Fig. 1 shows the same bracket made from folded sheet and machined from solid bar. Explain how the choice of stock form changes the manufacture, the strength...
Question 1 Report
Fig. 1 shows the same bracket made from folded sheet and machined from solid bar. Explain how the choice of stock form changes the manufacture, the strength and the cost of this component. [6]
Answer Details
The same bracket can be made from different stock forms, but the choice changes the manufacturing route, structural behaviour and economic suitability.
- Manufacture: The sheet version is blanked to shape and folded, two rapid operations. The solid-bar version must first be cut to length and then machined on a mill to remove material, taking much longer per component. [2]
- Strength: The folded shape gains stiffness from its formed profile and fold. The machined bracket is solid and is stronger at the corner, but it is also much heavier. [2]
- Cost: Sheet uses a fraction of the material and pressing takes seconds, making it much cheaper in quantity production. It does require a press tool, however. Machining needs no dedicated press tool, so it can be preferable for one or two parts despite its greater material and labour cost. [2]
Judgement and marks: For high-volume manufacture, the folded sheet bracket is usually the lower-cost choice. For a very small quantity, machining from solid may avoid the cost of press tooling. Developed coverage of manufacture, strength and cost with a judgement reaches [5-6].
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