12/8/2009. Prof. A.K.M.B. Rashid Department of MME BUET, Dhaka
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1 Prof. A.K.M.B. Rashid Department of MME BUET, Dhaka Introduction and classes of properties Case studies showing selection of the right material for the job Deformation of material under the action of a mechanical force Concept of stress and strain Elastic behaviour of materials Reference: 1. MF Ashby & DRH Jones, Engineering Materials 1: An Introduction to their Properties and Applications, 1 st Ed., Ch. 1, pp WD Callister, Jr. Materials Science and Engineering An Introduction, 5 th Ed., Ch. 6, pp Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 02 1
2 An engineer has a vast range of materials at his disposal. metals and alloys, polymers, glasses and ceramics, composites How does he go about selecting the material, or combination of materials, which best suit his purpose? by selecting properties Mistakes can cause disasters. SS John P. Gaines split in two (1943) Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 03 Bulk Mechanical Properties Modulus Yield strength, tensile strength, ductility Hardness Impact strength Fracture toughness Fatigue strength Creep strength Thermal fatigue resistance Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 04 2
3 Bulk Non-mechanical Properties Physical properties Chemical properties density corrosion and oxidation melting point Thermal properties Optical properties thermal stability refractive index heat capacity colour thermal expansion light absorption, reflection thermal conductivity and transmission Magnetic properties Electrical properties para-, dia-, and electrical conductivity ferromagnetic properties diaelectric properties Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 05 Production Properties Ease of manufacture Castability Heat treatability Hardenability Formability Machinability Weldability Surface Properties Oxidation and corrosion Friction, abrasion, and wear Aesthetic Properties Appearance, texture, feel Economic Properties Price and availability Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 06 3
4 Plastic-handled screwdriver Shaft and blade high-carbon steel (metal) High modulus, measuring the resistance of the material to elastic deflection or bending. A polymer, if used, would twist far too much. High yield strength, so that it would not bend plastically or permanently if twist it hard. High hardness, otherwise it would be indented by the material of the head of the screw and damaged. Why not use glass? Must have high fracture toughness to resist brittle fracture, so that it gives or bends before it breaks. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 07 Plastic-handled screwdriver Handle perspex (polymer/plastic) Have large section, so its twisting or modulus is less important. Cannot be made using rubber, since its modulus is too low. Other commonly used material is wood, a rather complicated but cheap polymer. Perspex is preferred because of its ease of fabrication soft and moulded easily when hot aesthetic value appearance, feel, texture low density not unnecessarily tiring to hold cheap Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 08 4
5 Roll-Royce RB211 Turbofan Aero-engine Air is compressed into the engine by Turbofan, which also provides the aerodynamic thrust around the outside of the casing. Air is further compressed by the compressor blades, then mixed with fuel and burnt in the combustion chamber. The expanding gases drives the engine blades, which provide power to the turbofan and the compressor blade, and finally pass out of the rear of the engine, contributing to the thrust. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 09 Roll-Royce RB211 Turbofan Aero-engine Turbofan blade Titanium alloy (metal) Requires good modulus, yield strength, fracture toughness. Must also resist fatigue (due to rapid fluctuating loads), surface wear (from striking water droplets at high speed), and corrosion (important when taking off over the sea) Finally, it must have low density. Why not use composite blades of CFRP? Although it has a density less than one-half of that of titanium alloy, it is simply not tough enough even a bird strike would instantly demolish a CFRP turbofan. 5
6 Roll-Royce RB211 Turbofan Aero-engine Engine blade Complex nickel-base super alloys (metal) Requirements in addition to those used for turbofan blade must be used. For economy, fuel must be burnt at as high temperature as possible. The first row of engine blades nowadays runs at about 950 C. This adds high creep and oxidation resistance to the requirement. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 11 Spark Plug for IC Engine Spark Electrode Tungsten alloys (metal) thermal fatigue (from rapidly fluctuating temperature) wear (from spark erosion) oxidation and corrosion (from hot gases containing S, Pb, etc.) Insulation Alumina (ceramic) Good electrical insulation Good resistance to thermal fatigue, corrosion and oxidation Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 12 6
7 What happens to material when it is loaded with a mechanical force? Material deforms, either elastically or plastically, depending on the magnitude of the force applied. X-sectional area reduced due to tensile deformation Initial state Small load applied Load removed bond stretch Elastic means reversible!! This happens when strains are small (except for the case of plastic materials) δ F F Linear elastic return to initial Non-linear elastic δ Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 14 7
8 Initial 1. Initial state At lower temperatures, T < T m /3 Large 2. Large load applied load Load 3. Unload removed bond stretch and planes sheared planes still stretched F δ e+p δ p F δ e linear elastic δ p δ e δ Plastic means permanent!! The mechanical behaviour of material under applied force may be ascertained by a simple stress strain diagram or, load deformation diagram One of the most commonly performed mechanical stressstrain test is known as the tensile test. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 16 8
9 The machine Two categories of machines are available: Screw-driven: allows selection and control of the strain rate (dε/dt) Hydraulically driven: allows selection and control of the loading rate (dσ/dt) The sample 505 bar Nickname for the ASTM standard specimen most commonly used in tensile testing; a cylindrical specimen, 0.505" dia. along 2" gauge length (i.e., the length of the straight section between threaded ends). This diameter gives a convenient 0.20 in 2 cross-sectional area. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 17 Stress: force per unit area Engineering stress, σ = F F = load or force A 0 = original x-sectional area A 0 Unit: Pascal (N/m 2 ) or psi (lbf/in 2 ) 1 MPa = 10 6 Pa = 145 psi ; 100 ksi (=10 5 psi) = 700 MPa Strain: change in length per unit length Engineering strain, Unit: dimensionless ε = L L 0 L = change in length L 0 = original length Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 18 9
10 stress, σ σ uts σ y σ p 0.2 % E strain, ε ε f σp proportional limit max. stress in linear region σ y yield strength / proof stress stress that results in a specific amount of permanent strain ( 0.1 or 0.2%) σ uts ultimate tensile strength max. engineering stress on curve ε f elongation or strain to failure total strain at break E modulus of elasticity slope of curve in linear region Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 19 In the Elastic Region In tensile test, if the deformation is elastic, the stress-strain strain relationship follows the Hooke s law: σ = E ε E is known as the Young s modulus, or the modulus of elasticity E has the same unit as those of stress, MPa or psi, although GPa (10 9 Pa) is commonly used. Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 20 10
11 In the Elastic Region Young s Modulus of Elasticity E is a measure of : intrinsic stiffness of material bond strength (on the atomic level) E is decreased with increasing T Hooke s law applied for only a small value of ε (typically < ~ %) ceramic materials follow Hooke s law up to fracture In the elastic region, E For single phase (or, nearly does not vary with the single phase) materials, applied stress, i.e. E is insensitive to : E E(σ) degree of plastic deformation microstructure (i.e., grain size, inclusion) Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 21 E (GPa) E ceramics > E metals >> E polymers 11
12 The stress-strain curve does not follow linear relation in the elastic limit In such cases, instead of Young s modulus, either a Tangent modulus or a Secant modulus is used. Common materials showing such behaviour: grey cast iron concrete polymers Stress, σ σ 2 σ 1 σ Tangent modulus ε (at any stress σ 2 ) σ ε Secant modulus (between origin and any stress σ 1 ) Strain, ε Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 23 Atomic Scale Picture Microscopic elastic strain can be related to the small changes in the interatomic spacing and the stretching of interatomic bonds. Magnitude of modulus of elasticity is a measure of the resistance of separation of adjacent atoms. This is proportional to the slope of interatomic force separation curve at the equilibrium spacing, r 0, i.e., E Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 24 df dr r 0 12
13 Materials subject to tension shrink laterally. Those subject to compression, bulge. The ratio of lateral and axial strains is called the Poisson's ratio, ν. ε ν = - x = - ε z ε d y 0 ε d z i ν is dimensionless, sign shows that lateral strain is in the opposite sense to longitudinal strain. Theoretical value for isotropic material: 0.25 Maximum value: 0.50, Typical value: Many materials are elastically anisotropic. y z x Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 25 Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 26 13
14 Problem A tensile stress is to be applied along the long axis of a cylindrical brass rod that has a diameter of 10 mm. Determine the magnitude of the load required to produce a 2.5x10-3 mm change in diameter if the deformation is entirely elastic. d 0 = 10 mm d = 2.5x10-3 mm For brass, ν = 0.34 E = 97 GPa ε x = - d d 0 ε z = - ε x σ = ε z E -2.5x10-3 mm = = -2.5x10 10 mm -4 ν = x = -7.35x10-4 = (7.35x10-4 ) (97x10 3 MPa) = 71.3 MPa Rashid, DMME, BUET MME 291, Lec 09: Mechanical properties of materials 1 P 27 Next Class MME 291: Lecture 10 14
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