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

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)

Pump Housing Cover

<Introduction providing justification for choosing this component>

Function [2]

Function: the main function of the pump housing cover is to provide an enclosure for the both the fluid as well as the internal parts of the fluid pump. It is designed so that there is a specific volume inside of the pump to allow for sufficient pressure to be generated based of the size of the motor attached. If the pump housing id designed to small the power from the motor will not be able to be fully transferred to the fluid, to large and there will be a lack of pressure built up. Another important function of the housing is to allow for a primer and a drain plug to be attached.

Flows: there is a mass transfer of fluid through the inlet and outlet attached to the pump housing

Environment: the pump housing cover operates in two different environments. The outside is subject to atmosphere while the inside is subject to pressurized fluid.

Form [3]

Geometry:

The general geometry of the pump housing cover is hollow-circular with added blocks of the same material to station other parts, and a hollowed pipe stub in the middle. The housing cover is not an axis symmetric component. The housing cover is a three-dimensional object, with a diameter slightly less than 9 inches, and an overall height of 2 ¾ inches. The hollowed geometry plays to this component’s function of being a cover to the pump housing. Disregarding the attached steel pipe, this aluminum-made part weighs approximately 2-3 pounds.

Material:

Compared to steel, cast aluminum tends to look better as a die cast part, and has three times greater axial strength. As a cover piece, the latter is an important material property that is integral in the overall function of the component.

Appearance:

The component is painted on the outside, and has white-powered corrosion on the hollow inside. The paint serves as the sole aesthetic property of the component (surface finishes were not considered) – the part has a combined gray, white, and red color profile (where the red is from painting).

Manufacturing Methods [2]

Manufacturing Processes: casting and machining

Evidenced By: parting lines (casting), non-ferrous material (casting), draft from tapering (casting), holes and threads (machining)

Affected by Material Choice? Yes, aluminum is more commonly cast as opposed to steel.

Impact of Shape: The shape is only feasible obtained by a molding process – for aluminum, that process is casting.

GSEE Factors

Casting this material, then machining was most economically feasible, given the part geometry. Along that point, die castings are readily recyclable – they are being made predominantly from recycled aluminum. When considering global factors, one can find the U.S. specifically uses casting methods in 90% of all finished manufactured products. The die casting industry continues to be an integral part of the success of U.S. manufacturing, meaning that jobs within successful die casting businesses are secure – directly affecting the blue-collar society in America.

Pump Housing / Bell (Part #4)

Pump Housing / Bell

<Introduction providing justification for choosing this component>

Function [2]

Function: the bell has three important functions. The first of which is to attach provide a location for the pump to be attached to the motor. The second important function is to house the internal components of the fluid pump. The crankshaft of the motor directly enters the bell through a hole in the center, attached to this is the impeller. The bell helps to ensure that none of these parts can move freely. The next function of the bell is to provide channels for the water to flow towards the exit pipe. After the fluid is accelerated due to the impeller, groves in the bell direct the flow around the outside radius and towards the exit pipe.

Flows: The bell is bolted directly to the crankcase and provides a connection to allow the flow of energy in the form of rotational kinetic energy to be transferred from the motor to the impeller via the crankshaft.

Environment: the pump bell operates in two different environments. The outside is subject to atmosphere while the inside is subject to pressurized fluid.

Form [3]

Geometry:

The general geometry of the pump housing bell is partially hollow-circular, with an added block of the same material protruding from the surface, along with several sets of machined holes. The bell is not an axis symmetric component. It is a three dimensional object, with an approximate diameter of 9 inches, and overall height of 3 inches. The partially hollow circular shape and machined holes (for connection) are conducive to a good support for the internal and surrounding components. This component weighs roughly 7 pounds – the heaviest of all our seven components. From that statement, it comes as no surprise that the material of choice for the bell was cast iron. Casting is most feasible for iron for reasons of cost-effectiveness, and iron doesn’t shrink when it gets cold, allowing the effective molding of any shape.

Material

As stated before, a material property of cast iron is its damping ability in regards to vibrations and noises. For a large support component, cast iron gives the most stability, with an environment full of vibrations and noises.

Appearance:

The component is painted on the outside, and has reddish rust all over the partially hollowed section. The interfaces are machined to create a tighter tolerance to ensure a proper connection to the internal components.

Manufacturing Methods [3]

Manufacturing Processes: casting and machining

Evidenced By: parting lines (casting), non-ferrous material (casting), draft from tapering (casting), holes and threads (machining)

Affected by Material Choice? Yes, aluminum is more commonly cast as opposed to steel.

Impact of Shape: The shape is only feasible obtained by a molding process – for aluminum, that process is casting.

GSEE Factors '

Casting this material, then machining was most economically feasible, given the part geometry. Along that point, die castings are readily recyclable – they are being made predominantly from recycled aluminum. When considering global factors, one can find the U.S. specifically uses casting methods in 90% of all finished manufactured products. The die casting industry continues to be an integral part of the success of U.S. manufacturing, meaning that jobs within successful die casting businesses are secure – directly affecting the blue-collar society in America.

Gasket Plate (Pump Housing) (Part #5)

Gasket Plate (Pump Housing)

<Introduction providing justification for choosing this component>

Function [2]

Function: the most important function of the gasket plate is to provide a seal between the pump housing cover and the bell. The gasket is designed to direct the flow of fluid in a specific manner such that the inlet fluid (relatively unpressurized) and the exit fluid (pressurized) stay separated. Without the gasket plate the pressurized and unpressurized fluid would mix and the fluid become would become effectively useless. Another function of the gasket plate is achieved through its geometry. A hole has been stamped out of the center directly above the impeller. This allows for unpressurized fluid to enter the impeller at only one specific point. Holes are also stamped out in decreasing diameter around the gasket plate. The functions of these are to allow for pressurized fluid to exit the pump through the outlet.

Flows: a mass flow exists through the gasket plate through the inlet hole and outlet holes

Environment: the gasket plate operates submerged in fluid and also under pressure

Form [3]

Geometry:

The general geometry of the gasket is a thin circle with ten circular cutouts, some varying in size. Aside from a prominent cutout in the middle, the cutouts travel in a non-continuous and somewhat sporadic path along the inner circumference of the gasket. It is a three dimensional object, with an approximate diameter of 9 inches, and overall height of a 1/3 inch. The gasket’s stamped features allow for the channeling of the fluid in the correct locations. The component weighs approximately 1-2 pounds. The material of choice was plate steel, along with a rubbery material, circled just inside the gasket’s diameter. To achieve the cut outs from steel, stamping is the most feasible manufacturing process, and plate metal is consequently the most feasible material of usage.

Material:

The specific material choice was fairly independent of the component’s function. As implied before, stamping is the most economically feasible way to manufacture this component. Also, stamping requires a functional and efficient recycling system (extra costs)– sheet metal is a very commonly recycled material. This depicts a mixture of two factors rolled into one (economic, environmental).

Appearance:

The component is red rust covered due to its surroundings, and does not consider surface finish - plate metal is already relatively smooth.

Manufacturing Methods [2]

Manufacturing Processes: stamping, injection molding

Evidenced By: relatively thin profile of sheet metal with cut-outs (stamping), thin ring of rubbery material - susceptible to indentation (injection molding), faint parting lines on ring (injection molding)

Affected by Material Choice? Yes, sheet metal is typically steel, so the magnetic properties were the conclusive indicator of stamped sheet metal, as opposed to some sort of casting.

Impact of Shape: The relative and constant thinness of the part definitely indicated the part began as sheet metal, so we were then able to make proper assumptions for manufacturing process.

GSEE Factors

Part geometry determines these manufacturing methods to be most economically feasible. Also, one might think that stamping in particular is a waste of material and a detriment to the environment, however sheet metal is one of the most common materials for recycling. With this, the stamping process in would have to take into account the cost to recycle scrap metal – an environmental and economic factor rolled into one.

Impeller (Part #10)

Impeller

<Introduction providing justification for choosing this component>

Function [2]

Function: the function of the impeller is to create the pressure gradient required in order to force the fluid to accelerate inside of the pump. As the impeller rotates and fluid is pushed into the middle, centripetal forces pushes the fluid outward causing it to accelerate outward and eventually out of the outlet of the pump.

Flows: there is and energy transfer or rational kinetic energy given to the impeller from the crankshaft into the kinetic energy of the fluid

Environment: the impeller operates submerged in fluid and also under pressure

Form [3]

Geometry:

The general geometry of the impeller is circular with protruding fin-like profiles, with a hole containing internal threads on the bottom. The impeller is not axis symmetric. It is a three-dimensional object, with diameter of around 4 ½ inches, and an overall height of 1½ inches. The fin-like protrusions are directly involved in creating the pressure difference and moving the fluid from the inlet to exit. The impeller is very dense for its size, weighing about 2 pounds. The component is made from cast iron, a heavy material. Casting is most feasible for iron for reasons of cost-effectiveness, and iron doesn’t shrink when it gets cold, allowing the effective molding of any shape. A material property of cast iron is its damping ability in regards to vibrations and noises. A highly functional and involved component such as the impeller would require the maximum amount of sturdiness achievable, which would need maximum damping from its surroundings.

Material:

Aside from cost effectiveness, environmental factors are influenced in casting. The die is created from recycled aluminum, meaning that the mold is most likely a recyclable product as well. Also, the U.S. creates most of their finished manufactured products from some sort of die casting, aiding for a thriving job atmosphere for the metal workers in America (specifics, including statistics are expounded upon in the manufacturing methods section). These GSEE factors are applicable to all other cast materials in our component analysis.

Appearance:

The component itself has been affected by its surroundings, as a constant layer of red rust has developed over the entire part. With that said, surface finish wasn’t considered in the making of this part; the finish was left unchanged after leaving the mold.

Manufacturing Methods [2]

Manufacturing Processes: casting and machining

Evidenced By: parting lines (casting), draft from tapering (casting), holes and threads (machining), magnetic properties, along with weight (casting)

Affected by Material Choice? Absolutely – the typical ferrous material to be cast is iron, which is very dense. This part weighs more than the pump housing cover, despite a 3x size difference!

Impact of Shape: The basic shape is only feasible (for economic purposes) by means of casting. From there, the sections that need tighter tolerances or slight adjustments in part geometry could be machined.

Base Foot (Part #101)

Base Foot

<Introduction providing justification for choosing this component>

Function [2]

Function: the base feet are designed to give stability to the engine when it is resting on a surface. They are designed to be flat and long such that there is as much area in contact with the ground as possible in order to disperse the weight of the fluid pump over as large of area as possible. This is important because the pump is designed to be used only outdoors where it is possible that the surface the pump is placed on can be uneven or possible wet. Having the large surface area of the feet helps to prevent the product from moving or possible sinking in mud due to the vibrations of the engine.

Flows: none

Environment: the base feet operating environment can vary from anything to resting on concrete to in a shallow puddle

Form [3]

Geometry:

The shape of the Base Foot is rectangular with a small circle cut out off-centered from the middle. In the Base Foot when you remove the base springs there are an additional two circles near the ends of the Base Foot. The Base Foot is three-dimensional and is axis-symmetric. This component’s shape provides a solid base for the fluid pump to be placed upon. The Base Foot’s width is the same length as the water pump that provides stable support when the product is in motion.

Material:

The Base Foot is made out of steel which is material that can be effective, cheap, and durable. This component must be durable enough to handle the amount of force the water pump is generating. The Base Foot is connected to the springs on opposite ends which are also made out of steel. It must be durable enough to withstand the force of the spring attached to the water pump. The Base Foot is bent and machined which could give additional support.

Appearance: The aesthetic property of this component is that it contains oxidized rust. The water pump is fairly old, but if it was new it would be dull gray and it wouldn’t be contributing much to the overall function of the product. It would not normally be seen to the user of the product because the base foot is attached to the bottom of the water pump. The Base Foot now has a rough finish with a bit of orange coating from the rust the steel received over the years. The Base Foot does not really have any functional or aesthetic purposes for the overall product besides providing support at the bottom of the water pump.

Manufacturing Methods [2]

Manufacturing Processes: bending, stamping

Evidenced By: sheet metal with flanges (bending), multiple cut out holes (stamping)

Affected by Material Choice? Yes, determining the part was steel (while considering its geometrical features) was the conclusive indicator of sheet metal – from there, we were able to make proper assumptions in regards to manufacturing processes.

Impact of Shape: The relative and constant thinness of the part definitely indicated the part began as sheet metal, so we were then able to make proper assumptions for manufacturing process.

GSEE Factors

The part geometry only calls for bending rather than press forming – the latter being the more expensive process. As stated before, stamping has underlying environmental (and economic) factors – the scrap material must be recycled to prevent waste in the environment, so a proper recycling system must be installed.

Springs (Base Feet) (Part #102)

Springs (Base Feet)

<Introduction providing justification for choosing this component>

Function [2]

Function: these springs were placed on the feet in an effort to both reduce vibrations of the engine due a certain amount of damping provided by the springs as well as to absorb energy that could be created due to dropping the fluid pump from a certain height. These springs may have also been implemented in order to prevent the product from moving when placed on a hard surface. Without the springs it is possible that the vibrations from the engine and pump could cause the feet to move with the pump in an upward and downward motion. This could cause the pump to slowly move slowly by itself

Flows: harmonic oscillations are possible

Environment: atmosphere

Form [3]

Geometry:

The General shape of the spring is a reduced end spring where it is straight across the center coil and it tapers at the end. The spring is axis-symmetric because it the spring is straight from the top of the spring to the bottom. The spring is three-dimensional and is very thick in material.

Material:

The spring is made out of steel because it can be easily acquired and manufactured. Steel is very durable and effective when having a serious amount of force acting on the spring. The spring is extruded and coil wound and it is made to absorb the impact created by the vibration of the fluid and engine pump. There is no specific property needed for this property to function but it must be material that is able to withstand an amount of force exerted on the spring by a water pump.

Appearance:

This component did not really have an aesthetic purpose and the spring feels rough with the color gray and oxidized orange rust. Assuming the spring was still new that it would be dull gray. The surface of this is very rough and it is more based for functional reasons because the spring is a small part of the water pump that can barely be seen by the user. The spring sole purpose is to absorb the shock the water pump exerts.

Manufacturing Methods [2]

Manufacturing Processes: extruding, coil winding

Evidenced By: constant cross section (extruding), retained coil-shape (coil wound)

Affected by Material Choice? Yes, springs are almost always made of steel as opposed to aluminum. We were able to then disregard any molding methods, and allocate proper manufacturing processes for steel, considering the part geometry.

Impact of Shape: The constant circular cross section led to our assumption of extruding, while the retained coil-shape asserted coil winding.

GSEE Factors

The part geometry determines this process to be most economically feasible. Similar to the pump housing cover, extrusion dies are typically made of recycled aluminum – making them readily recyclable and therefore good for the environment to conserve waste.

The spring can absorb the amount of force acted upon it. The life cycle of the water pump could be strengthened since it will not be damaged by the force acting on the pavement. Thus damaging the product.

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

Bracket (Crankcase - to - Base)

<Introduction providing justification for choosing this component>

Function [2]

Function: the purpose of the bracket is to connect the two base feet and attaches them to the engine. When the bracket is attached to the engine it provides a level surface for the feet to be attached to. Without this piece changes would have to be made to the engine block casting to create a surface for the feet to be attached to. This would greatly increase the cost of production and force extra materials to be used

Flows: none

Environment: atmosphere

Form [3]

Geometry:

The general shape of the bracket is rectangular with several cuts to have the actual shape of the component formed. Additionally, there are four small circles and opposite ends of the bracket that are stamped out. The bracket itself is axis- symmetric but the circles on the bracket are not symmetrical. This Bracket is three-dimensional. The component shape is thin in the middle with the ends being wide to hold on to the width of Base Foot to provide stability and support.

Material:

The component is material is made from steel and is made by being press-formed stamping. Steel is durable and could withstand the amount of force the overall water pump is generating. There is no specific material needed for this product to function, but this is a solid material to hold the Base feet steady.

Appearance:

This component does not have much of aesthetic properties since it is rusted. The Bracket is a dull dark gray with a little bit of an orange coating. The orange color signifies the corrosion of steel exposed to air in which over time starts to rust and turn into the orange color. The component has a smooth surface even if it is corroded a bit. Even though it has a smooth surface it is more of an functional purpose. The component functional purpose is to provide support for the engine and Base Feet stability. It helps lock the two base feet on opposite ends of the water pump in place.

Manufacturing Methods [1]

Manufacturing Processes: stamping

Evidenced By: plate metal with multiple cut out holes (stamping)

Affected by Material Choice? Yes, determining the part was steel (while considering its geometrical features) was the conclusive indicator of plate metal. We were then able to make proper assumptions in regards to manufacturing processes.

Impact of Shape: The relative and constant thinness of the part definitely indicated the part began as a plate of metal, so we were then able to make proper assumptions for manufacturing processes.

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

Design Revisions

Intro