Material Selection

MATERIAL SELECTION

QUESTION 11.3

Which material property would you select as a guide in material selection if the chief performance characteristic of the component was:

	PERFORMANCE CHARACTERISTIC	MATERIAL PROPERTY
a)	Strength in bending	Tensile strength
b)	Resistance to twisting	Hardness
c)	The ability of a sheet material to be stretched into a complex curvature	Ductility
d)	Ability to resist fracture from cracks at low temperatures	Malleability
e)	Ability to resist shattering if dropped on floor	Toughness
f)	Ability to resist alternating cycles of repeat heating and cooling	Thermal shock resistance

Assignment Chapter 6

Q16.1)

From eq 16.19:

We get cost for size or capacity difference:

C₁=C_o (L₁/L₀) ^x=C_o (1000/100)^0.61

In 1985, for purchasing 10 new units, it will not cost 10 times more due to the economy scale but if purchasing for 22years later, the cost will increase due to the inflation.

Inflation per year = 5%

Original cost = $35,000

New original cost due to the inflation for 22 years later = 35,000 (1+0.05)22= $102,384

So, the estimate of the cost is:

C1 = 102,384 (1000/100)0.61 = $ 417,092

Q16.2)

Overseas subcontractor

Labor per shoe                                                            2.75

Materials                                                         9.00

Shipping and import duty                               3.50

Operating cost                                                 3.00

Profit                                                               1.75

U.S brand name shoe company

Purchase from subcontractor                          20.00

Research and development                             0.25

Promotion and advertising                              4.00

Sales, G&A                                                     5.00

Profit                                                               6.75    

Q16.3)

At break-even point, Q_B, cost using hard tooling = cost of using soft tooling.         

The chief cost elements are:

·         Cost of tooling, CH = $7500 and CS = $600

·         Cost of tool setup, SH= $60 and SC = $100. Parts made in batches, b, of 500 units.

·         Cost of making one part, CpH = $0.80 and CpS = $3.40

So, at break-even point

C_H+ (Q_B/b) S_H + C_pH Q_B = C_S + (Q_B/b) S_S + C_pS Q_B

Q_B = (C_H-C_S) / (((S_S-S_H)/b) + (C_pS - C_pH)) = (7500-600)/ ((100-60)/500) + (3.4-0.80))=6900/2.68 = 2574

At break-even point, hard tooling approaches become more effective than soft tooling. So, for 500 units, the best decision is to use hard tooling.

Q16.4

Prime cost

Direct labor                                                                 950,000

Direct material                                                                        2,150,000

Direct expenses                                                                       60,000

Direct engineering                                                       90,000

Direct engineering expenses                                       30,000

                                                                                    3,280,000                                (1)

Factory expense

Plant utilities                                                               70,000

Plant & equipment depreciation                                             120,000

Warehouse expense                                                     60,000

                                                                                    300,000                                   (2)

General and administrative expenses (G&A)            

Plant manager and staff                                                          180,000

Administrative salaries                                                            120,000

Office utilities                                                             10,000

                                                                                    310,000                                   (3)

Manufacturing cost = (1) + (2) +(3) = 3,890,000                   (4)

Sales expense = 100,000                                             (5)

Total cost = (4)+ (5) =3,990,000                                             (6)

Profit margin = profit / sales = P/S = 0.15

Sales (S) = Total cost (C_T) + Profit (P)

S =C_T + P = C_T + 0.15S ;

S = C_T / 0.85 = 3,990,000/0.85 = 4,694,118

The unit selling price of turbine is $4,694,116/60 units sold = $ 78,235

Material Selection

MATERIAL SELECTION

QUESTION 11.3

Which material property would you select as a guide in material selection if the chief performance characteristic of the component was:

	PERFORMANCE CHARACTERISTIC	MATERIAL PROPERTY
a)	Strength in bending	Tensile strength
b)	Resistance to twisting	Hardness
c)	The ability of a sheet material to be stretched into a complex curvature	Ductility
d)	Ability to resist fracture from cracks at low temperatures	Malleability
e)	Ability to resist shattering if dropped on floor	Toughness
f)	Ability to resist alternating cycles of repeat heating and cooling	Thermal shock resistance

Detail Design

Evolution Design of Evorella

Other example on Source of Information

List of Carbon Fiber Reinforced Composite Material consultancy website:

1.      http://www.schnitzhoferandassoc.com/?p=837

2.      http://www2.intota.com/experts.asp?strSearchType=all&strQuery=carbon+fiber+reinforced+plastic

3.      http://www.zintro.com/area/carbon-fiber-reinforced-polymer

4.      http://www.compositesworld.com/articles/carbon-fiber-market-cautious-optimism

5.      http://www.compositesconsultants.com/cats/reinforcements.php

6.      http://www.orcexperts.co.uk/experts.asp?

Source of Information about Taxidermist

TAXIDERMIST

Taxidermy (from the Greek for arrangement of skin) is the art of preparing, stuffing, and mounting the skins of animals (especially vertebrates) for display (e.g. as hunting trophies) or for other sources of study. Taxidermy can be done on all vertebrate species of animals, including mammals, birds, fish, reptiles, and amphibians.

A person who practices taxidermy is called a taxidermist. Taxidermists may practice professionally for museums or as businesses catering to hunters and fishermen, or as amateurs, such as hobbyists, hunters, and fishermen. To practice taxidermy, one should be very familiar with anatomy, sculpture, and painting, as well as tanning.

Brainstorm on uses of old newspaper

Survey on Our New Product

Survey Question

TOPIC: URBAN UMBRELLA DESIGN

We are from department of research and development from Evotech design. We are conducting a research on new design of umbrella. In order to assist us in gathering important information, we will be grateful that you take some time to complete this survey. Please be honest while answering this survey. Thank you.

Affinity Diagram

Affinity Diagram

            An Affinity Diagram is a tool that gathers large amounts of language data (ideas, opinions, issues) and organizes them into groupings based on their natural relationships. The Affinity process is often used to group ideas generated by Brainstorming.

            The Affinity process is a good way to get people to work on a creative level to address difficult issues. It may be used in situations that are unknown or unexplored by a team, or in circumstances that seem confusing or disorganized, such as when people with diverse experiences form a new team, or when members have incomplete knowledge of the area of analysis.

Quality Function Deployment

            Quality Function Deployment is a systematic approach to design based on a close awareness of customer desires, coupled with the integration of corporate functional groups. It consists in translating customer desires (for example, the ease of writing for a pen) into design characteristics (pen ink viscosity, pressure on ball-point) for each stage of the product development (Rosenthal, 1992).

Ultimately the goal of QFD is to translate often subjective quality criteria into objective ones that can be quantified and measured and which can then be used to design and manufacture the product. It is a complimentary method for determining how and where priorities are to be assigned in product development. The intent is to employ objective procedures in increasing detail throughout the development of the product. (Reilly, 1999) Quality Function Deployment was developed by Yoji Akao in Japan in 1966. By 1972 the power of the approach had been well demonstrated at the Mitsubishi Heavy Industries Kobe Shipyard (Sullivan, 1986) and in 1978 the first book on the subject was published in Japanese and then later translated into English in 1994 (Mizuno and Akao, 1994).

Concurrent Engineering

Concurrent engineering which is sometimes called Simultaneous Engineering or Integrated Product Development (IPD). It was defined by the Institute for Defense Analysis (IDA) in its December 1988 report 'The Role of Concurrent Engineering in Weapons System Acquisition' as a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support. It refers to an approach used in product development in which functions of design engineering, manufacturing engineering and other functions are integrated to reduce the elapsed time required to bring a new product to the market. This approach is intended to cause the developers, from the outset, to consider all elements of the product life cycle from conception through disposal, including quality, cost, schedule, and user requirements. 

The basic premise for concurrent engineering revolves around two concepts. The first is the idea that all elements of a product’s life-cycle, from functionality, producibility, assembly, testability, maintenance issues, environmental impact and finally disposal and recycling, should be taken into careful consideration in the early design phases.