Case study 5 – ABC Brake Pedal

Figure 1: Autokeen's body parts

Figure 2: Autokeen's hinge

 Product selected: ABC pedal

Figure 3: ABC brake pedal

Part of product Type of Function Manufacturing

materials processes

 Convert that kinetic energy

into heat. When pressing
1. ABC brake Aluminium foot down on the brake
pedal alloy pedal, a connected lever Sand casting
pushes a piston into the
master cylinder, which is
filled with hydraulic fluid.
 Light material to reduce
car weight but at the same
time have high strength.
Manufacturing processes:
 ABC brake pedal – sand casting

1. Sand preparation

2. Mold making

3. Melting

4. Pouring

5. Cooling and solidification

6. Removal of sand mold

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7. Cleaning and inspection

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1. Sand preparation
 The appropriate bonding agent (typically clay) is mixed or produced with sand. The
mixture is moisturized, usually with water, but sometimes with other substances, to
develop the strength and plasticity of the clay and to make the molding compound
suitable.

Figure 4: Sand mixer

2. Mold making
 A sand mold is formed into every half of the mold by packing sand. The sand is
packed around the border pattern that is a replica of the casting’s external shape. The
cavity that forms the casting remains when the pattern is removed.

Figure 5: sand mold

3. Melting
 The aluminium alloy is melt below its melting point in the furnace

Figure 6: molten aluminium alloy Figure 7: Pouring process

4. Pouring
 The molten aluminium alloy is poured into the mold.
5. Cooling and solidification
 The molten aluminium alloy is allowed to cool and solidify for a certain time.
6. Removal of sand mold
 The solid aluminium alloy is then removed from the mold to get the brake pedal
product.

Figure 8: Brake pedal after removed from mold

7. Cleaning and inspection
 The brake pedal is cleaned and trimmed to get better surface finish
 Further inspection for the brake pedal is needed to get accurate dimension.

Figure 9: Brake pedal product

 Main parameter involves in sand casting:

 Different metallic properties required different time cooling to solidify.
 Sand mixture must have accurate ratio.
 High efficiency of air ventilation system.

 Suggestion to reduce the unit cost:

1. Reduce Material Costs

 When material costs dominate product expense, focus on ways to procure materials for
less money or find ways to use less material in the building process. Purchase materials
in large lots to drive down unit costs.

2. Reduce Overhead Costs

 Monitor and control the expenses associated with running the factory
 Keep debt and interest expense as low as possible.

3. Reduce Labour Costs

 Labour cost reductions can be generated by lowering the dollars paid to factory workers
or by making workers more efficient.