KEVOS® MAKEOS · Materials
Panel Material Substitution (Equal Stiffness and Strength Thickness, Mass, Cost)
If I change this plate or panel to another material, how thick must it be to keep the same stiffness and strength, and what happens to weight and cost?
Substitution of a bending plate, cover or panel with another material: the thickness for equal bending stiffness and for equal bending strength, the governing thickness (as the equivalent stiffness thickness tool), mass per square metre and cost of the original and the new panel, the panel mass and cost over its area, and checks against the thickest stock available and whether the change saves weight.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Original thickness | mm | Thickness of the existing panel. |
| Original modulus | GPa | Elastic modulus of the existing material. |
| Original allowable stress | MPa | Allowable stress of the existing material. |
| Original density | kg/m³ | Density of the existing material. |
| Original material price | $/kg | Price of the existing material. |
| New material | ||
| New modulus | GPa | Elastic modulus of the new material. |
| New allowable stress | MPa | Allowable stress of the new material. |
| New density | kg/m³ | Density of the new material. |
| New material price | $/kg | Price of the new material. |
| Thickest stock available | mm | Thickest sheet or plate of the new material you can get. |
| Panel area | m² | Area of the panel. |
Method and formulas
- Equal bending stiffness: t₂ = t₁ ∛(E₁ ÷ E₂); equal bending strength: t₂ = t₁ √(S₁ ÷ S₂); the larger governs (as the equivalent stiffness thickness tool).
- Mass per m² = density × thickness; cost = mass × price.
- Panel mass and cost = per m² × area.
- Example: the new panel must be 2.838 mm (stiffness 2.838, strength 2.582 mm); it weighs 48.806% of the original and costs 57.469 $ against 47.1 $.
Limitations
- Bending of flat panels; in-plane loads and buckling scale differently.
- Same shape and supports; ribbing or forming can save more than thickness.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Swap a steel cover for aluminium or plastic
- Estimate weight saving from a material change
- Check a plastic guard against the steel original
Who it is for
- Design engineers
- Product designers
- Value engineers
What you get
- Thickness for equal stiffness and for equal strength
- Mass and cost per square metre, old and new
- Panel mass and cost
Interpreting the result
- Lower-modulus materials need disproportionately more thickness for stiffness, so weight savings are smaller than density alone suggests.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 575–580. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
Open the Panel Material Substitution (Equal Stiffness and Strength Thickness, Mass, Cost) calculator
