Group 32 - Chainsaw

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===Component Summary===
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==Executive Summary==
  
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Our group was given a Pioneer 1074 chainsaw to dissect and analyze. This chainsaw was top of the line during it's day, however it is now 29 years old. Technology has not changed to much on chainsaws since then, but newer models have much more power. There are no specs online of the chainsaw that could be found.
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! width="120pt" align="center" style="background:#00aa00;"|'''Part'''
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! width="100pt" align="center" style="background:#00aa00;"|'''Material'''
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== Group info ==
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! width="200pt" align="center" style="background:#00aa00;"|'''Reason the Material Was Used'''
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! width="200pt" align="center" style="background:#00aa00;"|'''Manufacturing Process'''
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===Group Members===
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! width="200pt" align="center" style="background:#00aa00;"|'''Reason for the Shape of the Part'''
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! width="50pt" align="center" style="background:#00aa00;"|'''Quantity'''
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Cam Borowiec - Project Leader
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! width="250pt" align="center" style="background:#00aa00;"|'''Function'''
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! width="200pt" align="center" style="background:#00aa00;"|'''Forces Applied'''
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! width="50pt" align="center" style="background:#00aa00;"|'''Complexity'''
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! width="300pt" align="center" style="background:#00aa00;"|'''Photo'''
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| Main Casing||Aluminum Alloy||Aluminum is a light and cheap material and the alloy used is very durable||Molded and then tapping was used to create threaded holes||The part contours the hidden components while minimizing the total size of the chainsaw.||align="center"|2 parts||It houses all of the rest of the components.||The casing will endure any forces from dropping or misuse. Also, it supports the chainsaw's weight in the user's hands.||align="center"|1||[[Image:Chainsaw_Casing.jpeg|200px]]
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| Clutch Cover||Aluminum Alloy||Aluminum is a light and cheap material and the alloy used is very durable||Molded and then tapping was used to create threaded holes||The part contours the hidden components while minimizing the total size of the chainsaw.||align="center"|1||It covers and protects the clutch.||There should only be the force of the screws holding the cover on. However, the cover may endure forces from dropping or misuse.||align="center"|1||[[Image:Chainsaw_Clutch_Cover.jpeg|200px]]
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| Fly Wheel Cover||Aluminum Alloy||Aluminum is a light and cheap material and the alloy used is very durable||Molded and then tapping was used to create threaded holes||The part contours the hidden components while minimizing the total size of the chainsaw.||align="center"|1||It covers and protects the flywheel, and it also houses the starter unit which is a pull cord on a spring.||There should only be the force of the screws holding the case on. However, the cover may endure forces from dropping or misuse.||align="center"|1||[[Image:Flywheel_Cover.jpeg|200px]]
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| Bottom Cover||Aluminum Alloy||Aluminum is a light and cheap material and the alloy used is very durable||Molded||The part contours the hidden components while minimizing the total size of the chainsaw.||align="center"|1||It covers bottom of chainsaw.||There should only be the force of the screws holding the case on. However, the cover may endure forces from dropping or misuse.||align="center"|1||[[Image:Bottom_Cover.JPG|200px]]
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| Intake Cover||Plastic||Plastic is lightweight and the case should not undergo any strong forces.||Molded||The square shape maximizes the cross-sectional area available to the filter to allow for the largest intake volume.||align="center"|1||It covers intake and protects the filter from large debris.||There should only be the force of the screws holding the case on. However, the cover may endure forces from dropping or misuse.||align="center"|1||[[Image:Intake_Cover.JPG|200px]]
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| Fuel Lines||Rubber||Rubber is safe to use with oil and gasoline without contamination, and it can be easily moved to fit in many places.||Molded||A hose is the simplest method of transporting fluids and lightweight.||align="center"|3||It carries fuel from the tank to the intake and the cylinder. Also it carries excess gas out of the system.||The only forces acting on the fuel lines are negligible.||align="center"|1||[[Image:Fuel_Lines.JPG|200px]]
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| Pull Cord||Plastic handle and rope connected to a steel spring and plastic cover and plastic gear||The materials were selected to reduce weight||The handle was molded. The rope was wound, then knotted at one end and connected to handle. The plastic cover and gear wear also molded. The spring was extruded and bended.||The handle was made to fit in an average hand comfortably, while the other parts were shaped to perform their assigned tasks. The rope and spring are standard shapes, and the gears were made to allow the cord to engage the flywheel.||align="center"|1||The pull cord and assembly, start the rotation of the crankshaft and allow the chainsaw to start running.|| The forces applied are the external pull from the user, and the counter-torque from the flywheel, when it is engaged.||align="center"|3||[[Image:Pull_Cord.JPG|200px]]
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| Bar||Iron||Iron is a very strong material, and this part undergoes the main force of the chainsaw.||Pressed||The shape holds the chain in tension.||align="center"|1||It holds the chain in place, and transfers the driving force from the user to the wood.||This part undergoes the largest force, when the chainsaw is pushed into the wood.||align="center"|1||[[Image:Bar.jpg|200px]]
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| Cylinder ||Aluminum Alloy||The alloy used was chosen to reduce weight but still be strong enough to withstand the forces of general use. ||Molded and then milled||The cylindrical bore is the common shape for an engine to have for the chemical reaction to occur. There are two notches at the bottom of the cylinder to allow the oil and fuel to move in and out of the crankcase. The outside has spaces to allow air cooling of the cylinder during operation. ||align="center"|1||It houses the piston, and it is the location of the main source of energy, which is combustion.|| The cylinder undergoes a continuous change in forces as the chainsaw is used. The forces result from the expansion, heating, and compression of gases inside of it.||align="center"|1||[[Image:Cylinder.jpeg|200px]]
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| Spark Plug||copper, ceramic, and plastic||The copper is used to transfer the electric charge. The ceramic and plastic are used as insulators to prevent any shorting within the spark plug.||Molded, then threaded with a die||Spark plugs are always the same shape, to reduce size and allow the movement of charge easily.||align="center"|1||It provides a spark for the combustion.||The spark plug should only undergo the force from the gases.||align="center"|2||[[Image:Spark Plug.jpeg|200px]]
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| Handle & Grip||Steel and Rubber||The steel handle is very stiff and sturdy preventing any damage that may occur from the misuse of the chainsaw. The rubber grip reduces vibrations in the handle and makes it more comfortable to hold.||Molded and bent||The large handle allows for a wide variety of hand positions and gives you a sturdy grip.||align="center"|1||It allows the chainsaw to be held and manuevered accurately and comfortably.||The handle undergoes all of the forces the user applies to the chainsaw and the weight of the chainsaw acting on it.|| align="center"|1||[[Image:Handle1.jpeg|200px]]
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| Exhuast||Steel and Aluminum||Steel is used on the exterior of the exhaust to withstand any misuse and damage. Aluminum is used in the interior parts of the exhaust to save weight, and to absorb the vibrations from the engine.||Molded||The exhaust is shaped to maximize the noise reduction from the engine while still not getting in the way of the user. Also, the gases are directed away from the user off to the side to prevent inhalation or burns.||align="center"|3 pieces, 1 unit||It directs exhuast fumes out of the cylinder into the air and also muffles sound of the engine.||There should only be the force of the screws holding the exhaust on. However, the exhaust cover may endure forces from dropping or misuse.||align="center"|1||[[Image:Chainsaw_Exhaust.jpeg|200px]]
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| Heat Shield||Aluminum||Aluminum is a lightweight material that can deflect a decent amount of heat.||Bent and Pressed||The heat shield contours the cylinder around the edges facing the user. This causes the heat to be deflected away from the user.||align="center"|1||It guards the operator from the heat coming off of the cylinder||The only force exerted on this part is the compression force holding it in place.||align="center"|1||[[Image:Heat Shield.JPG|200px]]
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| Air Filter||Foam and Plastic||The foam is porous, allowing air to flow and dirt particles to be blocked.||Not Machined||The shape maximizes surface area to allow for a larger amount of filtering.||align="center"|1||It filters the air and protects the intake from taking in debris.||The only force on the filter is the flow of air entering the chainsaw.||align="center"|1||[[Image:Air_Filter.JPG|200px]]
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| Flywheel||Aluminum and Magnet||The magnet is necessary to trigger the magneto. The heavy aluminum creates a high rotational inertia keeping the crankshaft moving.||Molded||The fins on the flywheel allow air to be drawn in, cooling the system. The cylindrical shape has a radial symmetry, which is necessary for high rpms.||align="center"|1||It keeps the crankshaft spinning and triggers the magneto.||There is a torque applied to the flywheel from the crankshaft, and from the pull cord gear.||align="center"|1||[[Image:Flywheel1.JPG]]
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| Magneto||Iron, copper and rubber||Iron is necessary because it is highly affected by a magnetic field. The rubber insulates the signal and the copper transfers the signal with a low resistance.||Milled||The iron has two curved parts that match the curve and location of the magnets on the flywheel. The rubber casing and hosing is shaped to transfer the signal to the spark plug.||align="center"|1||It send signal from the flywheel to the spark plug.||There is a magnetic force exerted on the magneto from the flywheel.||align="center"|3
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| Ignition switch/cables||aluminum and copper wire||The aluminum is lightweight, and the copper has a low resistance for transferring current.||Lathed||The switch is small, but still large enough to easily be used.||align="center"|1||It allows the engine to start.||There is a force exerted on the switch whenever the chainsaw is turned on or off.||align="center"|2
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| Battery and cables||Alkaline Battery and copper wire||N/A||N/A||The battery is a cylinder to maximize capacitance.||align="center"|1||It is the energy source for the electrical system.||N/A||align="center"|2||[[Image:Chainsaw Battery.JPG|200px]]
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| Fuel and oil caps||Plastic||Plastic is lightweight and fuel safe. Also it is easily molded.||Molded||The cap provides a large enough surface for the user to easily remove, and the thread holds the caps in tight.||align="center"|2||They help contain the contents of fluids in the tanks.||There is a torque applied by the user to remove and attach the caps. ||align="center"|1
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| Spring loaded timing mechanism||plastic and aluminum||The aluminum is flexible allowing pressure to be provided to the cam and pin. The plastic is lightweight.||Molded and Bent||N/A||align="center"|1||It controls the timing of the spark plug.||There is a force on the aluminum strip that holds it against the pin. A force is exerted against the plastic piece from the cam.||align="center"|2
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| Trigger and connecting wire||plastic and aluminum||The materials are used to reduce weight.||Molded and Bent||Plastic can be easily molded. The metal is a stock aluminum rod bent into the desired shape.||align="center"|1||It converts user input into mechanical system.||||align="center"|1
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| Piston ring||Steel||Steel has a higher boiling point then the aluminum parts around it, resulting in less expansion from heat. Also steel is a stronger material than aluminum.||Pressed||The ring has a gap to allow it to be slightly stretched and compressed to fit on the piston.||align="center"|1||It seals the wall of the cylinder to the piston and creates a ring of oil around the piston for lubrication.||The force from the expanding gases and friction from the cylinder are acting on the piston ring. Also, the piston ring moves along with the piston causing a transfer in forces between them.||align="center"|1
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| Timing mechanism cover||Plastic||The plastic is lightweight and flexible.||Molded||The cover is shaped to reduce the space it takes up, while fully covering the parts below.||align="center"|1||It prevents damage to timing mechanism.||N/A||align="center"|2
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| Timing mechanism switch||Aluminum||||Pressed||||align="center"|1||It completes the circuit with the battery.||||align="center"|2
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| Fuel ratio adjuster||Rubber and Iron||||||||align="center"|1||It Regulates fuel to air mixture.||||align="center"|2
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| Air intake lock||Steel||||Pressed||||align="center"|1||It locks the air intake nut.||||align="center"|1
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| Choke switch||Plastic||||Molded||||align="center"|1||It triggers the choke in the intake.||||align="center"|1
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| Intake||Aluminum, Plastic and Rubber Gaskets||||Die Cast||||align="center"|1||It regulates the air intake and mixes the air with the fuel.||||align="center"|5
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|Piston||Aluminum Alloy||Aluminum is lightweight, machined with a low coefficient of friction.||Die Cast||The piston contours the cylinder with aslot cut into it for the piston ring. The shape is designed to minimize weight while maintaining strength.||align="center"|1||It transfers the pressure force from the expanding gases to the connecting rod.||The forces from combustion and expanding gas are acted on the piston. Also, the crankshaft exerts an initial force on the piston when the chainsaw is first started.||align="center"|1
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|Connecting Rod||Aluminum Alloy||A high strength aluminum alloy was used, because it is easily machined, and has a high tensile strength.||Pressed||A single piece connecting rod was used to reduce weight, and there is no need for it to be disassembled many times.||align="center"|1||It transfers the mechanical force from the piston to the crankshaft.||Forces are transferred between the piston and the crankshaft via the connecting rod.||align="center"|1
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|Crankshaft||Iron||Iron is used to endure the high stress, and to transfer high torque to the clutch.||Die Cast and cut in a lathe||a three part crankshaft was used because they are stronger and easier to machine.||align="center"|1||It transfers rotational motion between the clutch, flywheel, and piston.||High torque is transferred between the flywheel, piston and clutch.||align="center"|2
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|Clutch||Iron||Steel is very strong and the weight is needed to balance the flywheel.||Die Cast||Since the clutch is constantly rotating, it must be round. Also, the two springs cause the clutch to engage/disengage at a certain rotational velocity.||align="center"|1||It engages and disengages the gear connected to the bar at different rpm speeds.||A torque is applied from the crankshaft to engage/disengage the clutch.||align="center"|3
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|Bolts||Steel||Steel is a common material used for Bolts.||Molded and extruded through a die||||align="center"|40 (The different sizes are listed below)||They hold the parts together.||A torque is applied to attach/remove the bolt.||align="center"|1
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|Nuts||Steel||Steel is a common material used for nuts.||Molded and tapped||Steel is strong, and a common material for nuts.||align="center"|11 (The different sizes are listed below)|| They help the bolts attach to the parts.||A torque is applied to attach/remove the nuts.||align="center"|1
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''The complexity scale is rated as listed below.
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Andrew Koonce - Wiki Expert
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*1 = One or two parts that easily fit together
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*2 = Three to seven parts that require some knowledge to assemble
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Scott Chown - Communications Liason
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*3 = Seven to twelve parts that require accuracy, and full knowledge of the products use, to assemble.
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*4 = More than twelve parts that require full knowledge of the mechanical system.
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Matt Lang - Solid Modeling Expert
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*5 = It has many parts that require machines and careful examination to assemble.
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Gagan Reddy - Dissection Leader
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===Group Member Pros/Cons===
  
 
{| cellspacing="0" border="1" style="margin: 1em auto 1em auto"
 
{| cellspacing="0" border="1" style="margin: 1em auto 1em auto"
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|+'''Flat Head Bolts'''
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| align="center" style="background:#00aa00;"|'''Members'''
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! align="center" style="background:#00aa00;"|Length!!align="center" style="background:#00aa00;"|Thread Width!!align="center" style="background:#00aa00;"|Quantity
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| align="center" style="background:#00aa00;"|'''Pros'''
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| align="center" style="background:#00aa00;"|'''Cons'''
 
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| align="center"| 3/8"||align="center"| 1/8"||align="center"| 1
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| align="center"|Matt Lang||-5 Years of CAD Experience
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-Works Well in Groups
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||-Little Understanding of Engines
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-Poor Public Speaking
 
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| align="center"| 3/8"||align="center"| 3/16"||align="center"| 1
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| align="center"|Andrew Koonce||-Knowledge of Engines
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-Good With Computers
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||-Poor Public Speaking
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-Procrastinator
 
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| align="center"| 7/16"||align="center"| 3/16"||align="center"| 1
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| align="center"|Cam Borowiec||-Good Public Speaking
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-Natural Leadership Skills
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||-Poor Writer
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-Procrastinator
 
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| align="center"| 3/8"||align="center"| 3/16"||align="center"| 1
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| align="center"|Scott Chown||-Good Communication Skills
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-Good With Computers
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||-Lacks Dissection Knowledge
 
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| align="center"| 1 1/8"||align="center"| 3/16"||align="center"| 1
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| align="center"|Gagan Reddy||-Prior Dissection Experience
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-Knowledge of Engines
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|align="center"|  15/16"||align="center"| 3/16"||align="center"| 2
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||-Procrastinator
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-Busy Schedule
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|align="center"|  5/8"||align="center"| 1/8"||align="center"| 5
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|align="center"|  2 3/16"||align="center"| 3/16"||align="center"| 2
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|align="center"|  2 9/16"||align="center"| 3/16"||align="center"| 2
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|align="center"|  1 3/8"||align="center"| 3/16"||align="center"| 12
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|align="center"|  1 1/16"||align="center"| 3/16"||align="center"| 4
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|align="center"|  2 1/8"||align="center"| 3/16"||align="center"| 1
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|align="center"|  1/2"||align="center"| 5/32"||align="center"| 3
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|}
 
|}
  
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{| cellspacing="0" border="1" style="margin: 1em auto 1em auto"
 
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|+ '''Hex Head Bolts'''
 
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! align="center" style="background:#00aa00;"|Length!!align="center" style="background:#00aa00;"|Thread Width!!align="center" style="background:#00aa00;"|Head Size!!align="center" style="background:#00aa00;"|Quantity
 
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| align="center"| 1 3/16"||align="center"| 1/4"||align="center"| 7/16"||4 with lock washers
 
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{| cellspacing="0" border="1" style="margin: 1em auto 1em auto"
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== Gate 1: Request for a Proposal ==
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|+ '''Nuts'''
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Gate 1 can be found [[Group_32_Gate_1 | here]].
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! align="center" style="background:#00aa00;"|Shape!!align="center" style="background:#00aa00;"|Size!!align="center" style="background:#00aa00;"|Hole Diameter!!align="center" style="background:#00aa00;"|Thickness!!align="center" style="background:#00aa00;"|Quantity
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This Includes our work proposal, management proposal, Gantt Chart, and an initial product assessment.
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| Square||align="center"| 7/16" x 7/16"||align="center"| 2/8"||align="center"| 3/16"||align="center"| 4
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== Gate 2: Preliminary Project Review ==
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| Square||align="center"| 3/8" x 3/8"||align="center"| 3/16"||align="center"| 1/8"||align="center"| 2
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Gate 2 can be found [[Group_32_Gate_2 | here]].
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| Hex||align="center"| 1/2" x 1/2"||align="center"| 5/16"||align="center"| 5/16"||align="center"| 2
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This includes any causes for corrective action, an analysis of the disassembly, and a step by step process of the disassembly.
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| Hex||align="center"| 9/16" x 9/16"||align="center"| 5/8"||align="center"| 3/16"||align="center"| 1
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== Gate 3: Coordination Review ==
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| Hex||align="center"| 9/16" x 9/16"||align="center"| 7/16"||align="center"| 1/16"||align="center"| 1
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Gate 3 can be found [[Group_32_Gate_3 | here]].
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| Hex||align="center"| 3/8" x 3/8"||align="center"| 1/8"||align="center"| 1/8"||align="center"| 1
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This includes a component summary,  some suggested design revisions, solid modeling of a main system, and an analysis of engine seizure.
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|}
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==Gate 4: Critical Design Review==
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Gate 4 can be found [[Group_32_Gate_4 |here]].
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This includes a step by step reassembly process, and a final assessment of the chainsaw.
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==References==
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[1] "How Stuff Works: Chainsaws". How Stuff Works. 10 Oct 09. <http://home.howstuffworks.com/chainsaw.htm>.

Latest revision as of 04:16, 16 December 2009

Contents

Executive Summary

Our group was given a Pioneer 1074 chainsaw to dissect and analyze. This chainsaw was top of the line during it's day, however it is now 29 years old. Technology has not changed to much on chainsaws since then, but newer models have much more power. There are no specs online of the chainsaw that could be found.

Group info

Group Members

Cam Borowiec - Project Leader

Andrew Koonce - Wiki Expert

Scott Chown - Communications Liason

Matt Lang - Solid Modeling Expert

Gagan Reddy - Dissection Leader

Group Member Pros/Cons

Members Pros Cons
Matt Lang -5 Years of CAD Experience

-Works Well in Groups

-Little Understanding of Engines

-Poor Public Speaking

Andrew Koonce -Knowledge of Engines

-Good With Computers

-Poor Public Speaking

-Procrastinator

Cam Borowiec -Good Public Speaking

-Natural Leadership Skills

-Poor Writer

-Procrastinator

Scott Chown -Good Communication Skills

-Good With Computers

-Lacks Dissection Knowledge
Gagan Reddy -Prior Dissection Experience

-Knowledge of Engines

-Procrastinator

-Busy Schedule


Gate 1: Request for a Proposal

Gate 1 can be found here.

This Includes our work proposal, management proposal, Gantt Chart, and an initial product assessment.

Gate 2: Preliminary Project Review

Gate 2 can be found here.

This includes any causes for corrective action, an analysis of the disassembly, and a step by step process of the disassembly.

Gate 3: Coordination Review

Gate 3 can be found here.

This includes a component summary, some suggested design revisions, solid modeling of a main system, and an analysis of engine seizure.

Gate 4: Critical Design Review

Gate 4 can be found here.

This includes a step by step reassembly process, and a final assessment of the chainsaw.


References

[1] "How Stuff Works: Chainsaws". How Stuff Works. 10 Oct 09. <http://home.howstuffworks.com/chainsaw.htm>.

Retrieved from "http://gicl.cs.drexel.edu/wiki-data/index.php?title=Group_32_-_Chainsaw&oldid=42229"
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