Materials selection and design

A tie (tension member) of fixed length L must carry a tensile load F without yielding, and its cross-sectional area may be chosen freely. To make it as light as possible, which performance index should be maximized, with σf the yield strength and ρ the density of the material?

  1. Aσf/ρ
  2. BE/ρ
  3. C∛(σf²)/ρ
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Answer: A. σf/ρ

The condition for not yielding is F/A ≤ σf, so the required area is A = F/σf. The mass of the tie is m = ρAL = FL(ρ/σf), and since F and L are fixed, minimizing mass means choosing the material with the largest σf/ρ (specific strength). E/ρ (specific modulus) is the index to maximize for a tie whose constraint is not strength but the amount of extension, that is, stiffness. ∛(σf²)/ρ is the index for a beam in bending whose cross-section size is varied to avoid yielding; it comes from the bending stress varying inversely with the cube of the section dimension. The key point is that even for “light and strong,” the index changes with how the load is applied.

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More Materials selection and design questions

  1. A beam of square cross section with fixed length and bending stiffness is to be made as light as possible by freely varying the size of the cross section. Which performance index should be maximized, with E the Young's modulus and ρ the density?
  2. On a log–log materials selection chart (Ashby chart) with Young's modulus E on the vertical axis and density ρ on the horizontal axis, what is the slope of the guideline along which the performance index for a light, stiff beam, √E/ρ, is constant?
  3. Beams of square cross section designed for the same length and bending stiffness are made of steel (E = 210 GPa, ρ = 7.8 g/cm³) and an aluminum alloy (E = 70 GPa, ρ = 2.7 g/cm³). If the size of the cross section can be varied freely, about how many times the mass of the steel beam is the mass of the aluminum alloy beam?
  4. A tie of fixed length and tensile stiffness is made of steel (E = 210 GPa, ρ = 7.8 g/cm³, price per kg taken as 1) and of quasi-isotropic CFRP laminate (E = 70 GPa, ρ = 1.6 g/cm³, price per kg 20 times that of steel). If the cross-sectional area can be varied freely, about how many times the material cost of the steel tie is that of the CFRP tie?
  5. For a component used at a stress equal to its yield stress σy, the largest crack size that still lets it yield before brittle fracture can be estimated as a = (1/π)(K_IC/σy)² (geometry factor Y = 1). For a steel with σy = 800 MPa and K_IC = 120 MPa·√m, which value is closest to this critical crack length?