MECN2010 assignment 2663541

MECN2010: Assignment, 1st Semester 2024

Tumelo Mantame, 2663541

INTRODUCTION & BACKGROUND

A company has reached out for assistance in improving its underground mining machine
fleet and possibly reducing costs. This work will focus on the material selection process for
improving two components of their CATR1700, namely its bucket dump and braking system.
The material selection process will also aim to reduce company costs in its fleet
improvement without compromising component functionality. The brake system used in the
CATR1700 is a Full hydraulic enclosed wet multiple-disc braking system. Hydraulic braking
systems use hydrostatic pressure to slow the vehicle motion(Automotive Training Centres).
The brake components discussed are the friction and spacer plates. Friction plates are
circular components that press against the brake disc(Ferodo). Spacers' function is to
prevent any significant or damaging friction between the friction plates and disc (CATParts)
by being placed between the two components. Improving the brake components may lead
to the overall system improving. These improvements could lead to improved energy
efficiency and resistance to wear and tear of the braking system. Improved energy efficiency
would mean less energy, diesel in this vehicle, would be required to slow the machine(CAT).
Increased resistance to wear and tear would mean less maintenance and downtime, thus
reducing costs, due to a longer life cycle. The bucket dump may be improved in different
ways to aid the optimization of the truck. The first improvement would be to select a
lightweight material as a lighter bucket would be able to carry greater loads without
impacting the truck's functionality according to Gupta(2010). A greater payload capacity
would result in improved productivity in the mine. Another improvement that may be
considered is improving the bucket's wear resistance. A material with great wear resistance
and hardness gives leeway to a lighter bucket therefore increasing its payload capacity
for reasons previously discussed and according to Fiscor(2020) an "improved bucket life".

METHEDOLOGY

The material selection methods considered were the ASBHY and the decision matrix
methods. The Ashby method, named after Michael F. Ashby, is a material selection process
that consists of four distinct steps. The first step, translation, describes the process of setting
out any design constraints that will be considered during the selection process. This step is
where the functionality of the part being discussed will be defined concerning the material
selection. The second step, screening, is where material candidates that fail to meet the
translation requirements will be disregarded. The following step is to rank the materials that
passed the screening process. The ranked materials are then documented with all their

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attributes so that in the event of having to reconsider the selected material the other
shortlisted candidates are documented. The selection process used in this report,
however, is a decision matrix. A decision matrix is a selection process where a set
of important considerations must be laid out and weighted according to their
importance. This importance or weight is determined by the reporters( Salmeron,
Smarandache: 2010). The next step in the decision matrix method( DMM ) is to tabulate the
alternative materials and compare them according to the set considerations. This is known
as the decision matrix. The following step is to assign the materials points for their different
attributes. To determine a material's total score, multiply its points by the corresponding
attribute's weight and tally. The properties that will be weighted heavily will be cost, local
availability, and load capacity for the bucket load. There are many costs to consider in the
material selection process such as raw material, manufacturing, and life-cycle
costs(Technosoft, 2024). In this report, the first two costs will be discussed while aiming to
maintain material quality without significant compromise. The load capacity of the bucket
dump is incredibly important as the main functionality of the bucket is to carry an extreme
load, especially considering its environment. A compromise between a lower cost and load
capacity and durability or fatigue resistance may have to be met.

MATERIAL SELECTION

The chosen vehicle is the CATR1700, an underground mining truck used to dig, load, haul,
and dump mined materials. The loader uses a bucket dump attachment, with a payload
capacity of 16.5 tons, to carry out its main functionalities alongside its hydraulic system that
controls the bucket as it carries out these functions. A wet disc braking system was best
suited for the environment as the hydraulic fluid used, oil, is corrosion resistant and
prevents parts of the system from corroding (Stage, 2010). This brake system is best used
for heavy-duty applications as it is an internal system. Factors that could affect the system
include "excessive water, dust, mud, and moisture" - (KNOTT). Brakes in the truck hold it in
place when stationary, especially on slopes and inclines, and allow for precision and control
of the loader's maneuvers, and are responsible for abruptly stopping the loader in
emergencies.

Typical materials used for friction plates in heavy-duty applications and wet disc systems are
friction materials or wet friction materials(WFM). The function of a spacer in a brake pad is
to separate discs to allow for their free movement when the brakes aren't in use or
engaged(Stratson,2020). According to Borawski(2020), brake pads consist of three tiers, the
back plate, the underlayer, and the friction plate or material. The friction materials also
consist of multiple layers namely the binder, reinforcement, filler, and
abrasive. The properties that will be discussed for the various material options in the
decision matrix(Fig 1.) are the coefficient of friction, wear resistance or fade resistance, and
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stability at varying temperatures and pressures (Roymech). The following binder

materials were considered: phenol, silicon, COPNA, cyanate ester, and metal matrix
resins. Aramid(Kevlar) and glass(fiber) were reinforcement materials considered with barite
and fly ash being filler considerations. The abrasive materials discussed are boron, graphite,
titanium, brass, and steel. Spacer plate desirables that will be considered (fig 2.) are fatigue
resistance, high tensile strength(BONOSS, 2022), and the ability to withstand high pressures
and temperatures. The materials compared are brass(free cutting, C36000),
aluminum(6061), and stainless steel(304 Austenitic).

Binder

Material Coefficient Wear/Fade Pressure Varying Cost Crack Total

of friction resistance(5) stability(5) temperature (5) resistance (141)
(5) stability(4) (5)
Phenol 4 5 4 4 4 2 111
resin
Silicon 3 4 4 4 1 4 100
resin
COPNA - 4 - 3 1 - 40
resin
Cyanate 3 4 4 4 1 3 95
ester
resin
Metal 3 4 3 3 - 4 85
matrix
resin
Figure1. Decision matrix for the binder layer of the friction plate

The binder decision matrix(Fig.1) has a total score of 141 points where all the properties but
high temperature(4 points) out of 5 points each. The material with the highest score is
phenol resin. The reinforcement aramid(kevlar), according to Borawski(2020), has high
durability and resistance to high temperatures. It has great resistance to wear, because of
its high tensile strength (Final materials). Despite this material's high coefficient of
friction(Final Materials), it cuts that of the WFM almost by half. The second reinforcement
option, glass, has a low coefficient of friction(COF) and high resistance to wear unless the
fibers are exposed. It is also creep, heat, and crack-resistant. Another advantage is its low
production costs. The decision matrix for the filler layer(Fig.2) is out of 91 points and both
materials have 56 points. Boron can reduce the wear rate of the brake pad due to its wear
resistance resulting from its hardness. Boron also aids in increasing the COF of the brake
pads, but only at temperatures below 100 degrees(Celcius) as it decreases
rapidly thereafter. Graphite has lower costs, but because it is a lubricant it decreases the
COF. Titanium can increase the COF through a stabilizing film on the exterior of the friction
plate, leading to better wear resistance and therefore lower brake fade. The downside of
titanium usage is the cost of the metal. Brass is also an expensive metal as it is an alloy.
Brass stabilizes the COF, but because it is lubricant it also decreases it. Steel increases the

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COF, is resistant to increased temperatures, and is inexpensive. Its disadvantage is that its
adhesion properties can lead to brake disc scratches.

Filler

Material Coefficient of Wear/Fade Varying temperature Cost (5) Total

friction (5) resistance(5) stability(4) (91)
Barite 2 (reduces COF of 2 (accelerates 4 4 56
WFM) wear of brake
pad)
Fly ash 3(suitable for low - 4(properties remain 5(extremely 56
speed stops- unchanged) cheap as it is
reduces COF mining waste)
significantly if truck
stops abruptly from
speeds >100km/h)
Figure 2. Decision matrix of the filler layer of the friction plate

The spacer plate decision matrix(Fig.3) was out of 31 points, with three out of the four
properties being out of 3 points. The aluminium and stainless steel both got 31 points.
Upon further comparison using the Makeitfrom database to compare the two materials'
base metal costs, the aluminium was less costly and more lightweight contributing the
decrease in the friction plate's weight. That is why aluminium is the chosen spacer plate
material.

Spacer

Material Fatigue Tensile strength High High Total (31)

resistance (3) temperature pressure
(3) resistance (2) resistance (3)
Brass (C36000) 2 UTS = 469MPa 2 2 25
Yield = 310MPa
3
Aluminium(6061) 3 UTS= 310MPa 2 3 31
Yield= 276MPa
3
Stainless 3 UTS= 621MPa 2 3 31
steel(304) Yield= 290MPa
3
Figure3. Decision matrix for the spacer plate materials

For the bucket dump, the material that is most likely currently in use is the 400HB
steel. This may be the case as it is not only an incredibly hard material, but it is also
considered to be "specifically engineered to withstand wear and abrasion" -
P&DNorthernSteels. A decision matrix(Fig.4) will be used to compare other typical materials
to the 400HB steel. These materials are the AR500, AISI D2, 826M40(EN26), and
835M30(EN30B) steels. The desired properties for the bucket were dent resistance,
durability, operational temperature, abrasion resistance, payload capacity, impact

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resistance, corrosion resistance, cost, and local availability. Payload capacity

was considered, and weighed 5 points in the decision matrix, as the bucket's main
functionality is to carry a load. The cost and local availability of the material are also
weighted 5 as this work is focused on reducing current costs. The other properties were
considered due to the bucket's application and environment in an underground mine
several meters below the ground.

According to Figure 4, the steel with the most points is 835M30(EN30B) with 112 points out
of the 143 available points. It is closely followed by AISI D2 with 108 points, but this steel is
not typically used in the application of this report but rather as a knife, blade, or
cutter. Another material that was not selected is the 826M40 due to costs, the cost to
quench it to improve its abrasion-resistant properties, and the cost of the material itself due
to its alloying content. If the AR500 was available in South Africa, or if costs weren't such
a big consideration it would've been the steel of choice. This is because it has better
operational temperature and impact-resistant properties. The AR500 steel has additional
costs such as treatments for corrosion resistance and importing it from outside South
Africa.

Bucket Dump
Materials Dent resistance(3) Durability(3) Operational Abrasion resistance(3) Payload Capacity(5) Impact Corrosion Cost(5) Local Total(
(steels) Temp(4) resistance(3) resistance(4) availability (5) 143)
400HB HB=400 3 3 3 Yield=1100MPa 35J Would need Specialised MACSTEEL 106
3 UTS=1350MPa 3 treatment steel 5
3 2 2
AR500 HB>=450 3 4 3 Yield=1380MPa 27J Would need Specialised Not 102
3 (stable at UTS=1550MPa 2 treatment steel but due supplied in
both high 4 2 to high South
and low abrasion it Africa
temperat requires less 2
ures maintenance
3
AISI D2 HB=592 3 3 3 Yield=2200MPa 28J Contains 4 ZEES KNIFE 108
3 (compressive) 2 chromium SUPPLIES
3 3 3
826M40 HB>=444 3 3 3 Yield=1235MPa >11J 2 High alloy MACSTEEL 101
3 UTS=1550MPa 1 content 5
4 2
835M30 HB>=444 3 3 3 Yield=1125MPa 20J Contains 3 AMBRO 112
3 UTS=1540MPa 2 chromium STEEL
3 3 5
Figure 4. Decision matrix of the Bucket dump

To further compare AR500 and 835M30 a couple of stress calculations were done to
determine the safety factor of each of these materials. Equation 1 shows us that force(F) is
equal to mass(m)multiplied by acceleration due to gravity(a). The following equation(2) is
used to determine the area of one of the bucket's sides assuming it's a rectangular or
geometric prism that would follow volume(V) is equal to the product of the height(h),
length(l), and width(w). The technical specifications of the loader specify the volumes of its
various bucket sizes, the standard bucket was used in these calculations. The values
determined from Equations 1 and 2 are used in Equation 3, yield stress(Y) which is the

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quotient of force(F) and area(A). The final calculation uses the yield strengths of the
materials as the design stresses and the value of Equation 3 as the maximum stress to
determine the safety factor(Equation 4). It is important to note that these safety factor
values are for one panel/side of the bucket and not the entire bucket dump.

F = ma …[1]

= 15000kg x 9.81m/s^2

= 147150N

V=wxlxh …[2]

5.7m^3 = (2.83m)lh

2.014m^2 = A

Y = F/A …[3]

= 147150/2.014

= 73063.55511 MPa

Safety Factor = max stress/design stress …[4]

SF(AR500) = 73063.55/1550

= 47.14

SF(835M30) = 73063.55/1540

= 47.44

The materials chosen in this report are the phenol resin, glass, fly ash, and steel for the
binder, reinforcement, filler, and abrasive respectively in the friction plate. The chosen
material for the spacer plate is aluminium(6061). The bucket dump's new material will be
the 835M30 steel.

MATERIAL SELECTION ASSESSMENT

The change in materials for the two components doesn't depreciate the vehicle's
performance and design. The bucket dump's new material is suitable for the environment in
which it's applied. It has high abrasion resistance, which is desirable as its load will be mined
material that will most likely be abrasive as it will be raw material. This steel's high hardness

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also affects its durability, a highly desirable trait as this machinery is expensive, and having
to do maintenance or part replacements often will get extremely costly. It also had high-
temperature stability, a desirable property due to the underground environments reaching
temperatures of over 52 degrees(Celcius) which results in even higher machinery
temperatures(University of Arizona,2021). Its 4.5% Nickol-Chromium-Molybdenum
properties allow it to be corrosion-resistant steel without additional treatments that would
add to the cost. The previously calculated safety factor assures the bucket won't fail in its
high-stress environment. For the brake components, the material selection process focussed
heavily on properties best suited for a heavy-duty application. The properties that the
materials were based on were their coefficient of friction(COF) or their effect on the friction
plate's COF. Wear resistance was also considered as it assures the functionality and
longevity of the friction plates. The phenol resin was chosen not because it had the highest
points overall but was scored favourably for the heavily weighted properties, wear and fade
resistance, cost, and COF. The glass and aramid had similar properties, but the glass was
chosen as a result of the aramid compromising the COF of the friction plate. Fly ash is stable
at high temperatures, has a good COF, is extremely cheap, and is lightweight.
These properties made it the better option as barite decreases the COF.

The first limitation faced during the research and material selection process was not having
access to the database(s) on Granta. This led to cross-referencing with multiple sources and
smaller databases leading to accurate information. The next challenge faced was the lack of
information on the current materials that the components of the vehicle were
made of and this was a greater challenge than the first. It meant that would not be a control
variable that alternative materials could have been compared to directly, rather these
alternatives were compared to one another. The third limitation was the lack of detailed
sources for friction plates, their structures, and materials, particularly in a mining and heavy-
duty context.

CONCLUSION AND RECOMMENDATIONS

The use of multiple databases and data sources led to a more well-rounded set of
information with factors that affect your data and information, is the first recommendation.
The reporter also recommends that in a similar report ensure that there is a control material
that is the baseline for comparison with the alternative materials. The last recommendation
would be to make educated and knowledgeable assumptions and guesses, just as they did
by assuming that the bucket dump was made of 400HB steel. The bucket dump material
selection process successfully avoided a compromise on quality to save on costs as the
EN30B had similar and sometimes better properties than the 400HB steel. Both the friction
and spacer plates now have materials that add value to their functionality and that of the
mining loader. The reporter was able to maintain cost considerations for both the bucket
loader and brake components whilst adding value to the vehicle and the company.

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REFERENCES

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MECN2010 assignment 2663541

 400HB Steel | Huge stock | Great prices | Quick delivery (2024). [Online] Last
accessed at: https://pdnorthern.com/products/400hb-steel/. Last accessed:
20/05/24
 6061 Aluminum vs. AISI 304 Stainless Steel :: MakeItFrom.com (2020).
https://www.makeitfrom.com/compare/6061-AlMg1SiCu-3.3214-H20-A96061-
Aluminum/AISI-304-S30400-Stainless-Steel. Last accessed: 20/05/24
 Admin and Admin (2024) 'Metal Strength Chart: A detailed guide to metal strengths -
EZIIL - Best Metal fabrication software,' Eziil - Best Metal Fabrication Software -
Järgmine WordPress veebileht,. https://eziil.com/steel-strengths/. Last accessed:
20/05/24
 AR500- Hardness 477-534 Brinell – Steel Warehouse (no date.) [Online] Last accessed at:
https://www.steelwarehouse.com/ar500/ last accessed: 20/05/24
 AR500 (no date). https://www.leecosteel.com/ar500-500f-steel-plate/. Last
accessed:20/05/24 Atc (2024) The advantages of hydraulic braking systems
explained for those who want to become an auto mechanic. [Online] last accessed at:
https://www.autotrainingcentre.com/blog/advantages-hydraulic-braking-systems-
explained-auto-mechanic/. Last accessed: 20/05/24
 Aramid Fibre (no date). https://www.final-materials.com/gb/21-aramid-fibre. Last
accessed: 20/05/24
 Atc (2024) The advantages of hydraulic braking systems explained for those who
want to become an auto mechanic. [Online] last accessed at:
https://www.autotrainingcentre.com/blog/advantages-hydraulic-braking-systems-
explained-auto-mechanic/. Last accessed: 20/05/24
 AZoM (2024) Advanced surface treatments of steel for enhanced corrosion
resistance. https://www.azom.com/article.aspx?ArticleID=23551. Last accessed:
20/05/24
 Borawski, A. (2020) 'Conventional and unconventional materials used in the
production of brake pads – review,' Science and Engineering of Composite Materials,
27(1), pp. 374–396.[Online] last accessed at: https://doi.org/10.1515/secm-2020-
0041. Last accessed: 20/05/24
 EN26 High Tensile Steel | Interlloy | Engineering Steels + Alloys (no date).
https://interlloy.com.au/our-products/high-tensile-steels/en26-high-tensile-steel/.
Last accessed : 20/05/24
 EN30B Round bar Supplier in India | National Steel Industries EN 30B Exporter (no
date). https://www.nationalsteelind.com/en30b-round-bar-supplier-and-
manufacturer. Last accessed: 20/05/24
 Gupta,S. (2013) Lighter and better bucket. [Online] last accessed at:
https://contest.techbriefs.com/2013/entries/machinery-and-equipment/3725. Last
accessed: 20/05/24

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 Hillfoot (no date) 835M30 through Hardening Steel | EN30B | Hillfoot.

https://www.hillfoot.com/products/835m30-45-nickel-chromium-molybdenum-
through-hardening-steel. Last accessed: 20/05/24
 Macsteel (no date) PRODUCT CATALOGUE SPECIAL STEELS.
 Metal, F. (2023) 'Key factors to consider when choosing an aluminum alloy for press
brake,' Fuse Metal, [Online] last accessed at: https://fusemetal.com/key-factors-to-
consider-when-choosing-an-aluminum-alloy-for-press-brake-forming/. Last accessed:
20/05/24
 Multispace & Multistructure. Neutrosophic Transdisciplinarity (100 collected Papers
of Science) (no date).[Online] last accessed at: https://books.google.co.za/books?
hl=en&lr=&id=nK3dBAAAQBAJ&oi=fnd&pg=PA151&dq=decision+matrix+method&ot
s=CO-wMTth49&sig=YEfpt-
d63xpiv_aLsEDLjCfdC7k&redir_esc=y#v=onepage&q=decision%20matrix
%20method&f=false. Last accessed: 20/05/24
 Online materials information resource - MatWeb (no date). https://matweb.com/.
Last accessed:20/05/24
 Phenolic Novolac And Resol Resins - Phenolic thermosetting resin (no date).
https://plenco.com/phenolic-novolac-resol-resins.htm. Last accessed: 20/05/24
 Turning down the heat (no date). https://minerals.arizona.edu/research/heat. Last
accessed: 20/05/24
 Technosoft (2024) Material selection in manufacturing process to reduce cost.
[Online] last accessed at: https://technosofteng.com/material-selection-in-
manufacturing-process-to-reduce-cost-in-engineering/. Last accessed: 20/05/24
 Valverde, M. (2020) Abrasion-resistant materials protect high-wear zones. [Online]
last accessed at: https://www.coalage.com/departments/operating-ideas/abrasion-
resistant-materials-protect-high-wear-zones/. Last accessed: 20/05/24
 Virat (no date) AISI D2 | AISI D2 Tool Steel | AISI D2 Cold Work Tool Steel.
https://www.viratsteels.com/aisi-d2.html. Last accessed: 20/05/24

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Disclosure – Use of Artificial-Intelligence (AI) Generated

Content 2024 V2

Students must acknowledge all use of AI.

Select all applicable statements and complete the sections fully. Delete all
statements that are not applicable.

1. Disclosure: No AI use

I acknowledge that no AI tools/technologies (Grammarly, ChatGPT, Bard,

Quillbot, OpenAI etc) were used in the completion of this assessment.

2. Disclosure: Editing/refining grammar, spelling, formatting

✘ I acknowledge the use of Grammarly, version 2024(free subscription), May,

2024 () to improve the explain used to edit and refine my report by editing
grammar and spelling. I uploaded the text for my MECN2010 Assignment, and I
entered the following prompts on Date, Month, Year:

Original prompt: " Paste the prompt"

Follow-up prompt: " Paste the prompt"

The output from these prompts was used to state what action was made using
the output.

3. Disclosure: Generated/manipulated text – list each occurrence

✘ I acknowledge the use of Poe, webpage and app, May, 2024

(https://poe.com/s/UMn3W6TevVqGgO9vWJQf) to have a starting point for my report – guidance for an

approach. I entered the following prompt on 14, May, 2024:

"Create an outline of how my report could look including materials that could be
selected as part of the report "

The output from these prompts was used as a guide for how to approach the
report and ideas of points to cover.

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I acknowledge the use of Scribbr, webpage , May, 2024 (

https://www.scribbr.co.uk/referencing/generator/folders/5nVy75BlREF5htt3eAXkDt/lists/
1RI6m6xM6TlxI8A467ZSlE/f) to generate part references for my assignment. I entered the following
prompt on 14, May, 2024:

"Paste the prompt "

The output from these prompts was used as a basis for my references but not
the full reference

4. Disclosure: Generated/manipulated image – list each occurrence

I acknowledge the use of XYZ, version, Month, Year (web url) to explain what
you used AI for. I entered the following prompt on Date, Month, Year:

" Paste the prompt"

The output from these prompts was used as explain what the image was used
for.

5. Disclosure: Generated/manipulated code – list each occurrence

I acknowledge the use of XYZ, version, Month, Year (web url) to explain what
you used AI for. I entered the following prompt on Date, Month, Year:

" Paste the prompt"

The output from these prompts was used as explain what the code was used for.

✘ I declare that the disclosure is complete and truthful.

Student number: 2663541

Course code: MECN2010

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Date: 20/04/2024

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