Group 9 - Skilsaw Circular Saw 2

Component Summary

Component and Part Number	Photo	Component's Function	Materials Used	Manufacturing Process	Reason component is made out of specific material	Attributes of Part	Part # in "Saw Explosion" found above
Housing 2 610 912 983		Hold the internal electromagnetic motor in place and keep the shaft and inner components protected.	Plastic	Plastic injected into mold and let to solidify	Plastic is a durable material which is light making it easier on the user. Plastic is also relatively cheap which will keep the product cost down	Hard plastic protects inside and allows flow of air. Also aesthetic shape given to the housing	1
Field Magnet 2 610 341 367		Provide electrical current which causes the inner electromagnetic motor to rotate providing a turning force to the saw blade	Copper and Plastic	The copper wire is drawn providing the small cylindrical shape, the plastic is injected into a mold and let to solidify	Plastic is cheap and a good material for a housing for the copper wires because it is a good insulator for the copper wires which have current put through them. The copper wires are a good conductor of electricity while also being cheap to produce	Wires are spun in a certain coil pattern to provede optimal electromagnetic force used to spin the inner electromagnetic motor	2
Trigger 2 610 917 325		Act as a switch allowing power to motor when operator desires	Plastic	Plastic injected into mold and let to solidify	Part is made out of plastic because it is durable and can take a constant pressing by the user. It is also cheap and will keep parts cost down	Part is made to fit the shape of the human finger which is what interacts with it. Also built with a safety the user must toggle for extra protection	4
Screw 1 2 610 341 364		Holds plastic handle molding of the saw together	Steel	Steel is extruded and then lathed to apply the threading	Part is made from steel because it has to be strong enough to hold the handle together while still being cheap enough to keep total product cost down	(Three) Torx 20 bit screws are used	19
Screw 2 2 610 341 365		Holds the blade housing together with the housing of the saw (shaft, electromagnetic motor, field magnet, etc)	Steel	steel is extruded and then lathed to apply the threading	Part is made from steel because it has to be strong enough to hold the saw blade housing together with the plastic housing of the body of the saw while still being cheap enough to keep total product cost down	(Three) Torx 20 bit screws are used	27
Screw 3 2 610 347 103		Holds the electric field magnet inside of the housing component of the saw	Steel	Steel is extruded and then lathed to apply the threading	Part is made from steel because it has to be strong enough to hold the field magnet in place, while still being cheap enough to keep total product cost down	Torx 20 bit screw	39
Spring 4 2 610 914 057		Pushes the blade guard back to the safe position when the blade is not being used to cut material. Acts as a safety device for both the saw when it is put on the ground and keeping the user safe froma spinning blade	Steel	Extruded steel which is then spun to give it the shape and properties of the spring	Part is made from steel because it is a bendable material to fit into the spring shape and then a reliable material once the spring is finished	Keeps both the user and saw safe. This is stopped by the Rubber Stop inside the blade housing	33
Casing Foot 2 610 913 231		Keep the saw steady on surface and allow precision cuts to be made by using engraved dimensions and leading lines	Galvanized Steel	Steel which gets stamped out and engraved with dimensions	This hardened steel provides a reliable base for the saw that cannot be easily bent or broken and it also is rust resistant	Engraved with dimensions so that operator can mace precision cuts on a steady path	40
Head Bolt 2 610 346 554		Hold the saw blade within the saw blade guard connected to the rotating gear. It also keeps the blade spinning in a smooth circular motion	Steel	Piece is extruded steel. Then threaded using a lathe and forged at the end	Steel provides a strong enough material to overcome the forces acting on the saw and keep it stationary while allowing it to rotate. Also steel is relatively cheap which brings total cost down	Wrench tool attached to saw made to fit this size so as to allow easy switching of blades while on site	52
Wing Nut 2 610 029 562		Allow for quick adjustments while being strong enough to keep them secure one selected	Steel	Steel was forged and then stamped to get desired shape. Then drilled to get the hole for the screw.	Steel is strong enough to keep the part secure once the selection has been made. Also durable in case of impact on the nut	Wing nut feature allows for quicker readjustment when on the job. There is no need for big wrenches or torx kits	42
Rubber Stop 2 610 341 394		Protect the saw blade guard from damaging when released from the position while cutting. Blade guard swings down 180 degrees and the rubber stop is there to protect it	Rubber	Rubber is injected into mold and let to solidify	Rubber is the best material because it is soft enough to cusion an impact however durable enough to last and maintain its same functionality over time	Round shape allows for a cushioned impact from saw blade guard	49
Rubber Stop Screw 2 610 347 100	In photo with Rubber Stop	Secure the Rubber Stop in place	Steel	Steel is extruded and then threaded on a lathe. Then the end is forged	Steel screw is needed because this screw is holding the rubber stop which takes constant impact while on the job	Torx 20 bit screw	51
Blade Angle Screw 2 610 017 262		Keep the saw angle constant once selected and secure	Steel	Steel is extruded and then threaded on a lathe. Then the end is forged	Steel is needed because this part has to keep the saw angle from moving. If the blade moves it could be dangerous for the user as well as making unintended cuts	Allows greater variety of cuts which include angles	41
Blade Wrench 2 610 968 670		Allow the user to quickly remove and install a saw blade	Steel	Steel is stamped out of sheet metal and then bent giving it some shape to fit on the screw nicely	It is made of steel because it is sturdy enough to apply a high force unscrewing the blade, yet cheap enough to keep the total product cost down	Has two different sizes to adjust different size screws	651
Carbon Brush Set 2 610 993 156		Helps deliver the current from the outlet to the electromagnetic motor after the trigger has been initiated by the user	Plastic, steel, and copper	Plastic injected into mold and let to solidify, the copper contact sheet is stamped out from sheet metal, and the spring is extruded steel which is then spun to be a spring	Plastic because it is easily molded, the spring is made of steel which is reliable and sturdy, and copper because it is a good conductor and this piece is part of the electromagnetic motor	Small in size but a key component in the electricity transfer	810
Set Handles 2 610 915 260		Insulate the saws inner components and allow the user to maintain good control of the saw at all times	Plastic	Plastic injected into mold and let to solidify	Plastic is used because it is a lightweight material which makes the saw easier on the user, yet it is sturdy enough to withstand all of the forces put on it by both the user and the material being cut. Plastic is easy to mold into a shape that fits nicely in an operators hand and absorb any impact distributed through it	Designed with aesthetics in mind because this is the part of the saw the user interacts with most, houses wiring and trigger system, made with grip so the user has optimal control of the saw at all times	837
Blade Housing 2 610 312 398		Intended to protect the user from a spinning blade as well as protecting the blade when the saw is put on the ground	Aluminum	Cast used to create the piece then shaped to create necessary dimensions to house the blade, cover the upper half of the blade guard. Cutting and drilling used to create an exit for debris, ventilation behind blade, and the holes for screws to keep it in place.	Aluminum is cheaper and a better option for the larger components of the saw. It is lightweight and still durable enough for the function it plays	Given designs to look aesthetically pleasing while still performing its job	24
Blade Guard 2 610 916 428		Intended to protect the user from a spinning blade as well as protecting the blade when the saw is put on the ground	Aluminum	Cast used to create the piece then shaped to create necessary dimensions to house the blade, cover the upper half of the blade. Cutting and drilling used to create an exit for debris, ventilation behind blade, and the holes for screws to keep it in place.	Aluminum is cheaper and a better option for the larger components of the saw. It is lightweight and still durable enough for the function it plays	Given designs to look aesthetically pleasing while still performing its job	32
Bearing 2 610 341 347		Allows the pinion shaft to go through both the blade housing and blade guard and attach to the saw blade providing the rotational energy	Steel	Steel was cast and then bored out to give desired dimensions	Steel is needed for this part because there is a lot of rotational force acting on the piece	Well lubricated to prevent wear over time	26
Motor 2 610 341 306		Provide the electromagnetic force which is turned into rotational mechanical energy when the motor shaft meets the pinion shaft. Fan prevents motor from getting too hot	Shaft is made from steel, Wires are made from copper	Steel was lathed down to desired size and then machined at the end giving it the teeth. Wires were drawn providing small cylindrical shape. Fan was made from steel stamped out of sheet metal	Steel is a strong material and this piece has a lot of turning force acting on it. The copper wires are a great conductor of electricity without a high cost	Inner Electromagnetic coil sits on shaft and this is where the turning force begins	3
Pinion Shaft 2 610 997 776		Turns the rotational energy provided by the electromagnetic motor and transfers it using a gear to force the saw blade to spin	Steel	Steel is extruded and then given the teeth. Both ends are forged to provide more strength	Steel is needed for this part because it is relatively cheap and this function requires a part that is stronger than plastic because there is a strong turning force that plastic could not handle	Sits in a well lubricated socket to allow easiest rotation without friction to wear it down	825
Supporting Disc 2 610 341 361		Holds the blade onto the blade housing while allowing it to spin freely in a uniform circular motion	Steel	Cast steel and then bored out to allow the screw to fit through	Steel is needed for this part because this part holds the saw in place and can undergo a lot of force	There are two supporting discs, one for the outside of the saw blade and one for inside of the saw blade. These are also well lubricated to allow as little resistance as possible and protect from wear over time	28
Housing Cover (vent) 2 610 916 204		Allows air flow out of saw which keeps the saw from over heating. Also, it is made without sharp corners so it will not injure the user.	Plastic	Plastic injected into mold and let to solidify	Plastic is durable in case this piece takes impact and still lightweight. It is easiest and most cost efficient to make the vents that allow air flow through the saw out of a plastic material	Rounded shape and nice venting design are both aesthetically pleasing as well as functionally sound. This part is important to keep the saw from overheating and get rid of and debris that might have found its way into the internal part of the saw.	29
Lever 2 610 924 015		Allow the blade to meet the material when pulled back. This lever, attached to the blade guard spring is part of a safety system to protect the operator from a spinning blade	Plastic	Plastic injected into mold and let to solidify	Plastic is a durable enough material to fulfill the function of this piece, as there are only minimal forces put on it by the operator and it will keep the product cost down	Designed with some aesthetics to make the saw a little more appealing while still being functional	34
Bearing Sleeve 2 610 356 680		Keeps the shaft in alignment and stable when it meets with the gear. This allows the saw to work over time without damaging itself	Phosphoric Bronze	Piece is cast out of phosphoric bronze and then bored out to the appropriate diameter	Phosphoric bronze is a durable smooth material which is needed for this part which undergoes thousands of RPM's when in use	Simple part that has an important role in the saw	14