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Design and Manufacture 2 > Material Selection and costing > Flashcards

Material Selection and costing Flashcards

1
Q

What does material selection effect

A

Part function, cost, manufacture process, Quality test method, ability to be painted coated etc

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2
Q

Name 2 general material properties

A

Density and price

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3
Q

Name 2 Mechanical Properties

A 
Elastic modulus (stiffness)
Ultimate strength
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4
Q

What is a material index dependant on

A

Function, Geometry, How we want to optimise performance

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5
Q

Give an example of how we might want to optimise performance

A

Light and strong or strong and cheap

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6
Q

For material selection what is the function

A

What the part needs to do, e.g. support a tensile load or support a bending load

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7
Q

What are the objectives in material selection

A

Goals that need to be achieved when selecting the material

e.g. minimise mass or minimise cost

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8
Q

What are constraints on material selections

A

Specifications that constrain the selection when trying to meet the objectives
e.g have to have a thermal conductivity > 10

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9
Q

What are free variables in material selection

A

Parameters not fixed by the initial design specification,

e.g. Cross sectional area or Material

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10
Q

What is the first step of the material selection strategy

A

Identify the functions and objectives and constraints

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11
Q

The 2nd step of the selection strategy is to Screen, what does screening use

A

Constraints

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12
Q

What would you rank the material choices using for the 3rd selection step

A

Material Index

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13
Q

For an example to select a material for the lightest stiffest tie What is the Function

A

Safely support a tensile load without breaking

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14
Q

Light/ stiff tie. What are the free variables

A

Cross sectional area and material

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15
Q

Light/ stiff tie, what is the objective

A

Minimise mass

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16
Q

Light/stiff tie. What is the constraint

A

CSA must be strong enough to keep stress < failure stress

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17
Q

What material index would you use for a Light/stiff tie

A

(failure stress)/(density)

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18
Q

For a light/strong tie with a minimum value for electrical conductivity how many coupled constraints are there and what are they

A

2, Lightest/strongest

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19
Q

For a light/strong tie with minimum electrical conductivity what is the uncoupled constraint

A

Electrical Conductivity

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20
Q

For a problem with multiple constrains what constraint would you apply first

A

The uncoupled constraints

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21
Q

How many material indices would you need for the lightest/strongest/stiffest tie

A

2

22
Q

What is the material index for a light/stiff tie

A

(density)/(young’s modulus)

23
Q

What would be the equation for the minimum mass a tie will have using a given material if it is to meet both constraints (m’)

A

m’=max(m1,m2)

24
Q

What is the equation for m1, the mass for the lightest strongest tie

A

m1>FxLx((density)/(failure stress))

25
Q

What is the equation for m2, the mass of the lightest strongest tie

A

m2>SxL^2x((density)/(Youngs modulus))

26
Q

For the cheapest strongest tie what is the objective

A

Minimise cost

27
Q

For cheapest strongest tie what is the constrain

A

Area of rod must be great enough so that stress stays bellow failure stress

28
Q

For cheapest strongest tie what is the Free variable

A

Area

29
Q

What is the basic equation for cost

A

Cost=mass x Cost per part

30
Q

What is the material index for the cheapest strongest tie

A

(failure strength)/((density) x (cost per part))

31
Q

Name some basic shaping processes

A

Casting, moulding, deformation, powder formation

32
Q

Name secondary shaping processes

A

Drilling, punching, turning

33
Q

Name a property enhancing process

A

Heat treatment

34
Q

Name some joining processes

A

Adhesives, welding, fastening

35
Q

Name some finishing processes

A

Polishing, Coating, Painting, Turning

36
Q

List the key process steps in order

A 
Basic shaping
secondary shaping
Property enhancing
Joining 
Finishing
37
Q

What is the process selection dependant on

A

Material selection, size, shape, precision, quality of parts

38
Q

In process selection what are the classification steps

A

Family
class
member
attribute

39
Q

What does the family of process selection influence

A

Function

40
Q

What does the attribute of the process selection influence

A

Constraints

41
Q

What is the economic batch size

A

Size found by experience to e competitive in terms of cost

42
Q

How do batch size, investment cost and rate of production relate

A

Higher the batch size the higher the investment cost but also the higher the rate of production

43
Q

In the cost model what is Cm

A

Cost of material £/kg

44
Q

In the cost model what is Ct

A

Dedicated cost £

45
Q

In the cost model what is Cc

A

Capital cost £

46
Q

In the cost model what is the Coh

A

Overhead cost per hour £/hour

47
Q

in the material cost equation what is f

A

The scrap fraction

48
Q

In the dedicated cost equation what do n and nt mean

A

n is the number of parts

nt is the number of parts before replacing

49
Q

In the capital cost equation what does Two mean

A

Capital write off time

50
Q

In the capital cost equation what does L and n’ mean

A

L= labour cost and n’= rate at which units are produced

51
Q

What is the cost per part equal to

A

material cost per part + dedicated cost per part + overhead cost per part

Design and Manufacture 2 (5 decks)

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