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    Material Selection

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    Yousef Wally
    The document discusses three potential processes for manufacturing aluminum control quadrants, ceramic valves for taps, and plastic bottles. For the control quadrants, the viable processes identified are sand casting and die casting due to the part geometry, alloy material, and production quantity of 100-200 pieces. For the ceramic valves, the constraints of precision, surface finish, and large production quantity point to isostatic pressing as the recommended process. For the plastic bottles, the constraints of shape, wall thickness, tolerance, surface roughness and large batch size suggest blow molding as a suitable process to make the casings.

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    Material Selection

    Uploaded by

    Yousef Wally
    45 views3 pages
    The document discusses three potential processes for manufacturing aluminum control quadrants, ceramic valves for taps, and plastic bottles. For the control quadrants, the viable processes identified are sand casting and die casting due to the part geometry, alloy material, and production quantity of 100-200 pieces. For the ceramic valves, the constraints of precision, surface finish, and large production quantity point to isostatic pressing as the recommended process. For the plastic bottles, the constraints of shape, wall thickness, tolerance, surface roughness and large batch size suggest blow molding as a suitable process to make the casings.

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    The document discusses three potential processes for manufacturing aluminum control quadrants, ceramic valves for taps, and plastic bottles. For the control quadrants, the viable processes identified are sand casting and die casting due to the part geometry, alloy material, and production quantity of 100-200 pieces. For the ceramic valves, the constraints of precision, surface finish, and large production quantity point to isostatic pressing as the recommended process. For the plastic bottles, the constraints of shape, wall thickness, tolerance, surface roughness and large batch size suggest blow molding as a suitable process to make the casings.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    45 views3 pages

    Material Selection

    Uploaded by

    Yousef Wally
    The document discusses three potential processes for manufacturing aluminum control quadrants, ceramic valves for taps, and plastic bottles. For the control quadrants, the viable processes identified are sand casting and die casting due to the part geometry, alloy material, and production quantity of 100-200 pieces. For the ceramic valves, the constraints of precision, surface finish, and large production quantity point to isostatic pressing as the recommended process. For the plastic bottles, the constraints of shape, wall thickness, tolerance, surface roughness and large batch size suggest blow molding as a suitable process to make the casings.

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    © All Rights Reserved
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    Material Selection

    Sheet (5)
    1. Elevator control quadrant: - The quadrant sketched here is part of the control system
    for the wing-elevator of a commercial aircraft. It is to be made of a light alloy (aluminum
    or magnesium) with the shape shown in the figure. It weighs about 5 kg. The minimum
    section thickness is 5 mm, and – apart from the bearing surfaces – the requirements on
    surface finish and precision are not strict: surface finish ≤ 10 [m and precision ≤ 0.5 mm.
    The bearing surfaces require a surface finish ≤ 1 [m and a precision ≤ 0.05 mm. A
    production run of 100 – 200 is planned.
    (a) Itemize the function and constraints, leave the objective blank and enter “Choice of
    process” for the free variable.

    (b) Use the CES EduPack to apply the constraints and identify in more detail the viable
    processes

    2. Ceramic valves for taps: - Few things are more irritating than a dripping tap. Taps drip
    because the rubber washer is worn or the brass seat is pitted by corrosion, or both.
    Ceramics have good wear resistance, and they have excellent corrosion resistance in both
    pure and salt water. Many household taps now use ceramic valves. The sketch shows how
    they work. A ceramic valve consists of two disks mounted one above the other, spring-
    loaded so that their faces are in contact. Each disk has a diameter of 20 mm, a thickness
    of 3 mm and weighs about 10 grams. In order to seal well,
    the mating surfaces of the two disks must be flat and
    smooth, requiring high levels of precision and surface
    finish; typically tolerance < 0.02 mm and surface
    roughness < 0.1 [m. The outer face of each has a slot that
    registers it, and allows the upper disc to be rotated through
    90o (1/4 turn). In the “off” position the holes in the upper
    disc are blanked off by the solid part of the lower one; in
    the “on” position the holes are aligned. A production run of
    105 –106 is envisaged.

    1
    (a) List the function and constraints, leave the objective blank and enter “Choice of process”
    for the free variable.
    (b) Use the CES EduPack to identify

    3. Shaping plastic bottles: - Plastic bottles are used to contain fluids as various as milk and
    engine oil. A typical polyethylene bottle weighs about 30 grams and has a wall thickness
    of about 0.8 mm. The shape is 3-D hollow. The batch size is large (1,000,000 bottles),
    tolerance: 1mm, surface roughness: 10 μm. What process could be used to make them?
    (a) List the function and constraints, leave the objective blank and enter “Choice of process”
    for the free variable.
    (b) Use the CES EduPack to identify possible processes to make the casing.

    Material Selection
    2
    Sheet (6)
    1. There are three methods to manufacture an aluminum con-rod as tabulated in
    the following table.

    I. Draw (the number of components) versus (relative cost per component) for
    each process.

    II. Which process do you recommend if the number of components is 50 items?

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