Chapter 5
Qualitative Analysis of Material, Manufacturing Process and
Joining Process Selection
The selection of materials is a crucial aspect of the Product Design process, involving the
creation of innovative solutions to address various problems. The design of engineering
components is restricted by the materials that are currently available, while advancements in
materials open up opportunities for new designs. As the conceptual development and design
for the Automated Drain/Gutter Cleaner are reaching their final stages, the focus now shifts to
selecting specific materials and manufacturing processes for each part of the product.
The chosen materials must be capable of fulfilling the required functions while providing
adequate mechanical strength. To achieve this, a thorough qualitative analysis of material
properties, manufacturing processes, and joining methods is conducted, considering the
availability of these options among the alternatives.
5.1 Selection of Materials for Different Sections
Engineering is a field that applies knowledge from mathematical and natural sciences with
sound judgment to create economically efficient solutions. During the process, the
consideration of different materials, such as metals, polymers, rubber, etc., is essential. The
selection of materials is based on factors like their thermal, mechanical, and electrical
properties, as well as their availability and cost-effectiveness.
Table 5.1 Qualitative material selection for the garbage separator
Parts Material Option for Reasons Behind Selection
Selection Other
Material
Motor DC Motor AC Motor DC motor provides high efficiency, low
maintenance, and precise speed control. AC motors
are alternatives, but they may require more
maintenance and have slightly lower efficiency.
Conveyor Mild Steel PVC, Mild steel offers good friction and wear resistance
Belt Silicone for smooth waste movement. PVC could be an
alternative with lower cost but may have reduced
wear resistance. Silicone may provide better high-
temperature resistance but may not be as cost-
effective.
Gear Carbon Brass, Plastic Carbon steel offers excellent strength and wear
Steel resistance required for smooth gear operation. Brass
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could be an alternative with good wear properties,
but it may not be as robust as carbon steel. Plastic
gears could be an option for quieter operation, but
they may have lower durability.
Frame Mild Steel Aluminum, Mild steel provides a sturdy and durable frame for
Stainless steel supporting various components. Aluminum is a
lighter alternative, but it may not be as robust.
Converging Mild Steel Aluminum, Mild steel ensures corrosion resistance and
Plates Stainless steel durability for the converging plates. Aluminum is a
lighter alternative, but it may not be as robust.
Handle Mild Steel Aluminum, Mild steel provides a good balance of strength and
Stainless steel cost-effectiveness for the handle. Stainless steel
offers enhanced durability compared to aluminum,
suitable for a high-stress component like the handle.
Table 5. 2 Qualitative material selection for the garbage collector
Part Material Option for Reasons Behind Selection
Selection other
Material
Sensor HDPE ABS Plastic, HDPE plastic protects the sensor and
Polycarbonate electronics from environmental elements. ABS
plastic offers good impact resistance, while
polycarbonate provides enhanced optical
properties.
Indicat Electronic N/A Electronic components are essential for
ion Components efficient monitoring and alerting mechanism in
System the indication system.
Collecting Mild Steel High- Density Mild steel offers chemical resistance and ease
Bin Polyethylene of cleaning.
5.2 Qualitative Analysis of Manufacturing Process Selection
It is of utmost importance to carefully choose the most suitable manufacturing process for each
part of the product from a range of relevant options. This decision holds significant potential
for reducing production costs, minimizing material waste, and enhancing overall performance.
Devoting ample time to this selection process becomes imperative to achieve these benefits.
Utilizing inexpensive, adaptable, and appropriate manufacturing processes facilitates seamless
and efficient production of the product on a repetitive basis. Conversely, opting for intricate
and inflexible processes can significantly drive up the overall cost of the product.
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Considering outsourcing for standard parts that are readily available in the market can be a
wise strategy if the cost of production outweighs the cost of procuring these parts externally.
Table 5.3 Manufacturing process selection for the Garbage Separator
Part Make/Outsource Possible Selected Reasons Behind
Manufacturing Manufacturing Selection
Processes Process
Handle Make Turning, CNC Turning CNC machining
Machining provides high
precision, tight
tolerances, and
excellent surface
finish, which are
crucial for the
handle's
ergonomic design
and ease of use. It
also allows for
rapid prototyping
and efficient
production.
Gear Make Hobbing, Hobbing Hobbing is a well-
Casting established and
efficient method
for producing
high-quality gears
suitable for the
garbage separator's
gear mechanism. It
offers good
repeatability,
ensuring
consistent gear
performance and
smooth operation.
Motor Outsource Cheap, difficult to
manufacture,
available, cost-
efficient
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Frame Make Welding, Welding, In-house welding
Riveting, and Riveting, and and fabrication
Bolting Bolting provide the
flexibility to tailor
the frame design,
ensuring structural
integrity and
compatibility with
other components.
It also allows for
easy modifications
and repairs if
needed.
Converging Make Cutting and Cutting and Cutting and
Plates Bending Bending bending efficiently
produce uniform
plates critical for
proper function,
balancing
precision and
affordability.
Conveyor Make Cutting, Cutting, Bolting, These processes
Belt Bolting, and and Bending effectively shape,
Bending. join, and loop
material for a
durable conveyor
belt, ensuring
smooth waste
movement.
Table 5.4 Manufacturing process selection for the Garbage Collector
Part Make/Outsource Possible Selected Reasons Behind
Manufacturing Manufacturing Selection
Processes Process
Sensor Outsource Cheap, available
Alarm Outsource Cheap, available,
System difficult to
manufacture
Collecting Make Welding, Riveting Arc Welding Cheap, available
Bin
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This table has been created with cost and availability in consideration. Certain parts are both
easy and inexpensive to manufacture, while others are readily available in the market, making
outsourcing a cost-effective option for them.
5.3 Qualitative Analysis of Parts Joining Method Selection
There are three fundamental types of joints: permanent, semi-permanent, and temporary.
Proper part joining plays a vital role in the product development process, requiring careful
consideration of factors like operational flexibility, maintenance ease, and modification
possibilities. Below are the joining method selection tables for the "Automated Drain/Gutter
Cleaner":
Table 5.5 Joint method selection table for the Automated Drain/Grain Cleaner
Joining Parts Type of Joint Joining Joint Selected Reasons for
Method Selection
Options
Handle & Frame Permanent TIG Welding, Arc Welding Arc welding
MIG Welding, provides a
Arc Welding strong and
versatile bond
for joining the
handle and
frame. Suitable
for aluminum
alloy frame and
handle.
Gear & Shaft Permanent Riveting, Riveting Riveting
Soldering, provides
Bolted reusability,
Connection disassembly for
maintenance,
and sufficient
strength for the
gear and shaft.
Motor Housing Permanent TIG Welding, Arc Welding Arc welding
& Frame MIG Welding, provides a
Arc Welding durable and
robust
connection,
essential for
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protecting the
motor and
attaching it to
the frame.
Conveyor Permanent Riveting, Bolted Riveting Riveting offers a
Segments Connection, secure
Soldering connection with
minimal
material
deformation and
is suited for
joining
conveyor
segments.
Converging Permanent TIG Welding, Arc Welding Arc welding
Plates & Frame MIG Welding, provides a
Arc Welding strong and
reliable bond for
joining the
plates and
frame, ensuring
leak-tightness
and structural
integrity.
Indication Semi- Snap-Fit Snap-Fit Snap-fit offers
System & Permanent secure
Frame attachment with
disassembly
options for
maintenance,
suitable for the
alarm system
and its
connection to
the frame.
Bin Body Semi- Snap-Fit Snap-Fit Using a Snap-
Permanent Fit provides
greater
durability,
security, and
load-bearing
capacity,
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offering a more
robust and
reliable
connection for
applications that
demand stronger
fastening and
prolonged use.
Table 5.6 Finishing process selection table for the Automated Drain/Gutter Cleaner
Finishing Parts Finishing Process Process Selected Reasons for
Options Selection
Every Component Non-precision Non-precision Durable and Cost-
Grinding and Grinding and effective
Polishing, Precision Polishing
Grinding
Table 5.7 Coloring process selection table for the Automated Drain/Gutter Cleaner
Coloring Coloring Process Process Selected Reasons for Selection
Parts
Metal Painting with Painting with Durable, Uniform Color Finish,
Component Liquid Color, Liquid Color and Cost-effective
Spraying,
Electroplating
5.4 Conclusion
The qualitative analysis of material, manufacturing process, and joining process selection
offers valuable insights into the entire production process. Utilizing qualitative analysis in the
initial stages of product design helps eliminate less viable options for materials, manufacturing
processes, and joining methods, saving both time and computational resources. While the
qualitative approach may not be as detailed as quantitative analysis, it serves as a guiding
framework for production, allowing for the establishment of specific goals and the collection
of more accurate and precise data during the selection process.
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