Group 15 - Skil 7 1/4 in Circular Saw

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Executive Summary

This report will analyze and discuss the reverse engineering process of our chosen product, the Skil 7 ¼ in. circular saw. The following report is divided into four main sections. Respectively the four gates are Project Planning, Product Dissection, Product Analysis, and Product Explanation. A fifth gate also exists, which is the delivery of the assignment.

For Gate 1 the foundation for the rest of the project was laid. Over the course of this gate a work proposal was created to help deal with the management of the group. We analyzed in depth the disassembly process to help avoid any potential caveats that might arise during the process. To further assist with project management each group member was evaluated on their strengths and weaknesses. In coordination with this evaluation each group member was assigned a specific role that they would retain for the duration of the project. A plan to divide the work evenly and efficiently to the most capable group members for the designated task was also formulated. Finally various profiles were developed, which include usage, energy, complexity, user, and product alternative. These were essential in understanding the functions, interactions, and reasons for the design of the current product. This would be vital for later stages in the project.

Gate 2 started off a cause for corrective action section to help remedy any problems remaining within the group. The actual dissection of all major product components also occurred during this gate. This was to achieve an in depth understanding of the various subsystems, both inner and outer involved in the circular saw. The actual dissection process was documented, and all of the parts were cataloged. Each dissection step was given a difficulty rating as well. After the dissection the subsystems were analyzed in depth. The various connections between the individual subsystems along with their specific arrangement were taken into account during this analysis.

Gate 3 began the process of looking at the individual components more in depth. First off another cause for corrective action summary was documented to track the progress of the group. After that the product evaluation for the components was documented. This included an introductory summary and followed up with the actual product analysis. The analysis consisted of a complexity scale and a component analysis for eight major components of the circular saw. Namely the carbon brushes, saw blade, trigger, central power cable, handle, lower blade guard, motor housing, and upper blade guard. A number of these parts were rendered in Inventor in order to create a three dimensional model of their assembly. Another analysis section followed, this time however for the engineering aspects of the product. This included an introduction, problem statement, diagram of the process, the governing equations, example calculations a solution check to verify the results and lastly for that part a discussion on the analysis. Gate 3 closed out with three design revisions, consisting of the handle, torx screws and exhaust cover.

Gate 4 involved the reassembly of the circular saw. A final cause for corrective action was done to initiate things. The product archaeology section contains a product assembly guide in chart form. Within this is a difficulty scale to assess the difficulty of each individual part. The initial disassembly and final reassembly were also compared to evaluate the inherent changes between them. The assembly challenges were also documented. The primary mechanism of the circular saw, the motor, was explained in depth. Its purpose, design and function was all explained along with various equations for use during its design and manufacture. Gate 4 concluded with three potential design revisions for this circular saw. The revisions include a handle extension for easier maneuverability, a dust collection system to reduce debris while cutting and a rolling pin wheel structure to increase the safety and precision capable of the product.

The final task, Gate 5 included the finalization and revision of all previous gates. It also included an in class oral deliverable presenting one of our design revisions from gate 4. We chose to showcase the roller pin system.

Figure 1. Skil 7 1/4" Circular Saw

Project Overview

Over the course of the semester, group 15 dissected, reassembled, and analyzed a Skil 7 1/4" Circular Saw. Throughout this process, the design, functionality, and other aspects that went into the engineering of the product were observed in order to arrive at conclusions about it at a component and system level.

Team Members

  • Nicholas Grieco ( - Group Manager/Supervisor
  • Theodore Nalesnik ( - Co-manager/Wiki Specialist
  • Joshua Beres ( - Group Documenter/Modeling Expert
  • James Pullano ( - Dissection & Reassembly Technician
  • Colin Mutton ( - Communication Director

Gate 1: Project Planning

Gate 1 includes the initial assessment of both the product and the group members.

Gate 2: Product Dissection

Gate 2 includes the physical dissection of the product and an analysis of the subsystems found within it.

Gate 3: Product Analysis

Gate 3 includes a detailed analysis of the product on a component and subsystem level.

Gate 4: Product Explanation

Gate 4 includes the physical reassembly of the product and an analysis of all the information gathered in order to arrive at conclusions about it.