Group 3 - Homelite Fluid Pump (Gasoline Powered) - Product Evaluation

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	==== Pump Housing / Bell (Part #4) ====		==== Pump Housing / Bell (Part #4) ====
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	=== Solid Modeled Assembly ===		=== Solid Modeled Assembly ===

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Revision as of 16:28, 15 November 2012

Contents 1 Product Evaluation 1.1 Component Summary 1.1.1 Function 1.1.2 Materials 1.1.3 Manufacturing Processes 1.1.3.1 Identification / Description of Manufacturing Processes 1.1.3.2 Common Processes 1.1.4 Parts List 1.2 Product Analysis 1.2.1 Preface to Product Analysis 1.2.2 Pump Housing Cover (Part #1) 1.2.3 Pump Housing / Bell (Part #4) 1.2.4 Gasket Plate (Pump Housing) (Part #5) 1.2.5 Impeller (Part #10) 1.2.6 Base Foot (Part #101) 1.2.7 Springs (Base Feet) (Part #102) 1.2.8 Bracket (Crankcase - to - Base) (Part #77) 1.3 Solid Modeled Assembly 1.3.1 1.3.2 1.4 Engineering Analysis 1.4.1 Key Component 1.4.2 analysis... 1.5 Design Revisions 1.5.1 Design Revision 1 1.5.2 Design Revision 2 1.5.3 Design Revision 3

Product Evaluation

Description of product evaluation

Component Summary

This section serves to preface the evaluation of the Homelite fluid pump by cataloging the individual parts in the product with the inclusion of some high-level analysis of the parts. Before delving into the parts list we will first explore background information regarding the table's content fields including the function of the part, the materials used, and the manufacturing processes required to create the part.

Function

In describing the functionality of each component, only brief statements regarding high-level functionality are made in this section. The following section, product analysis, will take a more in-depth look at the analysis of select components.

Materials

In identifying unknown engineering materials, some sort of standardized process benefits successful part identification. The Following table records some important information that was used by group 3 regarding the identification of the materials found in the Homelite fluid pump.

Caption

Material	Magnetic? (Y/N)	Color	Other Characteristics
Aluminum	N	Gray	Thick naturally occurring oxide layer (white & powdery appearance)
Iron	Y	Gray/Black	Oxidation: Appears as reddish-colored rust
Steel	Y	Gray/Silver	Oxidation: Appears as reddish-colored rust
Brass	N	Gold (for yellow brass)	Brass parts are typically found with precise tolerances and high surface finish (for bushings, etc) because of its material properties.
Polymer (Plastic/Rubber)	N	Various	---

In general, the materials identification process involves the following steps:

1. Is the part magnetic? (test with a magnet)
2. Observe the color/other characteristics according to the table above
3. Further information regarding the nature of manufacturing processes involved in creating the part can narrow down the material possibilities further (e.g. A magnetic, gray, rusty part may be deduced to be steel (not iron) because it was press-formed from sheet metal. Steel is the most probable candidate for the rolling process required to manufacture sheet)

Manufacturing Processes

INTRO

Identification / Description of Manufacturing Processes

[Die] Casting

Metal casting process characterized by pouring molten material into a [steel] mold comprised of at least two dies. The molten material then experiences high pressures to take the mold’s shape, and then is left to harden. Typically used in non-ferrous metals. Process is cheaper than investment casting, which is only needed for very detailed components. From our component analysis, we concluded all cast materials to be manufactured by means of die casting. Evidenced by: Parting lines; Smooth yet uneven finish; Non-magnetic material (typically)

Injection Molding

Produces plastics and other polymers. Plastic granules are melted, and commanded to take shape by being forced (due to their low fluidity) into a metal cavity, where they are left to harden. The cavity is shaped in the desired material profile. Evidenced by: Plastic or rubber material (polymers); Parting lines

Forging

This process can be cold or hot worked. Beginning with an ingot between two dies, compressive forces are applied such that the metal is shaped, and some amount of flash (excess material) is created. Evidenced by: Materials of high strength (must withstand tensile and compressive forces)

Press Forming

Similar to forging – specific to the shaping of sheet metal. Due to sheet metal’s lack of strength, this process is only applicable for cold working.

Stamping: Subtractive process that is a sub-section of press forming. Compressive forces are applied to cut out a desired shape within the layer of sheet metal. Evidenced by: Stamped (cut-out) sheet metal

Bending: Simple bending on sheet metal – possible only with sheet metal because of its thinness. Evidenced by: Sheet metal with flanges

Machining

Subtractive process characterized by the removal of material to create part geometry (including threads), tighten tolerances, or enhance surface finish – each involving different machining tools. Evidenced by: Threads; Extremely smooth surfaces; Holes; Other adjusted part geometry

Extruding

This process pushes a material through a die to obtain desired profile and cross-section (e.g, pipes, beams). Evidenced by: Constant cross section; Considerable length perpendicular to cross sectional area (not a washer, for example)

Drawing

Similar to extruding, material is pulled through a die to obtain desired profile and cross section. Evidenced by: Metallic wire

Common Processes

In order to minimize clutter in the following component summary parts list table, some information has been compacted through specific nomenclature, and these points will be discussed here.

Steel (sheet)

Refers to Steel material that is taken in in sheet-metal form. The manufacturing process rolling is always required to form thin metal layer - therefore, rolling is implied whenever considering sheet metals.

Screws/Bolts [S/B]

For screws and bolts, this nomenclature is adopted [S/B]. The processes typically includes extrusion of a cylindrical blank, forging (to create head), machining(for threads)

Parts List

Parts List Table

P/N	Name	Qty	Function	Material	Manufacturing Process(es)	Image
1	Pump Housing Cover	1	Contains the pump system along with the pump housing/bell part	Aluminum	Cast
2	Pump Outlet Pipe	1	Provides an outlet for the fluid to leave the pump housing	Steel	Extruded, Machined
3	Pump Inlet Nipple	1	A fitting that allows for a pipe or hose to be connected to the pump housing through which fluid enters the pump housing	Steel	Extruded, Machined
4	Pump Housing / Bell	1	Provides an interface that connects the pump to the engine. Also supports all internal components of the pump	Cast Iron	Cast, Machined
5	Gasket Plate (Pump Housing)	1	Channels the fluid in the correct locations in relation to the impeller through holes in the gasket plate	Steel (sheet)	Stamped
6	Mounting Bolts (Pump Housing Cover)	4	Fastens the pump housing cover to the bell. Also ensures all components within the pump stay secure	Steel	[B]
7	Washers (Pump Housing Cover)	4	Distribute the load of the pump housing mounting bolts over a larger area	Steel	Press Formed (stamped)
8	Pump Drain Plug	1	Allows for fluid to be drained from the pump housing when not in use	Cast Iron	Cast, Machined
9	Pump Primer Port Plug	1	A plug used to fill the pump housing with fluid in order to create suction once the engine is started	Steel	Extruded, Machined
10	Impeller	1	Used to transform rotation kinetic energy taken from the engine and transfer the energy to the fluid through its unique shape	Cast Iron	Cast, Machined
11	Oil Drain Plug	2	A plug which allows for oil to be drained out of when draining the engine oil	Steel	Extruded, Machined
12	Oil Fill Plug	1	A plug which allows for new oil to be introduced into the engine	Plastic	Injection Molding
13	Air Filter Box Cover	1	Protects the air filter from any harmful substances such as water or leaves	Steel (sheet)	Press Formed (stamped)
14	Air Filter Box	1	Holds the air filter in place onto of the carburetor and also protects the filter from harmful substances	Steel (sheet)	Press Formed (stamped)
15	Air Filter Element	1	Removes impurities in the air to allow for a cleaner and more efficient combustion cycle and to prevent damage to any internal components	Polyurethane Foam	Hot Molding
16	Air Filter Spacer	1	Ensures a pathway for the now clean air to take into the carburetor	Steel (sheet)	Press Formed (stamped)
17	Air Filter Box Mounting Screw	1	Fastens the air filter box to the top of the carburetor	Steel	[S/B]
18	Fuel Fill Cap	1	Removable seal that allows for fuel to be added to the gas tank and prevents any harmful substances from entering the fuel tank	Steel (sheet)	Press Formed, Machined
19	Phillips Mounting Screws (Fuel Tank)	3	Fastens the fuel tank to the bottom of the carburetor	Steel	[S/B]
20	Fuel Tank Mounting Bolt	1	Attaches the bottom of the fuel tank to the engine block	Steel	[S/B]
21	Crankcase Ventilation Tube	1	Provides a channel through which pressures may be transmitted between the carburetor and crankcase	Steel	Extruded, Bent
22	Rubber Tube Fitting (45 deg - female-female)	1	Provides the angle necessary for the crankcase ventilation tube to connect with both the valve cover to the carburetor	Rubber	Injection Molding
23	Rubber Tube Fitting (45 deg - grommet-female)	1	Provides the angle necessary for the crankcase ventilation tube to connect with both the valve cover to the carburetor	Rubber	Injection Molding
24	Recoil Start Housing	1	Secures the recoil start mechanism	Steel (sheet)	Press Formed (stamped, bent)
25	Recoil Start Grommet	1	Provides a smooth edge for the reoil start rope to rub against - rather than a rough-edged sheet metal hole	Aluminum	Cast
26	Mounting Bolt (Recoil Start Housing)	1	Fastens the recoil start housing to the engine block	Steel	[S/B]
27	Recoil Start Handle	1	Gives the user an easy to hold object to pull when starting the engine	Rubber	Injection Molding
28	Recoil Start Handle Pin	1	Secures the recoil start rope to the recoil start handle	Steel	Extruded
29	Recoil Start Rope	1	Transfers the translation kinetic of the handle to rotational kinetic energy of the recoil start pulley	Hemp	Braiding, Twisting
30	Spring Steel Band	1	Provide tension to the recoil start pulley allowing it to return to its original position after being pulled.	Steel (spring)	Drawn, Bent
31	Recoil Start Pulley	1	Connects the recoil start handle/rope to the crankshaft	Plastic	Injection Molding
32	Governor Plate	1	Using the pressure gradient created in the air due to the flywheel Limits the engines RPM's so that the engine does not exceed the rated revolutions per minute	Steel (sheet)	Press Formed (stamped)
33	Throttle Return Spring & Linkage	1	Transfers the signal from the governor plate to the carburetor and in doing so tells the engine how much fuel to allow into the engine	Steel	Rod: Extruded Spring: Extruded, Coil Wound
34	Carburetor Mounting Bolts	2	Fastens the carburetor to the engine block	Steel	[S/B]
35	Air Intake Gasket	1	Seals the interface between the carburetor and the air filter box	Rubber	Injection Molding
36	Idle Adjuster Screw	1	The needle end of the screw works in conjunction with the idle adjuster jet to regulate air intake at low engine speeds (thus adjusting the air/fuel mixture at idle)	Steel	[S/B] , Additional Machining
37	Idle Adjuster Spring	1	Spring force locates the idle adjuster screw (taking up thread slop) for more precise idle adjustment	Steel	Extruded, Coil Wound
38	Idle Adjuster O-Ring	1	Seals the idle adjustment module to prevent unwanted air entry to the valve	Rubber	Injection Molding
39	Idle Adjuster Cap	1	Houses the idle adjustment components with its location being in the carburetor body	BLANK	BLANK
40	Idle Adjuster Jet	1	See part 36, idle adjustment screw	Brass	Extruded, Machined
41	Throttle Adjuster Arm Mounting Screw	1	Fixes parts 42 & 43 to the carburetor body	Steel	[S/B]
42	Throttle Adjuster Arm Bushing (Notched)	1	This part works in conjunction with part 43 to provide a rigid fixed axis about which part 44 can rotate freely (without being clamped normal to the rotational axis).	BLANK	BLANK
43	Throttle Adjuster Arm Bushing (Flat)	1	See part 42	BLANK	BLANK
44	Throttle Adjuster Arm	1	An intermediate rotational node of the throttle linkage.	Steel	Press Formed (stamped)
45	Minimum Throttle Adjustment Screw	1	Provides a mechanical stop to the rotation (in the direction of lesser throttle) of the throttle arm (part 53)	Steel	[S/B]
46	Spring (Minimum Throttle Adjustment Screw)	1	Provides resistance to part 45 rotation such as to prevent unwanted loosening of the screw	Steel	Extruded, Coil Wound
47	Mounting Screws (Cover Plate - Carburetor)	4	Fasten the cover plate (part 50) to the carburetor	Steel	[S/B]
48	Metal Ring (Cover Plate - Carburetor)	1	Provides a plane circular surface to make contact with part 51 (rather than the spring end of part 49)	Steel	Press Formed (stamped)
49	Spring (Cover Plate - Carburetor)	1	Provides spring force / pressure to an area on the gasket (part 51)	Steel	Press Formed (stamped)
50	Cover Plate (Carburetor)	1	Allows access to contained components for assembly (and) repair	Aluminum	Cast, Machined
51	Rubber Gasket (Cover Plate - Carburetor)	1	Seals contents from atmospheric pressure, also has mechanically functional features that block divert pressures to/from ports in the carburetor body	Rubber	Injection Molding
52	Carburetor Body	1	Contains all components of carburetor sub assemblies, mounted directly inline with the comustion chamber	Aluminum	Cast, Machined
53	Throttle Arm	1	Rigidly connected to the throttle plate. Its rotation opens / closes the throttle mechanically	Steel (sheet)	Press Formed
54	Choke Adjuster	1	Provide a way for the user to increase the fuel to air ratio of the engine allowing for an easier cold start	Plastic	Injection Molding
55	Fuel Straw	2	Allows fuel to be sucked into the fuel straw tube	Plastic	Injection Molding
56	Fuel Straw Tube	1	Transports the fuel from the fuel straw into the carburetor	Brass	Extruded
57	Steel Clip (Fuel Straw)	1	Fastens the fuel tank straw and tube together	Steel	Drawn
58	Spark Plug	1	Uses electrical energy to create a spark inside the combustion chamber which is used to ignite the fuel and air mixture	Ceramic, Steel, Other Metals	Extruded, Machined, Knurled, Molding (for ceramic insulator)
59	Exhaust Manifold	1	Create back pressure inside the combustion chamber. Also used to reduce the volume of the engine	Steel	Extruded, Press Formed, Forged, Machined
60	Carry Handle	1	Provide a simple way to carry the fluid pump from one location to another	Steel	Press Formed (bent)
61	Mounting Bolts (Carry Handle)	2	Fasten the carry handle to the engine head	Steel	[S/B]
62	Shroud (Engine Head)	1	Guards/protects engine head part from damage in the event that the product suffers a shock to its top side.	Steel (sheet)	Press Formed (stamped)
63	Engine Head	1	Houses the spark plug as well as the provides the top half of the combustion chamber	Aluminum	Cast, Machined
64	Engine Head Gasket	1	Ensures a seal between the engine head and the engine block. Also, its thickness contributes to the volume of the combustion chamber.	Steel (sheet)	Press Formed (stamped)
65	Bolts (Engine Head)	8	Fasten the engine head to the engine block	Steel (sheet)	[S/B]
66	Engine Shroud (Front)	1	Protects the engine from damage	Steel (sheet)	Press Formed (stamped)
67	Mounting Plate (Governor)	1	Provides a mounting location for the governor plate, with conscious design of the gorvenor mounting plate's functional geometry and proximity to the flywheel	Steel (sheet)	Press Formed (stamped, bent)
68	Coil	1	Produce an electrical charge through a rotating magnet on the flywheel	Steel, Copper, Plastic	Press Formed, Extruded, Injection Molding,
69	Spark Plug Wire	1	Transport the electrical charge created from the coil to the spark plug	Copper, Rubber	Extruded, Injection Molding
70	Mounting Screws (Coil)	2	Secure the coil to the block	Steel	[S/B]
71	Shroud (Mesh - Flywheel)	1	Protects the user from possible injury from the rotating flywheel	Steel (sheet)	Press Formed (stamped)
72	Mounting Screws (Mesh Shroud - Flywheel)	1	Secure the mesh shroud to flywheel	Steel	[S/B]
73	Shroud (Side - Flywheel)	1	Prevents debris/human parts from entering a location that is dangerous during product operation.	Steel (sheet)	Press Formed (stamped, bent)
74	Crankcase Cover	1	Seals the side of the engine. Also assists in containing the oil inside the engine	Aluminum	Cast, Machined
75	Rubber Gasket (Crankcase - to - Crankshaft)	1	Creates a seal between the crankcase and the crankshaft preventing oil from leaking out	Rubber	Injection Molding
76	Mounting Bolts (Crankcase Cover)	1	Fastens the crankcase cover to the block	Steel	[S/B]
77	Bracket (Crankcase - to - Base)	1	Helps support the engines attachment to the feet and provides stability	Steel (plate)	Press Formed (stamped)
78	Nuts (Base Bracket Hardware)	2	Secures the base bolts to the feet	Steel	Extruded, Hot Forging, Machined
79	Washers (Base Bracket Hardware)	2	Helps evenly distribute load of the base nut over a larger area	Steel (sheet)	Press Formed (stamped)
80	Bolts (Base Bracket Hardware)	2	Fasten the feet and springs to the pump/block of the engine	Steel	[S/B]
81	Bearing (Crankshaft Support)	1	Supports the crankshaft at one end, allowing friction - less rotation of the crankshaft	Steel	Extruded, Forged, Machined
82	Camshaft	1	Convert rotational motion into translational oscillations of the lifters	Steel	Cast, Machined
83	Lifters	2	Transport the translational oscillations created by the camshaft to the valves	Steel	Extruded, Forged, Machined
84	Connecting Rod	1	Direct the translational motion of the piston to the crankshaft	Aluminum	Cast, Machined
85	Connecting Rod Cap	1	Attach the connecting rod to the crankshaft providing a simple way of assembling/ disassembling the two parts	Aluminum	Cast, Machined
86	Oil Slinger	1	Repeatedly impacts the engine oil sitting in the bottom of the engine causing it to splash upward and coat moving parts	Steel (sheet)	Press Formed (stamped, bent)
87	Bolt Locking Plate (Connecting Rod)	1	Ensures connecting rod bolts will not become loose	Steel (sheet)	Press Formed (stamped, bent)
88	Bolts (Connecting Rod)	2	Clamps the connecting rod cap to the connecting rod, thus fastening the connecting rod to the crankshaft	Steel	[S/B]
89	Retaining Clips (Wrist Pin)	2	Connects the piston to the connecting rod	Steel	Extruded, Bent
90	Wrist Pin	1	Mates the connecting rod to the piston by way of insertion of the wrist pin through holes in the other parts. Allows for hinged rotation between the piston and connecting rod	Steel	Extruded, Machined
91	Piston	1	Provides a bottom seal for the combustion chamber which allows for translation motion downward when the fuel air mixture is ignited followed by upward motion at the bottom of the stroke	Aluminum	Cast, Machined
92	Piston Rings	3	Creates a seal between the piston and piston cylinder ensuring no gases escape from the combustion chamber	Steel	Extruded, Bent, Machined
93	Valves	2	Allows for exhaust gases to exit the combustion chamber and gas and fuel mixture to enter at specific moments in the combustion cycle	Steel (sheet)	Extruded, Forged, Machined
94	Valve Springs	2	Force the valves to remain closed when the lifters are in the downward position	Steel	Extruded, Coil Wound
95	Retaining Clips (Valve Springs)	2	Attach valves springs to the valves	Steel (sheet)	Press Formed (stamped)
96	Crankshaft	1	Allow for translational motion to be converted into rotation motion	Cast Iron	Cast, Machined
97	Crankshaft Nut / One-Way Bearing	1	Threads onto the end of the crankshaft, pressing the flywheel onto the crankshaft's taper, preventing the flywheel from translating relative the crankshaft's axis	Aluminum	Cast, Machined
98	Flywheel	1	Through rotational inertia created by the rotating mass of the flywheel smooths out the uneven motion of a combustion cycle	Cast Iron, Aluminum	Cast, Machined
99	Key (Flywheel - to - Crankshaft)	1	Prevents the flywheel from spinning freely on the crankshaft	Aluminum	Extruded
100	Crankcase	1	Serves as a foundation for all components in the engine	Aluminum	Cast (multiple piece mold)
101	Base Foot	2	Provides support for the engine and fluid pump as well as an even surface for the fluid pump to rest on	Steel	Bent, Machined
102	Springs (Base Feet)	4	Absorbs impact energy created from the vibration of the engine and from relocating the fluid pump	Steel	Extruded, Coil Wound
103	Bolts - Long (Base Feet Hardware)	2	Fasten the base of the fluid pump to the engine and pump	Steel	[S/B]
104	Bolts - Short (Base Feet Hardware)	2	Fasten the base of the fluid pump to the engine and pump	Steel	[S/B]
105	Washer - Larger (Base Feet Hardware)	2	Helps evenly distribute load of the base bolts over a larger area	Steel	Press Formed (stamped)
106	Lockwasher (Base Feet Hardware)	2	Prevents the base nuts and bolts from rotating and becoming loose	Steel	Press Formed (stamped)
107	Washer - Smaller (Base Feet Hardware)	2	Helps evenly distribute load of the base bolts over a larger area	Steel	Press Formed
108	Nuts (Base Feet Hardware)	2	Fastens the base feet to the base bolts	Steel	Extruded, Hot Forged, Machined
109	Mounting Bolts (Pump Housing / Bell)	4	Fastens the two main parts of the pump, the housing and bell	Steel	[S/B]
110	Spring (Impeller)	1	Exerts force / pressure over the area of the impeller.	Steel	Extruded, Coil Wound
111	Valve Cover	1	Covers the valve assembly access port. Serves as the portal through which the crankcase ventilation tube interfaces with the crankcase atmosphere. Contains a filter element to prevent oil from exiting the crankcase in the vapor that's exchanged through the ventilation tube.	Steel	Press Formed
112	Mounting Screws (Valve Cover)	2	Fasten the valve cover to the engine crankcase	Steel	[S/B]

Product Analysis

Intro

Preface to Product Analysis

The following table demonstrates the criteria that are considered in determining the complexity rating for a component (1: least complex, 3: most complex)

Complexity Ratings

Complexity Rating	Criteria
Function	Form	Manufacturing
1	The component performs one function which does not contribute to the overall performance of the product. It is very easy to understand and use towards the user.	Part geometry contain a low number of simple features with basic shapes and do not contain a lot of irregularity	Parts with relatively simple geometry that can be obtained by a single process from a single mold or die. Such processes include casting, injection molding, forging, press forming, and extruding.
2	This component contributes to the energy flow, physical and signal aspect of the product that is moderately complex than the other parts of the product	Part geometry contain a higher number of simple features with basic shapes and do not contain a lot of irregularity	Parts with multiple features that can only be achieved via multiple manufacturing processes, or even elements of assembly. This is determined by: a complex geometry that requires multiple molds/dies, a relatively simple geometry that is machined for a functional purpose (e.g., threads on a cast material), or a part that requires several steps to assembly.
3	This contains several components function and can contribute to the energy flow of the product.	Part geometry contain a many features with shapes that are complex and possibly irregular	Parts with complex geometry only obtainable by several molds or steps to assembly, and multiple distinct machined features that each serve a different functional purpose.

Pump Housing Cover (Part #1)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Pump Housing / Bell (Part #4)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Gasket Plate (Pump Housing) (Part #5)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Impeller (Part #10)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Base Foot (Part #101)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Springs (Base Feet) (Part #102)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Bracket (Crankcase - to - Base) (Part #77)

<Introduction providing justification for choosing this component>

Function [2]

function

Form [3]

Geometry:

g

Material:

m

Appearance:

a

Manufacturing Methods

Materials

Solid Modeled Assembly

Introduce the parts included in the assembly.

Relate the solid-modeled assy to a REAL picture of the modeled parts?

Engineering Analysis

Intro Informs Design Revisions

Key Component

analysis...

Design Revisions

Intro

Design Revision 1

Design Revision 2

Design Revision 3