Theoretical Exploration and Application Cases

Discuss about the Theoretical Exploration and Application Cases.

The chain catcher is a component of a chainsaw which is positioned between the body of the saw and the cover of the clutch. The chain catcher in most of the  cases looks like the  hook which is made up of the steel. The function of the chain catcher is to stop the chain especially the time the chain derails out from the bar , then the length of the chain shortens. The moment derailing the chain swings, and the derailing happens beneath the saw and also in the direction of the machinist or rather the operator. In addition, the process of shorting occurs in order to prevent the operator to be hit by the chain and rather, the chain hits the rear handle guard which is found on the rear part of the chainsaw. According to (Njiruth, 2017),This practically means tat the chat catcher blocks the chain from being terrified  to the direction of the user.       

The traits that was based on the material was also put into contemplation at the time the chain catcher was manufactured, some of the traits that were put into considerations includes the following;

The durability of the material : this particular factor was also considered during the making of the chain catcher. The core reason for the durability as a factor to be considered was to make sure that the loss of strength of the material is reduced in a large amount.

The ductility of the material was too considered , this is in order to enable the material which was used from in the making to be shaped with ease to a share which is desirable without distressing the strength of the material by the tensile forces

Reliability was the factor also which was highly considered in this case during the manufacturing of the chain catcher, this is according to (Kalpakjian Schmid, 2014). The reliability assists to make sure that the materials which were used in the process of manufacturing the chain catcher might sustain the extreme distress the could not exceed the elastic limit.

What are the material property constraints and objectives that would be required (you may use assumptions for the exact values of these properties.

In the manufacture of the chain catcher, most ordinarily utilized materials used include the following:

The steel, aluminum, titanium and also the carbon from fiber. Steel, aluminum and titanium are having   a kind mixture of traits which  are very vital in this talk. The steel is comprised of a third the thickness of aluminum, a third too of the quality of aluminum. The chain catcher was made utilizing the steel and aluminum which was to have a weight which is worthy comparison. The steel also comprises of the normal a third of the structural quality of the aluminum. Keeping into consideration how heavy aluminum is compared to steel,  thrice the bits of steel will be utilized in order to manufacture aluminum. According to (Russell & Vunji, 2013), The steel has the volume of 2/3 as the volume of aluminum provided that the weight is consistent.

In manufacturing of the of chain catcher, engineers are tested when outlining the chain catcher. The engineers are needed to guarantee that the chain catcher turn out to be marginally more slender as the breadth stays consistent. This is in order to educated that the thickness regarding the edges ought to be approximately 0.6mm. A diminishing in this could be awful as the chain catcher can undoubtedly clasp out and because of the weight and the landscape of the chain catcher, vibrations will build, unwavering quality will be traded off and henceforth gouging will happen. The pliable powers will surpass as the thickness won't have the capacity to prevent it from achieving as far as possible

Some of the constraints which are in this particular case  deliberated amid the choice of the material which are supposed to be utilized amid the process of  manufacturing incorporate solidness so they can oppose the forces due to tension,  which has desired ability and the strength with can endure pressure , the conductivity rate, the rate that the material can withstand conduction of electricity, comparatively very high price is costed in the process of manufacturing and also relative high weight.

According to (Yellishetty, et al., 2011),The objective which are highly considered during the manufacturing of the chain catcher is in order to make sure that the final cost of producing the chain catcher is low, that the ultimate weight of the chain catcher is low, that the volume that the material which was used is reduced, that the impact of the chain catcher to the environment is low and also the heat loss process is quick and therefore reservation of energy is hence increased.

Therefore, during the production of the chain catcher, it becomes very much important to put the limitation of the weakness into consideration that the chain catcher will be tested during its process of utilization.

The Steel isn't generally impacted by exhaustion, rather, it can drive forward through any weight which is in association with it completed a long extend of its use. On the other hand, the aluminum hardly continues on through the weariness that is associated with it. This uncovers the reason in the matter of why it is imperative to make it with extra quality of strength, one third or what is used as a piece of steel. Robustness as an impediment in the manufacture of the chain catcher is in like manner put into consideration. This goes for giving the impetus for trade out of the offering by recovering the cost of creation.

The limitations which are normally  put into consideration amid the choice of the material to be utilized ,amid the manufaturing process incorporate solidness so they can oppose pressure, have enough quality, capacity to withstand unfriendly pressure, the rate of conductivity, the rate at which it can oppose electrical conduction, moderately high cost is brought about amid assembling and the weight is generally high. The targets that are considered amid assembling include: guaranteeing that the cost of generation is low, guarantee that the weight is low, lessened volume of material utilized, low effect to the earth, snappy warmth misfortune and expanded vitality reservation.

When fabricating the bike forks, it is essential to consider the weariness imperative that the bike will be tested through amid its use. Steel is not really influenced by weariness. It can persevere through any pressure that is connected to it finished a long stretch of its utilization. Then again, aluminum scarcely bears the weakness that is connected to it. This discloses the reason regarding why it is essential to manufacture it with additional quality, 2/3 or what is utilized as a part of steel. Toughness as a requirement in the fabricate of the chain catcher is likewise put into consideration too. This goes for giving the incentive for cash in the offering by recuperating the cost of generation.

Consider these attributes, constraints and objectives in undertaking a basic material selection using level 2 of the CES software to initially identify what materials could be used for the component, and then to ultimately identify what you consider to be the best choice.

The material utilized in the carbon fiber contains  focal points of being very light in the general weight, the material assimilates stun better contrasted with aluminum, the material is moderately tough contrasted with aluminum and also  the simplicity of manufacturing  is generally great. It is so much disadvantageous in being costly to produce and it is unfixable when it gets harmed.

Aluminum is impervious to rust ,light in weight, modest in buying subsequently diminished cost in manufacturing, is also solid thus being sturdy and it goes on for a sensible timeframe. It is disadvantageous because of its decreased quality when contrasted with steel and has the most brief exhaustion life when contrasted with titanium, carbon fiber and steel. The sensible weight of titanium make it justified since it very difficult to deal with titanium, the material barely falls flat or lessened mechanical conditions will influence it and it is free from wearing away. In any case, its strength is generally low than that of the steel and its moderately overwhelming when contrasted with aluminum. Steel has a high elasticity and has a long life expectancy when contrasted with the above. Its fault is because of its weight that is impressively high and its capacity not to oppose consumption.

The data which is found in the table below was taken from the CES program software, but steel is having the least price with a high young modulus, hence when making the choice, I will lean on the steel since apart from the above reasons, it is very common and widely used in the making of the chain catcher.

Materials/Properties	Young’s modulus	Cost	Fatigue Strength at 10^7
Carbon fiber	150 GPa	44.5 $US/kg	300 Mpa
Aluminium	82 GPa	2.49 $US /kg	157 Mpa
Titanium	120 GPa	26.2 $US /kg	600 MPa
Steel	217 GPa	0.664 $US /kg	700 MPa

Based on the material you ultimately selected in question 2 for your component, use level 2 of the CES software to identify all of the manufacturing processes that could be used to make that component.

The production of steel is made up of the stages which are intricate in the making process of the steel. The initial process of which intricate slating the raw material in order to get the molten steel is the iron making,  this molten steel can be easily precast in much different shapes of the chain catcher.The most basic process of making steel is the second phase where oxygen gas  is pushed inside the metal in order to remove any carbon gas.

The auxiliary process of manufacturing steel includes endeavoring to filter the liquid steel. Literally this can be accomplished through the expansion or rather the evacuation of segments that makes up the whole structure of the steel. For this, it incorporates blending, scoop heater, spoon infusion, degassing and exchanging the organization of the liquid iron through blowing oxygen through it. The consistent throwing process may include shaping the liquid steel into thin shelled structures so it can harden. At the time of hardening, the tubing's are decreased into the coveted lengths as indicated by the determinations. Essential framing includes forming of the cast steel into various shapes as per the determinations of the chain catcher.

The chain catcher is finally manufactured and fabricated, also the peripheral beautification is done so that to appeal to the clients.

Choose two of the manufacturing processes that could be used for your component and explain why you believe them to be most suitable (clearly state any assumptions you have made to reach your conclusion (Welding and brazing)

According to  (Yellishetty, et al., 2011),As parts which are molded above are ready being sued in the process of manufacturing the chain catcher, the parts will therefore be shaped into the shape which can be fitted to the chain catcher, this is very much. The chain catcher is fitted in such a way that it can be comparted between the brake and the rear guard. The chain catcher can be painted if need be.

Find a resource/s online that details/outlines the key equipment and steps involved in each of the two processes. Use this to construct a process map or flow chart for each manufacturing process.

Most of the resources which are relevant and therefore required in the making of the steel includes the following: the coke, cast iron and the line that are heated in the furnace of blast in order to melt them. This process intricate in the process of welding involves the connection of various parts which were made out of the cast iron. The process of tubing is attained by being rammed by the use of mandrel and the die. The tubing which is butted is hydro formed into a chain catcher balde geometry

According to (Yellishetty, et al., 2011),It is then galvanized at a temperature of  865⁰c before being oil slaked. It is then back alleviated at 570⁰c before cooling at room temperature It is then shipped.

According  (Rando, et al., 2002)Brazing is a procedure that goes for reinforcing the metals that have been consolidated. Assets required amid brazing incorporate the filler, extra metal and a heater that will be utilized to warm the metals and the filler together. The joining must stick to great fitting that will empower appropriate narrow to happen. The metals will then be cleaned so fine will occur. The parts will then be fluxed before the metal will be collected for brazing. In the wake of brazing, the region is cleaned with the goal that it can acquire a spotless surface territory.

Use Microsoft excel and the cost equation below to construct a plot of the cost per component versus the number of components for both of the manufacturing processes for a range of production volumes from 1 to 100,000..   

Identify which of your processes is the most cost effective for the range of production volumes examined

As per ces software , the unit cost for;

Aluminium  is 2.49 + 315 / 5 + 210 / 12 =  83.0

Carbon is 44 + 315 / 5 + 210 / 12 = $124.5

Steel is 0.664 +315/6+210/13= 69.4

Titanium is 26.2 + 315/4 +410/12 =138.2

According to (Okuku & Vaughn, 1994) The steel in this case is the most competent metal which can be used in the making of the chain catcher, the steel is available readily too. The whole process of molding is also achievable since the tool which is used in the process is also available widely. Steel also is very much available as compared to carbon, aluminum and also titanium. It is also highly versatile as contrasted to the other materials.

Calculate the impact of doubling the production rate for a production volume of 10,000 components. Suggest and briefly explain one practical method to significantly increase the production rate of your process without the need to buy additional capital equipment

Effect of multiplying the creation rete of a volume of 10000 parts. The creation rate can be expanded by expanding the time that has been designated for the assembling of the bike forks. The rate can likewise be expanded by expanding the quantity of things that should be made (Ramakuv & Feng, 2016). This is encouraged by the rebate that is given when the heap being created is moderately high contrasted with when one produces a couple of bits of the bike fork. Utilization of current innovation e.g. the shoot heater rather than the customary incinerators helps in diminishment of cost of task.

Utilizing the table gave by Ces, we will expand the generation rate by 10.000

Materials/Properties	Young’s modulus	Cost	Increased production rate by 10000
Carbon fiber	150 GPa	44.5 $US/kg	445000$US/kg
Aluminium	82 GPa	2.49 $US /kg	24900$US/kg
Titanium	120 GPa	26.2 $US /kg	262000$US/kg
Steel	217 GPa	0.664 $US /kg	6640$US/kg

References

Kalpakjian Schmid, K., 2014. Manufacturing engineering and technology (p. 913).. Upper Saddle River NJ , USA:: Pearson.

Njiruth, R. W., 2017. Integration of continuous caster and hot strip mill planning for steel production. Journal of Scheduling, 3(4), pp.185-208.. s.l.:s.n.

Okuku & Vaughn, 1994. Steel production: processes, products, and residuals. Routledge.. s.l.:s.n.

Ramakuv & Feng, 2016. Generalized thermodynamic optimization for iron and steel production processes: theoretical exploration and application cases. Entropy, 18(10), p.353.. s.l.:s.n.

Rando, J, L. & A, R., 2002. A review of planning and scheduling systems and methods for integrated steel production. European Journal of Operational Research, 133(1), pp.1-20.. s.l.:s.n.

Russell & Vunji, K., 2013. Steel production: processes, products, and residuals. Routledge.. s.l.:s.n.

Yellishetty, Mudd & Ranjith, 2011. Environmental life cycle comparisons of steel production and recycling: sustainability issues, problems and. s.l.:s.n.