Exercise E5.5 Your task is to design a light-weight tie of length with a circular cross-section of radius R. It has to carry an axial force F, without stretching by more than 6. You will need to choose the material (with Young’s modulus E and density ) and the corresponding eross section radius to suit your choice of material, i.e. R is a ‘free variable’. (a) Show that the extension of the tie is given by O=FL/4E, where 4 =nR? (b) Rearrange this equation to find an expression for the radius R of the tie that will carry the load without excessive deflection.(a) Stress: Fun, o= é ale Q@) @ (© If the length of the tie is L=0.3m and the extension is not to exceed 0.1mm for a load of F=100N. what value of R is needed if the tie is made of: (i) PEEK: (ii) Butyl Rubber: (iii) Titanium; (iv) Copper? Use the material properties in the table below. (@ Write an expression for the mass m of the tie and determine the mass of each of the ties in (c). Which one would you choose? (©) Use values in the table below with #=1000N, 5=0.1mm and L=0.3 m. For PEEK, this gives: —e—rerevevs 1000x0.3 ° 51 = 15.9 mm ao.bao B.sx10 @ m=pAL=pzR?L. For PEEK, m=1300 2 (15.9 «10> (0.3)=0.31 ke.(e) Substitute the expression for radius R from (b) into the expression for mass._m from (d) to show that the material index to be minimised is o/E. Determine the value of the material index for the four ties. (Comment on the relationship between the mass of each beam and its material index p/E. FL FL (©) m=p7R?L_ Using (2) this gives maps |e | = (2 | So the material index to be TOE 6 le! minimized is (/E. ( The material indices are proportional to the mass of the tie, and consequently they rank the materials in the same order. For example, compare copper and titanium in the table: mg, /my, =1.6: (2) Ag)-(g) Examine Figure 5.14 to see how these three materials compare in terms of the reciprocal material index E/p. Young's Density p Radius R Mass m | Material index Modulus (kg/m?) (am) tke) we E (GPa) PEEK 3.8 1300 Butyl Rubber 0.0015 2400 Titanium alloy 110 4600 Copper alloy 120 3900(g) Selecting materials to minimize o/E is the same as selecting materials to maximize E/p. Materials with high values of £/p are furthest to the top left of Figure 5.14 above a line of slope 1. Titanium is the best of the bunch. Material | Youngs Modulus | Density R m W/E E (GPa) (kg/m?) (mm) (kg) PEEK 3.8 1300 15.9 0.31 342 Butyl Rubber 0.0015 2400 798 1440 1.6 x 108 Titanium alloy 110 4600 29 0.038 ALS Copper alloy 120 8900 28 0.067 74.2Modulus-Density Young's modulus, & (GPa)Exercise £5.60 You are asked to design a light-weight cantilever beam of length Z with a square cross- section of width b and depth b. The beam is to be built-in to a wall at one end and loaded at the free end with a point load F. The tip deflection is 6. When designing the beam, you are free to specify the b isa ‘free variable’. (@) Find an expression for the size of the beam D that can cany F with deflection 6 (b) If the length of the cantilever is Z=1m and the deflection 5 is not to exceed Smm fora load value of & to suit your choice of material, of F=1000N, what value of b is needed if the beam is made of: (i) Steel: CFRP? Use the material properties in the table below. Young's Density p | Sectionsize b| — Mass m Material Modulus ’ (am) tke) index E (GPa) Ee Steel 210 7800 Aluminium 80, 2600 CFRP 100 1500Answer, (@ The deflection ofthe cantilever beam i given by equation 8.5 with fom Figure $3. ie. oe mr ° For abeam with eos seston bb r=bth2 @ combining (1) a) ves pote sndco [BEE © iB 3E0 3B (@) Themumbers for steel are: b: [ 12(1000)° nok) =0.044m = 44mm, sGi0«10" 5107(© Write an expression for the mass m of the beam and determine the mass of each of the beams in (b). Which one would you choose? (@ Substitute the expression for beam dimension D from (a) into the expression for mass m from (c) to show that the material index to be minimised is p/E". Determine the value of the material index for the three beams. (©) The mass of the beam is m=b7Le @ For steel, m = (0.044)°(1(7800)=15.2 kg. The CFRP beam is the lightest by far: 4.2 kg. 12 1 , 12FL* aFlz? (d) Substitute for b from (3) into (4): n-| ] oo [| For steel the material index is —°— E* Gioo'f* .017.©) @ Comment on the relationship between the mass of each beam and its material index. 9/E!?. Examine Figure 5.14 to see how these three materials compare in terms of the reciprocal material index E!/ p. (©) The masses of the beams are proportional to p/E"?, so you don’t need to calculate b and m in order to know that the CFRP beam will be the lightest... just compare values of p/E!!? for the ‘three materials, The same result holds if you change the boundary conditions — for example, use simple supports instead of a cantilever... All that changes is the vaiue of C) in Figure $.3 - and that doesn’t affect the material performance index. Of course, the boundary conditions do affect the deflection — so if you have different boundary conditions, you will need to calculate a new valne for the cross section of the beam, 2. (® Selecting materials to minimize p/E"? is the same as selecting materials to maximize _B!7/p. ‘The best materials are ones nearest to the top left of Figure 5.14 above a line of slope 2. CFRP is. best followed by Aluminium and steel. It isn't surprising that aircraft wings are made of Aluminium of, more recently, CERP. Material | Youngs Modulus | Density >’ m pee E (GPa) e (kgim’) (uum) (kg) Low Alloy Steel 210 7800 44 152 0.017 Aluminium 80 2600 $6.2 8.22 0.0092 CFRP 100 1500 532 424 0.0047Modulus-Density Young's modulus, & (GPa)Exercise £7.13 You are to design ast of rising bollards" (tai, cokmns that rise up stom beneath ‘he road to provide a barrier to prevent cars from passing) The boards havea specified heat 1 and say be assimed 0 be tein atthe around (te. eanlevered). A solid cylindrical cross-section has been chosen, bathe radins & sany-be varied. Inservice te bollards are emcal and ane emppor& siven maximum load JV, applied orizontally at mid-heiah witout fale. To minimise the power Feizements for lifting the bollards, they ast be a ight os possible ami aR (&) Derive performance index. including only material properties, his should be mininized for the piven design specification. Hence select the best te muerials forthe boards fom these sven in the Table below (@) Show thar the maximum sess in a bollards given by o- A bollard of height 0.6m is required to resist a load of 4ORN at midsheight without failure. An ‘appr lini of Som is imposed on the radius ofthe bolard. Show that this sts a lower init an dhe five szes ofthe material, and if necessary. revise Sour nena election from the Table. Briefly outline two factors other than strength, which might eliminate eter of your chosen snstenil ‘Matesal Density (Mein?) | Fale sess (Pa) CHRP 16 300 Weed 06 100 ‘Mild sesh 380 Alalley 30 Conesete 80Answer. (©) Maxinm momen Mae MR aa awit () Mas m= ARE p (objective) rm. oy 22! oa subst for (ie variable) ving mass m = 21°? ary?” * Performance index: af = "2 (maximize for minim ms) ° Neveral | cre | 280 ‘Wood | 359 sel | 6s al 14 Consists | 8 | SOCFRP and wood appenethe best.2Wwl 7Rox For W=40KN, /=0.5m, R<0.05m, of 2122MPa. This rules out wood (and concrete). so the best two materials are now CFRP and Al alloy. 21 ©) op = Ty: OF RE Raw Tp = (@ Other factors: Cost — CFRP or Al alloy Corrosion - Al alloy Difficulty with fabrication ~ CFRP Fracture toughness — CFRP (and perhaps Al alloy) (Stiffness should not be an issue for either CFRP or Al alloy).Exercise E7.15 There is a plan to build an energy storage system for the London Underground rail system. The objective is to slow trains down using ‘regenerative braking’ by running their electrie motors ‘int reverse’ as electricity generators. The electricity generated by the trains will be injected back into the rail system’s power grid. A flywheel (located in a hole in the ground in central London) will be used to store the surplus electrical energy and then supply it back to the next accelerating train. The goal is to store at least the kinetic energy of a single train of mass 100 tonnes, decelerated to rest from a speed of 60 knv/h. The flywheel is a spinning dise with thickness t= 1m and radius R = 4m. (a) How much energy must be stored in the flywheel (assuming that all energy conversions are 100% efficient)? (b) Find the maximum speed @ for bursting of flywheels made of low alloy steel, GFRP and CFRP. using the property values in the table below and a safety factor of S= 2. Spinning diss (checs) be Spinning disks or rings store kinetic energy U (Figure 7.5). Centrifugal forces generate a radial tensile sess inthe disk that eaches a maximum value Analysis fa disk of density, radius R and thickness ¢ oraing at an angular ‘locity w adianssecond, gies the kinetic energy and the maximum stress (when Poissons ratio is taken 35 1/3) as 7.8) U = Foret RY and oy, = 042 pe’Answer. (a) The kinetic energy of the train, which must be stored in the flywheel is KE = >” With v= 60 knvh = 16.7 ms, and m= 100 x 10° kg, this gives: KE= +loo 108 (16.7? )=1.4» 10" J=14GI. (b) From equation (7.8). O,,4, = 0.42 po R= o,/S fee \0.420R?- For steel with R=4m and the material properties in the table: So the maximum speed is: @, | 900x108 /2 Ong = .=92.7 rad/s = 885 RPM. ms" Y'0.42(7300)47(c) Determine the corresponding stored energy U in each case, and compare with the enerey recovered from stopping the train. (@) Calculate the mass and the material cost of the flywheels. Which material would you choose? Failure stress o (MPa) Density e ken) ‘Material cost Cm (GBP/kg) U ‘Mass m (kg) Cost (GBP) Low alloy steel 900 7800 06 GFRP 190 1850 2 CFRP 700 1600 25(©) From equation (7.8), the energy stored is U Foto’ x For steel this is U (7800) (1.0) 92.77 44 =1.35 x10! J=13.5.GJ. (which is approximately right for the KE of the train). Values for other materials in table below. (d) The mass of the steel flywheel is m = 7 R? t p= ae )(.0)(7800). 392 tonnes. This is four times the mass of the train! The material cost of the steel flywheel alone (not including the cost of the bearings. drive system, the housing. and all the construction, ete) would be C= mC,, = 392.000 0.6 = 235,000GBP. Values for other materials in table below.Failure stress | Density | Material cost e Mass m | Cost a (MPa) | p (kg/m) | Cy (GBPIkg) | (rad/sec) | ( (Mz) | (GBP) Low alloy steel 900 92.7 302 | 0.23: GFRP 190 5 87.4 92 CFRP 700 180 5 80 The steel flywheel is very heavy and nuns relatively slowly, but is by far the cheapest. Of course the bearings to support such a heavy flywheel might be very expensive. The GFRP isn’t up to the jab — it can’t store enough energy at this size — you would need to increase the size significantly. The CFRP is much lighter and faster than the stzel, but much more expensive, It can almost store all the energy at this size — so some adjustments to the geometry would probably get it up to specification. CFRP ‘would be significantly better for use on a moving vehicle, where mass would be important, but would not be a good choice here.