Materials and Process Selection for Engineering Design: 3rd Edition (Paperback) book cover

Materials and Process Selection for Engineering Design

3rd Edition

By Mahmoud M. Farag

CRC Press

538 pages | 95 B/W Illus.

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Description

Introducing a new engineering product or changing an existing model involves making designs, reaching economic decisions, selecting materials, choosing manufacturing processes, and assessing its environmental impact. These activities are interdependent and should not be performed in isolation from each other. This is because the materials and processes used in making the product can have a large influence on its design, cost, and performance in service.

Since the publication of the second edition of this book, changes have occurred in the fields of materials and manufacturing. Industries now place more emphasis on manufacturing products and goods locally, rather than outsourcing. Nanostructured and smart materials appear more frequently in products, composites are used in designing essential parts of civilian airliners, and biodegradable materials are increasingly used instead of traditional plastics. More emphasis is now placed on how products affect the environment, and society is willing to accept more expensive but eco-friendly goods. In addition, there has been a change in the emphasis and the way the subjects of materials and manufacturing are taught within a variety of curricula and courses in higher education.

This third edition of the bestselling Materials and Process Selection for Engineering Design has been comprehensively revised and reorganized to reflect these changes. In addition, the presentation has been enhanced and the book includes more real-world case studies.

Reviews

"This third edition of the bestselling Materials and Process Selection for Engineering Design has been comprehensively revised and reorganized to reflect changes [in the fields and teaching of materials and manufacturing]. In addition, the book's presentation has been enhanced and includes more real-world case studies."

––Materials and Corrosion 2014, 65, No. 1

"The key elements of materials selection are handled exceptionally thoroughly. The quantitative treatment of the topics make this book a perfect adjunct, if not outright the textbook, for undergraduate courses. Staff engineers at manufacturing companies and at product design firms will find this book to be an essential resource."

––Stephen H. Carr, Northwestern University, Evanston, IL, USA

"Many of the topics in the book, especially the relationship between design, materials, and manufacturing are increasingly discussed in the curricula of materials engineering and mechanical engineering. This book explains these topics very clearly and would be of interest to many faculty members in these departments. …The front matter explains what the book is all about very clearly and presents a strong case for why faculty members should adopt it for their course…"

––Theodoulos Z. Kattamis, University of Connecticut, Storrs, USA

"… a valuable resource on materials and process selection. … an ideal reference for final year thesis students undertaking integrated design projects. The book also reviews other approaches such as the Ashby maps and design for manufacturing concepts and as such provides a complete guide to the important topic of materials and process selection."

—Amal Esawi, Professor, Mechanical Engineering Department, The American University in Cairo, Egypt

"… presents a broad range of topics important for material and process selection. … the approach uses is truly engineering and realization oriented and therefore particularly suited for mechanical, industrial, and design students."

—Rémy Glardon, EPFL

Praise for the Previous Edition

"Dr. Farag is a recipient of the Egyptian State Award for promotion of science and the First Order of Merit in arts and sciences—he is clearly a highly respected teacher. The strength of his book lies in its many worked examples and review questions set at the close of every chapter. The material data provided is also excellent."

—Peter C. Gasson, CEng, MIMechE, FRA, The Aeronautical Journal, October 2008

Table of Contents

Product Design and Development in the Industrial Enterprise

Introduction

Feasibility Study, Identification of Needs, and Concept Selection

System-Level Design

Detail Design and Selection of Materials and Processes

Testing and Refinement

Launching the Product

Selling the Product

Planning for Retirement of the Product and Environmental Considerations

Product Market Cycle

Summary

Review Questions

Bibliography and Further Readings

Performance of Materials in Service

Failure under Mechanical Loading

Introduction

Types of Mechanical Failures

Fracture Toughness and Fracture Mechanics

Ductile and Brittle Fractures

Fatigue Failures

Elevated-Temperature Failures

Failure Analysis: Experimental Methods

Failure Analysis: Analytical Techniques

Failure Prevention at the Design Stage

Failure Mode Effect Analysis

Summary

Review Questions

Bibliography and Further Readings

Corrosion, Wear, and Degradation of Materials

Introduction

Electrochemical Principles of Metallic Corrosion

Types of Metallic Corrosion

Combined Action of Stress and Corrosion

Corrosion of Plastics and Ceramics

Oxidation of Materials

Corrosion Control

Wear Failures

Radiation Damage

Summary

Review Questions

Bibliography and Further Readings

Selection of Materials to Resist Failure

Introduction

Grouping and Identifying Engineering Materials

Selection of Materials for Static Strength

Selection of Materials for Stiffness

Selection of Materials for Fatigue Resistance

Selection of Materials for High-Temperature Resistance

Selection of Materials for Corrosion Resistance

Coatings for Protection against Corrosion

Selection of Materials for Wear Resistance

Wear-Resistant Coatings

Summary

Review Questions

Bibliography and Further Readings

R elationships between Design, Materials, and Manufacturing Processes

Nature of Engineering Design

Introduction

General Considerations in Engineering Design

Design for Six Sigma

Major Phases of Design

Environmentally Responsible Design

Design Codes and Standards

Effect of Component Geometry

Factor of Safety

Reliability of Components

Product Reliability and Safety

Product Liability

Summary

Review Questions

Bibliography and Further Readings

Effect of Material Properties on Design

Introduction

Designing for Static Strength

Designing for Stiffness

Designing with High-Strength, Low-Toughness Materials

Designing against Fatigue

Designing under High-Temperature Conditions

Designing for Hostile Environments

Designing with Specific Materials (Material-Specific Design Features)

Summary

Review Questions

Bibliography and Further Readings

Effect of Manufacturing Processes on Design

Introduction

Product Manufacture in the Industrial Enterprise

Classification of Manufacturing Processes

Selection of Manufacturing Processes

Design for Manufacture and Assembly

Design Considerations for Cast Components

Design Considerations for Molded Plastic Components

Design Considerations for Forged Components

Design Considerations for Powder Metallurgy Parts

Design of Sheet Metal Parts

Designs Involving Joining Processes

Designs Involving Heat Treatment

Designs Involving Machining Processes

Automation of Manufacturing Processes

Computer-Integrated Manufacturing

Summary

Review Questions

Bibliography and Further Readings

Selection and Substitution of Materials and Processes in Industry

Economics and Environmental Impact of Materials and Processes

Introduction

Elements of the Cost of Materials

Factors Affecting Material Prices

Comparison of Materials on Cost Basis

Value Analysis of Material Properties

Economics of Material Utilization

Economic Competition in the Materials Field

Processing Time

Processing Cost

Economics of Time-Saving Devices

CostBenefit and Cost-Effectiveness Analyses

Environmental Impact Assessment of Materials and Processes

Recyclability of Engineering Materials and Recycling Economics

Life Cycle Cost

Summary

Review Questions

Bibliography and Further Readings

Materials Selection Process

Introduction

Nature of the Selection Process

Analysis of the Material Performance Requirements and Creating Alternative Solutions

Initial Screening of Solutions

Comparing and Ranking Alternative Solutions

Selecting the Optimum Solution

Computer Assistance in Making Final Selection

Using MATLABR in Materials and Process Selection

Sources of Information for Materials Selection

Summary

Review Questions

Bibliography and Further Readings

Materials Substitution

Introduction

Materials Audit

Considerations in Materials Substitution

Screening of Substitution Alternatives

Comparing and Ranking of Alternative Substitutes

Reaching a Final Decision

Using MATLABR in Materials Substitution

Summary

Review Questions

Bibliography and Further Readings

Case Studies in Material Selection and Substitution

Introduction

Design and Selection of Materials for a Turnbuckle

Design and Selection of Materials for Surgical Implants

Design and Selection of Materials for Lubricated Journal Bearings

Analysis of the Requirements and Substitution of Materials for Tennis Rackets

Material Substitution in the Automotive Industry

Bibliography and Further Readings

Appendices

Appendix A: Metallic Materials—Classification, General Characteristics, and Properties

Appendix B: Polymers—Classification, General Characteristics, and Properties

Appendix C: Ceramic Materials—Classification, General Characteristics, and Properties

Appendix D: Composite Materials—Classification and Properties

Appendix E: Semiconductors and Advanced Materials

Appendix F: Conversion of Units and Hardness Values

Appendix G: Glossary

Index

About the Originator

Subject Categories

BISAC Subject Codes/Headings:
TEC009070
TECHNOLOGY & ENGINEERING / Mechanical
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing
TEC021000
TECHNOLOGY & ENGINEERING / Material Science