Product Analysis -(Group 10)

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Gate 3 - Product Analysis (Group 10)


Component Function:

  • The component is what is moved by the explosion in the piston chamber. This is also what moves the piston linkage in order to turn the crankshaft.
  • Its only function is to move the piston linkage in order to turn the crankshaft.
  • Combustion energy from the explosion that causes expansion moves the piston downward and in turn moves the linkage down which, once connected to the crankshaft is turned into rotational energy.
  • The piston functions in a lubricated chamber enclosure, called the piston chamber. On one side of the piston there is oil and on the other is the explosive side.

Component Form:

  • The piston is a symmetrical 3 dimensional cylindrically shaped object with one side being slightly hollowed out.
  • The height is 1.75 inches
  • The diameter is 2.75 inches
  • Since it is a cylinder, the diameter suffices for both length and width
  • The component is shaped so there is a tight seal to the sides of the chamber so that gas doesn’t escape.
  • The piston weighs 1.25 pounds.
  • The piston is made from stainless steel.
  • Stainless steel is stronger than aluminum but lighter than iron but manufacturing decisions didn’t effect this decision.
  • The material choice needs to be lightweight but strong to withstand the explosive force.
  • Environmental and economic factors effected this decision. Being stainless steel allows the piston to not rust and also have the strength that comes with steel as opposed to aluminum so there is less a chance of breaking and is better on the environment due to the lack of waste. Being that stainless costs about the same as aluminum but is stronger, it is a better deal cost wise to use it rather than aluminum.
  • The piston has zero aesthetic qualities and therefore has a bare finish, no paint, stain or coloration needed since it’s a purely physical component.

Manufacturing Methods:

  • The piston is press-punch forged, lathed, precision ground and milled.
  • The precision grinding is evident due to the precision finish in the holes where the pin fits into.
  • Milling is evident due to the fact that there are holes, and for the slots that the rings fit into.
  • Lathe work is evident from the lines on the top of the piston that come from the facing operation performed by a lathe.
  • Forging is evident due to the lack of parting lines, and the internal shape that would be very difficult to mill. There are also stamped numbers in the bottom.
  • It would be more cost effective to forge stainless steel rather than completely mill or investment cast it.
  • Being a cylindrical shape it effected the choice to perform multiple lathe operations. The need for a snug fit to the pin required precision grinding and milling was needed for minor holes and slotting.
  • The need for a strong yet light, product with minimal waste and the ability to withstand rust or decomposition, effected material choice, manufacturing process and finish of the final product.

Component Complexity:

  • This is a fairly simple component and would get a rating of #2 for its complexity.
  • The categories above serve as a representation of all of the components of the piston, in detail and therefore is what determines its complexity.
  • The interactions are very simple and would get a rating of #1