Materials Selection Project
Choose a product which has components
made from a range of materials and components. This must include
various metals and plastics.
No less than 25 components. (Although this might
be achieved by taking something "apart". For example: A light bulb or a
bearing...
The ideal product would be something like a broken 4" angle
grinder, although we don't want a dozen repeated projects!.
It is a lot
easier if you have an exploded assembly diagram - often seen in a repair or
instruction book. Otherwise the components will need to be photographed or CAD
modeled.
Example products: Most electrical appliances and electric
tools are very suitable. Small power tools, appliances. Do not pull apart
electrical products if you are not competent to reassemble them safely - which
is why it is preferable that the product is discarded. Look for something
that has components that are machined, cast, injection moulded, possibly sheet
metal. Special treatment processes such as hardness are found in most cutters,
tools and bearings. Powder metallurgy is common in bronze bearings. Die castings
are common in tool and appliance gearboxes, motors. Injection moulded components
are seen almost anywhere plastic is used.
Larger products could also be
used, but this may be a problem if you have parts to bring in for
identification.
Part 1:
List all the components. (There should be at
least 25 parts). Give every part a number, and also make up names for each
component - an interesting task in itself! Designers and engineers often
get the job of making up a name for something, and it's not always easy.
Try to make each name unique.
Part 2:
Identify/estimate/assume
the material that each component is made of.
State how you made your
identification.
List some alternative materials that could have been used
instead.
Part3:
Identify/estimate/assume and describe the processes
that were probably used to produce each component listed in Part 2 - from
the semi-finished materials. (i.e. Don't describe the process of making a steel
spring from iron ore, but from steel wire)
Identify post-treatment
processes such as heat treatment, coating, plating, painting etc for any
relevent components.
Example exploded assembly drawing from a manual:
(This is an angle grinder)
Example photo
ready for putting numbers on the parts using "Paint" or other graphics program.
(A carburettor. Plastic parts are limited - a few seals
etc.