material is simply the reciprocal of

resistivity:
Electrical conductivity = conductivity has units of ( -m)-1 or ( -in)-1
• Metals are the best conductors of electricity, because of

their metallic bonding

54
Electrical Properties in Manufacturing

• Electric discharge machining - uses electrical energy in
the form of sparks to remove material from metals
• The important welding processes, such as arc welding

and resistance spot welding, use electrical energy to
melt the joint metal
• Capability to alter electrical properties of

semiconductor materials is the basis for
microelectronics

55
Electrical-discharge Machining
Source: https://www.youtube.com/watch?v=L1D5DLWWMp8&ab_channel=ToolingU-SME
56
Electrochemistry
• Field of science concerned with the relationship between
electricity and chemical changes, and the conversion of
electrical and chemical energy
• In a water solution, molecules of an acid, base, or salt are

dissociated into positively and negatively charged ions
• Ions are the charge carriers in the solution
• They allow electric current to be conducted, playing the

same role that electrons play in metallic conduction

57
Electrolysis
• The name given to these
chemical changes occurring
in the solution
• At each electrode, chemical

reaction occurs, such as:
o Deposition or
dissolution of material
o Decomposition of gas
from the solution

58
Electrolysis in Manufacturing
• Electroplating - an operation that adds a thin coating
of one metal (e.g., chromium) to the surface of a
second metal (e.g., steel) for decorative or other
purposes
• Electrochemical machining - a process in which

material is removed from the surface of a metal part
• Production of hydrogen and oxygen gases

59
Electrochemical Machining
Source: https://www.youtube.com/watch?v=Ej-GWNPYFVM&ab_channel=ManufacturingIE-Purdue
60
Summary
61
Summary
62
Fundamentals of Materials Join at slido.com with
63
Property Modification Join at slido.com with
• Many structural metals undergo

some special treatment to ____
_________________________
_________________________
so that they will perform better
for their intended use.
• This treatment can include

mechanical working, such as
rolling or forging, alloying
and/or thermal treatments.
Source: https://www.rapiddirect.com/blog/heat-treatment-of-metals/#:~:text=Generally%2C%20heat%20treatment%20of%20steel,the%20microstructure%20of%20the%20metal.
64
• _________________involves
the use of _________________,
normally to extreme
temperatures, to achieve the
desired result such as hardening
or softening of a material.
• Heat treatment techniques

include annealing, case
hardening, precipitation
strengthening, tempering,
carburizing, normalizing and
quenching – done by different
heating temperatures and
different colling rates
Copyright © 2014 Pearson Education South Asia Pte Ltd 65
Heat Treatment of Steel
Source: https://www.azom.com/article.aspx?ArticleID=313
66
Heat Treatment Example (Quenching)
Source: https://www.youtube.com/watch?v=xihraKAokCs&ab_channel=RadyneCorporation
67
Course Wrap-Up Join at slido.com with
68
Reminder Join at slido.com with
• Homework will be uploaded to NTU COOL today
69

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Mechanical Properties Join at slido.

Shear Elastic Region

• G is called shear modulus, or

• For most materials, _________,

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Shear Plastic Region

• Since cross-sectional area of

Torsion Testing Machine

• So far, we have reviewed the three main types of static

o Tensile - stretching the material

• In addition to the above three tests, there are still many

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

• Good hardness generally means material is resistant to

• Most tooling used in manufacturing must be hard for

• Variety of testing methods due to differences in hardness

Brinell Hardness Test Rockwell Hardness Test

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Rockwell Hardness Test

• When a material fails at stresses below its yield point

• Fatigue test methods involve testing specimens under

• Value of stress at which failure

• Maximum stress without fatigue

• Endurance limit for metals can be

Fatigue S-N Plots for Different Materials

Engineering Stress-Strain Plot

o Tensile - stretching the material

• As long as there is a linear region, you “should” be

• Properties that define the behavior of materials

• Components in a product must do more than

• They must conduct electricity (or prevent its

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Physical Properties in Manufacturing

• Important in manufacturing because physical properties

• In machining, thermal properties of the work material

• In microelectronics, electrical properties of silicon and

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Volumetric and Melting Properties

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

• Typical units are g/cm3 (lbm/in3)

• Strength may also be important, and the two

• Useful ratio in comparing materials for structural

• In general, density ________ with increasing temperature

• Volume per unit mass (1/density) increases with

• Thermal expansion is the name for this effect of

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

• Length ratio rather than volume ratio because this is

• Change in length for a given temperature change:

 = coefficient of thermal expansion

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

Thermal Expansion in Manufacturing

• Part is heated to increase size or cooled to decrease size to

• When part returns to ambient temperature, a tightly-fitted

• Thermal expansion can be a problem in heat treatment and

Thermal Expansion in Manufacturing

Example: If a meter long brass scale expands by 0.45 mm in length

Source: Fundamentals of Modern Manufacturing 7/e, M P Groover

• The reverse transformation occurs at the same

• Heat of fusion = heat energy required at Tm to