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Group 23 – Product: Angle Grinder Alan Smith Jared Bosinski Katie Kremer Kevin Garvin Mitchell Wheeler

Gate 1: Request for Proposal Work Proposal The disassembly of the angle grinder will require several tools. A size 1 Phillips head screwdriver will be used to unscrew and remove the aluminum casing from the angle grinder, exposing the motor and the gears. A set of standard wrenches and vice grips will also be used to separate the detachable plastic parts that make up the casing of the angle grinder. The disassembly of the angle grinder should take approximately twenty minutes. Various challenges have been identified through the initial inspection of the angle grinder. One challenge is not knowing exactly what tools will be needed to dissemble the inner workings of the motor and gears. Also we speculate that the gearbox could be complicated involving a series of bearings. Our group has the advantage of having all the tools we need right in our rooms to use at any time. Also, two of our group members, Alan and Mitch, have past experience working with solid modeling which will be used in the dissection process. Our group also has several shortcomings. We all have different schedules, and finding a time when we all can meet to work on the project is challenging. Also, no one in our group has any experience making or editing a wiki web page. Lastly, our group has limited experience working with and taking apart an angle grinder. We plan to develop these skills in order to be successful with our project.

Management Proposal In order to effectively manage our group and ensure completion of the project, general meeting times and locations have been determined. Each group member decided upon an individual role and must fulfill the responsibilities assigned to that role as decided by the group. Additionally, a Gantt chart was created to track our progression from start to finish throughout the project. Group meetings will be held regularly, usually once a week, after MAE277 lecture, in room 208 of Roosevelt Hall. The meetings will either take place directly after class ends at five o’clock, or later in the evening. This will vary as schedule conflicts arise. For a broad plan of completion of the project within the time constraints, see attached Gantt chart.

Group member roles are outlined as follows: Wiki Developer: Jared Bosinski This role’s responsibilities are to update the Wiki page with all text and technical writing as it is completed. This role is also in charge of formatting the Wiki to make it look professional, including the embedding of pictures and/or videos, and must be done in a timely manner.

Project Manager: Katherine Kremer This role’s responsibilities include making sure that the time spent during meetings is used effectively. Also must double check that each group member is aware of his or her tasks to be completed for the next meeting. In addition, the Project Manager will act as the main communicator for the group, and can be reached at

Head Solid Modeler: Alan Smith This role’s responsibilities include learning the necessary skills to complete all of the solid modeling for the project, and then using those learned skills to solid model the product in a timely fashion.

Dissection Leader: Mitchell Wheeler This role’s responsibilities include overseeing and leading the main disassembly and reassembly of the product. This leader is also in charge of managing a large amount of the technical writing, at least in a first draft form.

Technical Writing Editor: Kevin Garvin This role’s responsibilities are to proofread and edit the majority of the writing done for the project, as well as compile it together when appropriate. This is to be done at least several days before the project is due so the rest of the group can approve the quality of the work.

Initial Product Assessment 1) Angle grinders are used to refinish materials like metal, wood, carbon fiber and even plaster by removing any excess material from its surface to achieve a more desirable finish. a) The use of this product in both home and professional settings would be appropriate. Home owners who take charge of their own home, or even automobile, repairs would find this tool to be particularly useful. Contractors, as well as auto repair shops, all have a need for an angle grinder. b) In addition to the angle grinder being used to grind away excess material, it can also be used to cut through sheets of metal or plywood with the correct cutting head attached. One more important function of an angle grinder is that, with a soft head attachment, it can be used to polish metal to a dull sheen or a bright shine.

2) We think the angle grinder works by using its motor to spin a gear which spins a second gear turned 90° to the first one, then spins the grinding wheel at a very high RPM. a) The angle grinder uses just electrical and mechanical energy. b) The electrical energy coming in through the cord powers the angle grinder’s motor, which converts it to mechanical energy which spins the gears and then the grinding wheel.

3) Our angle grinder will run so long as it remains plugged in to an electrical outlet with a grounding prong, and the user engages the power switch to the ‘on’ position. a) When we just held it in mid-air it ran at a constant high speed. It felt rather powerful but it was also very loud too. b) There seems to be no problems with our angle grinder.

4) If we follow the idea that what makes a product complex is its design and functionality compared to other products used to perform the same task, angle grinders should be considered a complex power tool. This is contrary to our group’s opinion that an angle grinder is a rather simple put together tool. Grinders may be considered complex simply because there are not many products available that are more complex than an angle grinder but still accomplishes the same tasks. For example, a power sander can mimic the grinder’s ability to refinish and remove excess material, but not on metal surfaces, also, a power sander can’t cut through material like an angle grinder can. Another example is a circular saw, which can cut through material but can’t polish or refinish material like an angle grinder can. So by comparison an angle grinder is one complex little multi tool. a) When going over the angle grinder we can point out approximately 30 components. We see things like screws, a push button, a power switch, the electrical cord, the finger guard, the body casings, and the grinding wheel mount. Some components on the inside include but are not limited to the motor, the gears, and possibly bearings, and probably more screws. b) The components in the angle grinder are not very complex because you can find all of these things in other power tools, just in different sizes, shapes, and assemblies.

5) The angle grinder houses a motor and gears inside of a fitted body casing that is maneuvered using a hand grip on the side of the body. a) What you see on the outside of the angle grinder is the body casing, the top is made out of aluminum and the rest is made out of plastic. Screws are used to hold the casings in place. The grinding wheel mount is made out of cast iron because it needs to be very durable. Also, the handle on the side is made of plastic with a rubber grip coating on it’s surface. b) Materials that are not visible but present in the angle grinder are the motors which are probably made of copper wire wound around an iron core. There are also gears on the inside that might also be made from cast iron. We believe that there are steel ball bearings on the inside to help the grinder wheel spin so smoothly.

6) If we had to use this product we do believe that we would be happy with it. It is a very easy to handle power tool that accomplishes multiple tasks. It seems very powerful and it will make many home improvement projects a lot easier. a) This angle grinder is very comfortable to use because the rubber coated grip keeps you hand firmly positioned and not sliding around. Also, the handle can be screwed into either the left or right side of the grinder to enable both left and right handed people to use it comfortably. b) The angle grinder is very easy to use, the user just plugs it in turns it on and gets to work. It is important for the person to have a steady hand while using the grinder so they don’t lose control of it. c) The only thing you have to do when you’re done using the angle grinder is to sweep away excess shavings off the head of the tool. Also, the guard for the user’s hands and fingers may need to be replaced if it is showing a lot of sign of wear.

7) There are other makers of angle grinders like Black and Decker, DeWalt, or Hitachi. They along are very similar in style, expect that some are powered by a cord while others are battery powered. a) Angle grinders range in price from a possible sale at around $30-$50, up to a much higher $135 or more. b) You could even compare an angle grinder to a bench grinder. They both accomplish the same job but a handheld one is always going to be more mobile and you get better leverage on it. c) Some other angle grinders are larger than others, and larger in size also means increase in weight which is not very ideal if you are more of a petite person. Sometimes you need to worry about the battery running out of power before you are even done with you project.