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Cambridge Engineering SelectorCES 4 EduPack

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UNLOCK THE POTENTIAL OF MATERIALS INFORMATION

Introduction: The CES4 EduPack

The CES4 EduPack contains a complete educational resource toolkit for courses on Material and Process Selection. The main elements are:

Professor Mike Ashby’s best-selling textbook ‘Materials Selection in Mechanical Design’: the methodological base

A comprehensive set of Powerpoint presentations for lecturers

Exercises and solutions for students

Handouts for students

The CES4 software: for demonstrations, exercises, and projects


Introduction

This presentation focuses on the CES4 Educational software and its unique graded databases of materials and manufacturing processes.

Three different levels of information are provided in the databases:

The Level 1 package helps to inspire newly-enrolled engineering students with real interest in materials, and encourages exploration of the world of materials.

The Level 2 package provides a serious tool with a structured methodology for use in intermediate courses (years 2-4). It assists understanding of the role of materials and processes in design and skill in selecting them.

The Level 3 package provides senior year and graduate students of engineering materials and design with a professional tool: to assist major design and research projects.


The Level 1 Database...


The Browse tool in CES4 is used to view the contents of the database.

The Material Universe data table contains all of the main classes of materials...


Browse Tree

View the contents of the Metals branch of the tree


Browse Tree


Browse Tree

Double-clicking onCopper Alloysdisplays its data sheet


Browse Copper Alloys

Each datasheet contains a description of the material...

… a picture ofits use in awell-known product...


Browse Copper Alloys

Some General Properties…

Mechanical Properties…

Thermal, Electrical and Optical Properties…

Typical uses


… and at the end of every datasheet, links between this material and items in other tables.

Clicking on the Process link shows ways to process Copper Alloys


Processes for Copper alloys. Clicking on one displays its details


Browse Tree

Very similar data is available for all other materials - eg examine information for Polycarbonate...


Browse Tree


Browse Polycarbonate


Level 1 Material Datasheet Polycarbonate


The EduPack Level 1 database contains 68 typical material records...


Materials Tree

Ceramics and Glasses...


Composites:Polymer matrixMetal matrix...


Polymer Foams...


Metals...


Natural Materials...


and Polymers.


Level 1 Process tree

The Process Universe data table contains three main classes of processes...

The EduPack Level 1 database also contains 65 typical process records...


Joining processes...


Shaping processes...


… and Surface Treatment processes.


The datasheet forDie Castingis typical of all datasheets for Shaping processes


Level 1 Process Datasheets Diecasting

It contains a description of the process...

… a schematic diagram of how the process works ...


Some Physical Attributes…

Some Economic Attributes…

Process and Shape types ...

Typical uses ...

… and links to other tables


The Level 2 Database


Materials in the EduPack Level 2 database contain more information than the materials in the Level 1 database...


Energy Content(a measure of environmental impact)...

4 more Mechanical properties,2 more Thermal properties...


4 more Electrical properties

Resistance to 11 common Environments


Similarly, Processes in the EduPack Level 2 database contain more information than the processes in the Level 1 database.

… and useful supporting information, Tradenames, etc.


Searching the database


The Search tool is used to search the database…


Search Plexiglas

What is “Plexiglas?”

Click on this search result to find out...


The search tool can be used to search for material designations, tradenames, typical uses, etc


Optimal Selection


Select

The Select view is used to select materials and processes from the database, using the Ashby methodology, described in the text book: ‘Materials Selection in Mechanical Design’

The selection process involves performing a series of independent selection stages. CES4 keeps track of the results...


There are three selection tools… Graphical selection will be discussed here.

The selection Results window shows the number of materials that have passed all selection stages so far. (All materials currently pass because no stages have been performed.)


Case Study: Materials for Flywheels

Ashby shows that to maximise kinetic energy per unit mass, it is necessary to find the material with the highest value of strength/density, with an adequate fracture toughness and reasonable price.

Consider selecting a material for the rotor of a high-speed flywheel...

Perform two materials selection stages...


The first selection stage is a chart of Elastic Limit (strength) vs Density.

Each bubble represents a material.

The size of the bubble indicates the range of its properties.

Clicking on a bubble adds a label...

…double-clicking opens the datasheet.


A line of gradient = 1 is a contour of constant strength/density ratio.

Materials above the line have a high value of strength/density…

…they pass the selection and appear in the results list.

Materials below the line have low values of strength/density. They fail the selection and are plotted in gray.


Flywheel case study

The second selection stage is a chart of Fracture Toughness vs raw material price


Select tough materials with a modest price


Display only the materials that passed both selection stages...


Now return to the previous selection stage...


… and show only the materials that passed both stages...


Now zoom-in to the area of interest...


… and move the selection line upwards to maximize the strength/density performance...


Two remaining materials are:

Carbon Fibre Reinforced Plastic (CFRP) &

Glass Fibre Reinforced Plastic (GFRP)

CFRP has high performance and a high price… good for flywheels to be used in aerospace applications; … for example, energy storage in satellites.

GFRP has lower (but still good) performance, but a considerably lower price… it is good for flywheels in automotive and other cost-sensitive applications.


The Level 3 Database


The EduPack Level 3 database is the full professional version of CES4. It contains over 3000 materials… all of the main classes; covered in considerable depth.


For example, there are 13 different records for Aluminium 7075, representing the most widely used heat treatments.


Each material has a substantially expanded data set, including: composition details; tradenames; equivalent designations; and many more mechanical, thermal, electrical and other properties.


The information in the database is impressive in its detail...


It has 1700 Metals...


…520 Polymers...


470 Ceramics & Glasses


310 Composites


75 Natural materials


and 130 polymer and metal foams


The process database is expanded in a similar way. For example, it has 21 deformation processes, instead of 3 in the level 1 & 2 database


Each process has a long list of attributes, including a cost model. This estimates the cost of making a component by the process, in terms of the important production variables, batch size, overhead rate, etc.


Optional Add-On

CES4 CAMPUS Plastics Database


CAMPUS

The optional CES4 CAMPUS database contains grade-specific polymer data on 5,500 industry-standard plastics resins from 31 producers.

It is particularly useful for Polymer science and engineering courses and polymer research.


For example, there are 327 specific polymer grades from BASF...


Each record has a large amount of pedigreed information, including functional data. It is measured to exacting ISO standards.


Optional Add-On

Mil-Handbook 5 and 17 Databases


The CES4 MIL-Handbook database contains industry-standard design data for aerospace metals (MIL-HDBK-5) and composites (MIL-HDBK-17).

It is particularly suited to senior year and graduate aerospace engineers.


There are 60 different records for Aluminium 7075-T6, in the MIL-HDBK-5 table.


Each record has a large amount of pedigreed information, measured on a specified statistical basis, including functional data.


The MIL-HDBK-17 table has ‘raw’ handbook data for several important aerospace composite systems, as well as special summary records which combine the results of a number of tests into ‘designer-friendly’ form.


‘Raw’ Handbook data...


‘Summarised’ data...


Conclusions

The CES4 EduPack provides a complete educational resource toolkit for

courses in material and process selection.

It includes a best-selling text, lecture notes, student handouts,

exercises, user-friendly software and unique databases.

Aspects of the material can be used throughout an engineering course:

from the freshman (first) year to ‘Capstone’ and graduate level.

The approach is tried and tested, and used in over 400 Universities

world-wide.

Visit: www.grantadesign.com for further information

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