Expert answer:Technical Report & Presentation

  

Solved by verified expert:Hello, I did a project using Matlab in my engineering class. And I need someone to do for me the technical report and a presentation based on the tech report. The project description and the way of doing the technical report is in the attached file. My project was only for the Automotive Bumper part, so ignore the other two parts.Regarding the PowerPoint presentation it should be as the following:It should include at least one slide for each of the sections in the Project 1 description document. You must include one background slide (My background research will be attched). And talk about the Fiberglass/Carbon Fiber material which is only related to the automotive bumper part. The order of the slides should also be similar to that of the sections of the Project 1 description document.
background_research.docx

summer_2019_project_1_description_1_.pdf

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Turki Almalki
ENGR102
Background Research
Fabrication methods are essential as they help in the provision of precise operation of the
systems and the variation that exists in the integration of the mechanical systems. The influence
of the processing is essential as this helps in the maintenance of porosity, density, and the
composition of the materials. In enhancing the process, there is a focus on the various
adjustments that should be made, enabling the homogeneity of the material and the structure that
is important in the reporting process. The changes in the composition of the materials are
essential as this influences the change in the engineering process and the desired controls in the
process. The type of materials determines the selection of the method, and this helps in focusing
on the interactivity of the materials in the process (Pogge & Yu, 2008). The mechanical process
enables the development of the functioning materials, and this helps in observing the changes
that arise in the selection of the methods of fabrication method.
One of the essential methods is the optical component machining method, and this looks
at the shapes in the production process and the operation of the conventional machines. The
principal method looks at precision in the production process, and this helps in increasing the
stability of the operations of the business, considering the time and costs undertaken in the
engineering process. There is factoring of the dimensions instability as this helps in influencing
the behavior of the optical systems. The importance of the processing system analyzes the types
of materials required, and this helps in the reduction of the tension that occurs in the different
stages in the manufacturing process.
In the method, there is consideration of the microstructure, and this ensures there is a
focus on the preparation of the methods of production. There is a need to focus on the desired
change and the routes that it undertakes in enhancing the properties of the oxidation processes.
The design of the techniques is essential as this helps in consideration of the strengths of the
fabrication method and the filtration that is important helping to observe the chemical factors in
the components of machines (Norman & Desai, 2006). The technology used in manufacturing
focuses on the different dimensions in property, and this helps in enabling the performance of the
different types of materials. There is the implementation of the various properties where the
focus on the method of fabrication that covers all the changes in the manufacturing process.
The selection of the different property dimensions is to enable the machining process, and
this helps in focusing on the geometrical processes in the production method. Various processes
are involved in the method, and this consists of the fixing of the different parts and components
in the process. The change that is instituted in the various components creates the need to
observe the environments and the costs that are incurred in the engineering process. The
assessment of the manufacturing units is vital as this helps in the evaluation of the change in
frequency and the application of the methods that are important in enhancing the reliability of the
systems (Campbell et al., 2004). The technique that is applied in the machining method includes
welding, and this helps in focusing on the adverse methods that might affect the manufacturing
process. The processes that are built using the different crafts are essential as this helps in the
specification of the materials that are used in the defenses of the materials and the application of
the installation processes. It enables the classification of the categories of change, and this leads
to the implementation of change in the engineering method.
Turki Almalki
ENGR102
References
Pogge, H. B., & Yu, R. (2008). U.S. Patent No. 7,354,798. Washington, DC: U.S. Patent and
Trademark Office.
Norman, J. J., & Desai, T. A. (2006). Methods for fabrication of nanoscale topography for tissue
engineering scaffolds. Annals of biomedical engineering, 34(1), 89-101.
Campbell, J. H., Hawley-Fedder, R. A., Stolz, C. J., Menapace, J. A., Borden, M. R., Whitman,
P. K., … & Hackel, R. P. (2004, May). NIF optical materials and fabrication technologies:
an overview. In Optical Engineering at the Lawrence Livermore National Laboratory II:
The National Ignition Facility (Vol. 5341, pp. 84-102). International Society for Optics
and Photonics.
Cost Estimation and Method Selection
for Manufacturing
Authors
Group Member Names Go Here
Engineering 102
Section ###
Submitted To
Professor’s Name Goes Here
Fundamentals of Engineering
Statler College of Engineering and Mineral Resources
West Virginia University
Morgantown, WV
Summer 2019
Abstract
Your final technical report for this project should follow the format of this document. Please use a
similar font type, font size, and spacing. You must include all of the sections found in the document
and follow the due dates listed at the end of this document. Your grade for the individual coding
portion of this Project will be based on the individual code grading scale at the end of this document.
Please note which of the assignments are group submissions and which are individual submissions.
For the individual submissions, you are expected to independently work on and submit the particular
assignment. You are welcome to brainstorm with other students in the class, but please
independently complete these assignments. Independently working on this project code will prepare
you for quizzes and exams in this course.
The first project in ENGR 102 this semester is to analyze a series of fabrication methods, in order to
recommend one method for implementation. The analysis team will have the choice of three parts to
analyze: an automotive bumper, the platform of a baby jumper, or a silverware tray for a dishwasher.
Each of the potential parts has two fabrication methods with two possible materials that need to be
evaluated for fabrication cost.
There are several individual components to the project, namely conducting background research into
their fabrication and material combination as well as creating the Matlab code needed to find the total
cost of fabrication. These individual components are then combined in the group final report and
presentation to determine which of the four studied parts is the best option for the company. The
analysis team has the ability to set is own criteria for optimal method.
ii
Table of Contents
Abstract ……………………………………………………………………………………………………………………………………….. 2
1
Introduction ………………………………………………………………………………………………………………………….. 1
2
Background Research ……………………………………………………………………………………………………………… 2
3
Methodology …………………………………………………………………………………………………………………………. 3
3.1
Replacement Automotive Bumper …………………………………………………………………………………….. 3
3.2
Replacement Baby Jumper Platform ………………………………………………………………………………….. 5
3.3
Replacement Dishwasher Silverware Tray…………………………………………………………………………… 7
4
Results ………………………………………………………………………………………………………………………………….. 9
5
Discussion……………………………………………………………………………………………………………………………. 10
6
Conclusion …………………………………………………………………………………………………………………………… 11
7
Recommendations/Future Work ……………………………………………………………………………………………. 12
8
References…………………………………………………………………………………………………………………………… 13
Appendix 1 …………………………………………………………………………………………………………………………………. 14
iii
1 Introduction
The first project of the semester is to analyze different ways to build the same replacement part and to
recommend which method should be used. There are several possible parts to be considered by each
group and one part should be selected for analysis. Please choose from the parts listed below:
1. Replacement Automotive Bumper
o
o
Additive Manufacture

Steel

Aluminum
Conventional Manufacture

Aluminum

Composite (fiberglass/carbon fiber)
2. Baby Jumper ‘Tray’
o
o
Additive Manufacture

Plastic

Metal
Conventional Manufacture

Plastic (vacuum formed)

Wood (machined)
3. Dishwasher Silverware Tray
o
o
Additive Manufacture

Plastic

Metal
Conventional Manufacture

Plastic (injection molded)

Metal (machined/welded)
**Note, traditionally, the number/bulleted list and a note like this do not appear in the introduction to
the report**
1
2 Background Research
As part of this project, each group member will research one of the fabrication methods/material
combinations listed with your group’s selected part, such that all four are reviewed and each member
is expected to be able to describe how the method is performed in at least one full page of the
technical report and in one slide of the final presentation. Each of the background research sections will
be submitted individually prior to the final due date of the project, and combined for the final report.
Please do not forget to utilize resources such as the WVU Engineering Library and Engineering
Librarians (if on-campus) or your local library, in addition to using the internet. Google Scholar
is an excellent resource for finding journal articles and conference proceedings. It is expected that each
member find at least 4 sources that are cited in their individual background portion, and at least
two of these sources have to be from a journal article or conference proceedings.
2
3 Methodology
The methodology portion of this report is subdivided into the respective parts in an attempt to make
understanding each of the different parts’ analysis requirements easier. For all of the parts it is assumed
that there is no existing tooling in the company and thus the estimated cost of tooling needs to be
included in the manufacturing costs. In the manufacturing world, the term tooling represents all the jigs,
molds, etc. that are needed in order to build the component(s) in the device. Looking into the cost
determination of building a part and for this project, a Parametric Cost Estimate technique uses
historical data and statistics to predict the cost.
3.1
Replacement Automotive Bumper
For the replacement bumper for a car, there are several options in consideration for the material of the
bumper, but the shape and size of the part is the same for all the materials as the same mount points are
used no matter the material choice. The parameters to be factored in for the bumper problem are the
raw material, tooling, consumables, and labor costs.
To estimate the raw material costs, an estimate of the raw material used in the part is needed. To get a
rough estimate for the bumper, consider it as an open rectangular box with a defined thickness, as
illustrated in Figure 1. The volume, V, of this approximated shape can more easily be estimated based on
the thickness of the material, t, and the dimensions of height, h, depth, d, and width, w, as listed in
Equation 1. Once the volume of material is known, then the mass, m, can be found based on the material
density, ρ. A standard bumper would have dimensions of 8 inches in height, 7 inches in depth, and 6 feet
in width.
Height
Depth
Width
Figure 1. Illustration of the rectangular estimated shape of the automotive bumper.
𝑉𝑉= 8𝑡𝑡3 − (4ℎ + 4𝑤𝑤+ 4𝑑𝑑)𝑡𝑡2 + 2(𝑑𝑑ℎ + 𝑑𝑑𝑤𝑤+ ℎ𝑤𝑤)𝑡𝑡
𝑚𝑚 = 𝑉𝑉ρ
Equation 1
Equation 2
3
Table 1. Cost of respective materials per metric ton of material
Material
Steel
Aluminum
Fiberglass
Carbon Fiber
Density (kg/m3)
8050
2800
1800
1600
Cost US$ per metric ton
500.00
1600.00
1800.00
10000.00
Tooling costs are also somewhat dependent on the material thickness in that the forms/molds need to
be stronger to account for the higher pressure needed to form the materials. For this part analyze
thicknesses ranging from 3 mm to 10 mm. But the tooling costs also vary by manufacturing method and
material. Thus, the relationships shown in Equations 3 – 6 represent the four scenarios for the
automotive bumper, with the thickness, t, is supplied in mm.
Table 2. Tooling cost estimates for manufacture method and material options being considered.
Manufacture
Method
Material
Additive
Steel
Additive
Aluminum
Traditional
Aluminum
Traditional
Fiberglass/Carbon
Fiber
Tooling Cost Relationship (per 1000 parts)
Equation
3
Equation
4
Equation
5
Equation
6
The consumables to be considered for this part depend on the manufacturing method and material
choice as well. For the additive manufacture methods, the consumable of “support” material that is
utilized to hold up hollow features of the part and are the same for both material options. Historically,
this material costs, on average, $2 for every cubic centimeter of printed volume of the part. Thus, the
volume estimate from determining the mass can be re-used to find the consumable cost. However,
traditional manufacturing methods have a higher consumable cost because of the safety aspects of the
finishing process, such as dust masks, gloves, etc., in addition to the sandpaper, grinding wheels, etc. that
are used as part of the process. It has been estimated that for this application, the consumables would be
~$15 per part built.
Likewise, the labor costs are considerably different for the manufacturing methods, with the additive
manufacturing method having the lower of the two labor costs. Based on preliminary manufacturing
estimates, it will take a 24 hour print cycle for each part in the additive manufacturing methods, with one
operator monitoring the machine, at a cost of $45 per hour.
4
As for the traditional manufacturing methods, material choice changing how much labor is required. For
the aluminum part, the casting of the general shape takes 3 employees 2 hours to prep, and ½ hour to
pour the molten aluminum. There is then a minimum of a 4 hour cooling period in which no employees are
needed, followed by a 4 hour sanding and finishing process with 2 employees. The average hourly cost for
these employees is $40 per hour. In contrast, the composite (fiberglass or carbon fiber) part requires a 4
hour, 4 employee prep session to build the layers of the composite and a minimum of an 8 hour baking
cycle to cure the composite followed by a 2 employee, 3 hour process to remove the part from the mold
and finish the part.
3.2
Replacement Baby Jumper Platform
Creating a replacement platform in a baby jumper can be done in two possible manufacturing methods,
with two possible materials in each method. In order to determine the fabrication cost of the platform,
the volume of material used needs to be estimated. In additional to the raw material costs, the tooling
cost, labor cost, and consumable costs need to be estimated to determine the most effective fabrication
method.
To find the part volume, the shape can be simplified to a hollow cylinder open on one end, as illustrated
in Figure 2. Using the height of the cylinder, h, the inner and outer diameters, Di and Do respectively, and
a uniform thickness, t, the volume can be estimated using Equation 7 and thus the mass, m, can be found
based on the material density, ρ, as shown in Equation 8. Table 3 provides the density of the respective
materials, as well as the cost of each material per metric ton. The standard baby jumper has a height of
1.5 inches, an outer diameter of 2 feet and an inner diameter 16 inches.
Solid Top
Hollow Center
Di
h
Solid Outside and
Inside Walls
Open Bottom
Do
Figure 2. Pictorial representation of the baby jumper platform volume estimate shape.
Equation 7
𝑚𝑚 = 𝑉𝑉ρ
Equation 8
5
Table 3. Cost of respective materials per metric ton of material
Material
ABS Plastic
(additive
manufacture)
Aluminum
Polycarbonate
Plastic (vacuum
form)
Wood (Teak)
Density (kg/m3)
1050
Cost US$ per metric ton
600.00
2800
1190
1600.00
750.00
640
34000.00
Tooling costs are also somewhat dependent on the material thickness in that the forms/molds need to
be stronger to account for the higher pressure needed to form the thicker materials as well as by the
manufacture method and material used. Thus, the relationships shown in Equations 9 – 12 represent the
four scenarios for the baby jumper platform, with the thickness t supplied in mm. For this part, the
thickness should be studied from one millimeter to seven millimeters.
Table 4. Tooling cost estimates for manufacture method and material options being considered.
Manufacture
Method
Material
Additive
ABS Plastic
Additive
Aluminum
Traditional
Polycarbonate
Plastic
Traditional
Teak
Tooling Cost Relationship (per 1000 parts)
Equation
9
Equation
10
Equation
11
Equation
12
The consumables to be considered for this part depend on the manufacturing method and material
choice, as well. For the additive manufacture methods, the consumable is support material that is
utilized to hold up hollow features of the part and are the same for both material options. These are
historically, on average, $0.50 (plastic) and $2 (metal) for every cubic centimeter of printed volume of
the part. Thus, the volume estimate from determining the mass can be re-used to find the consumable
cost. However, traditional manufacturing methods have a higher consumable cost because of the safety
aspects of the finishing process, such as dust masks, gloves, etc., in addition to the sandpaper, grinding
wheels, etc. that are used as part of the finishing process. It has been estimated that for this application,
the consumables would be ~$15 per plastic part built, and $35 for the finishing of the teak part.
6
Likewise, the labor costs are considerably different for the manufacturing methods, with the additive
manufacturing method have the lower of the two labor costs. Based on preliminary manufacturing
estimates, it will take a 13 hour print cycle for each part in the additive manufacturing methods, with
one operator monitoring the machine at a cost of $45 per hour.
As for the traditional manufacturing methods, material choice changes based on how much labor is
required. For the plastic part, the forming of the general shape takes 2 employees 1 hour to prep,
and ½ hour to set the plastic. There is then a minimum of a 2 hour cooling period in which no
employees are needed, followed by a 3 hour trimming process with 2 employees. The average hourly
cost for these employees is $40 per hour. In contrast, the teak part would require a one hour, one
employee prep session to rough cut and attach it to the machining jig, and 8 hours machining to
create the part. This would then need to be followed by a 2 employee, 3 hour process to finish and
stain the part for sale.
3.3
Replacement Dishwasher Silverware Tray
A replacement silverware tray for a dishwasher can be fabricated by either additive manufacturing or
traditional manufacturing methods of injection molded plastic or bent and wel …
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