The American University in Cairo

School of Sciences and Engineering Department of Mechanical Engineering Post Graduate studies Summer 2009 MENG 522: Design for manufacturing Assignment # 3

Presented to: Dr. Amal Esawi

Presented by: Nesma Tarik Aboulkhair ID: 800 08 1044

Case study #1: Materials for oars Function: Light, stiff beam Objective: Minimize mass Constraints: (a) Length L specified (b) Bending stiffness S specified (c) Toughness, Gc>1 kJ/m2 (d) Cost, Cm<$100/kg

m: Mass (m = A L) .. (1) A: Area (A = ) .. (2) ) (3)

I: Mass moment of inertia (I = E: Youngs modulus L: Length S: Bending stiffness (S =

) . (4)

o Substituting (2) in (1): m=L* Then, d2 = .. (5)

o Substituting (3) in (4): S=

... (6)

o Substituting (5) in (6): S=

Since our objective is to minimize the mass, then m = m=

Then to minimize mass, choose a material with smallest

Case study II: Materials for table legs

Function: Column (support compressive loads) Objective: a) Minimize mass b) Maximize slenderness Constraints: a) Must not buckle Pcrit = b) Must not fracture of accidently struck c) Cost of material is of interest, but not a constraint

Part (a): m: Mass (m = A L) .. (1) A: Area (A = ) .. (2) ) (3)

I: Mass moment of inertia (I = E: Youngs modulus L: Length

Pcrit: Critical compressive load (Pcrit =

). (4)

o Substituting (2) in (1): m=L* Then, d2 = .. (5)

o Substituting (3) in (4):

Pcrit =

.. (6)

o Substituting (5) in (6): Pcrit =

Since our objective is to minimize the mass, then m =

m=

Then to minimize mass, select a material with smallest

Part (b): Note: Maximize slenderness in other words is minimize the diameter. I: Mass moment of inertia (I = E: Youngs modulus L: Length Pcrit: Critical compressive load (Pcrit = ) (1)

). (2)

o Substituting (1) in (2):

Pcrit =

Since our objective is to minimize the diameter, d =

d=

Then to maximize slenderness, select a material with smallest

Case study III: Materials for heat Exchangers

Function: Heat exchanger Objective: a) Maximize heat flow per unit area Constraints: a) Support pressure difference b) Tolerate chloride ions c) Operating temp up to 150 C d) Low Cost
Level (3) Material U niverse; All Bulk Materials, Stage (1) Limit Stage; constrains were entered as follows; Thermal Properties Maximum Service Temperature; 0 DegC to 150 DegC Durability Fresh Water; Good & Very Good Salt Water; Good & Very Good Weak Acids; Good & Very Good (Chloride ions and water might form HCl) Stage (2) Relation between Thermal Conductivity () & Yield Strength ( Graph Stage; constrains were entered as follows; = Thermal Conductivity yield = Yield Strength Q = q A = A T / t t = A T / Q yield = P r /t yield = Q P r / A T Maximize Q = A T yield /P r Then the slope (S) = ( yield) yield = S/ Log yield = Log S Log ; then the slope is equal to 1 Stage (3) Relation between Thermal Conductivity () & Price
yield)

Graph Stage; using a selection box with the axis of the chart is the relation between the price and Thermal Conductivity () and by narrowing down the materials screened, in terms of the lowest possible price with the highest Thermal Conductivity Materials Selected Nickel Silver, Copper Beryllium, Expoxy Carbon Fiber, Wrought Marensitic Stainless Steel, Silicon Bronze, titanium alloy.