Problem For the list of product components given below, answer clearly the follo

Question

Problem For the list of product components given below, answer clearly the following questions for each component: a) Determine the key quality characteristics that you would worry about if you were the customer for the part. In other words, what are the key measures of output geometry (e.g. diameter) and of output constitutive properties (eg. hardness) for the part? b) Based on the processes listed, describe how the component is made and what the principal determinants of the part's geometry and its final constitutive properties will be c) For each process (listed in the table) used to make your component, identify the key process parameters Equipment state Equipment properties Material states Material properties d) What variable(s) are typically used to control the processes? e What variables can be expected to cause variation in the output and why? How would you "control" the processes to achieve the desired geometry/final physical properties and to minimize the chance that parts are unacceptable? Provide images/sketches to prove your justification whenever applicable. - Processes Fuselage skin panel Sheet forming Edge trimming Rivet hole drilling Cantilever-beam MEMS Photolithography Wet chemical etching

Explanation / Answer

Kindly upload the 'Cantilever-beam MEMS accelerometer' question separately. Thank you!

Fuselage Skin Panel:-

Quality Characteristics:-

Manufacturing Process:-

First of all, best material will be selected for the given component based on the various analyses such Ashby Analysis, weighted point method and so on. Then various heat treatments such as quenching, case-hardening and precipitation hardening etc. will be performed on it to achieve required hardness and strength. This will decide the constitutive properties of the component.

After that the sheet metal will be stamped to the required geometry of the component using forming process. External edge of this component will be removed by edge trimming with the help of cutter. Finally holes will be drilled on the component for riveting it to other components.

Key Process Parameters:-

Control Variables:-

Forming process typically depends on the yield strength of the sheet metal. The punch force required to form the metal will be calculated from the yield strength of the material and the thickness of the component. The size of the die for forming will be controlled by the overall geometry of the component. For edge trimming, the size punch cutter will also be controlled by the overall geometry of the component. Hole drilling operation requires the drills of diameter same as that of holes. So hole diameters and their locations will be the control variables for rivet hole drilling operation.

Variables causing variation in output:-

As far as the sheet forming process is considered, the curvature of the fuselage (which is not a major problem over here) can affect the final geometry of the component as more punching force will be required for forming operation. Also the hardness of the material is an anisotropic property. This it can create variation in the output i.e. some samples of the components will have uniform thickness while other may show some deviation in critical regions.

As the time passes, the tools and die will wear out due to successive operations. Hence the final dimensions such as diameters and lengths will start deviating from their true values. Also there may be human errors such as measurement error, errors in setting jigs and fixture etc. which can affect the output.

Controlling the Process:-

First, understand that parts is unaccepted if it is out of the tolerance zone, surface quality not matching, part design not as per specification etc. To ensure that the part always gets accepted, the part should strictly adhere to the tolerance zone provided by the designer. Hence tolerances should be given as large as possible. Geometric dimensioning should be used instead of part dimensioning.

Manufacturing process should be selected such that the finished product will have accurate surface quality as desired by the customer.

DFA and DFMEA are best option that ensures the part will get accepted. Hence these analyses should be performed on the part.

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