Model 1 – Slotted Angle Block

Density: 7.850 g/cm^3

Mass: 5.123 lbmass

Volume: 18.063 in^3

Surface Area: 46.78

1) What is the material cost of the part assuming that the cuttings are remelted
and the cost of mild steel is $6.25 per pound? What is the material cost of
the part assuming that the cuttings are not remelted?

The material cost of the part assuming that the cuttings are remelted and the cost of
mild steel is 6.25 per pound is 32 dollars. The material cost of the part assuming
that the cuttings are not melted would be 6.25*6.99=$43.72

2) The mass of the material lost in a typical machining process is 6.995-

5.123=1.872

3) 6.25*1.872= $11.7 is the cost of the lost material based on my calculations

above

4) (24.664^3/12*1000=14.27) The volume of the box (in cubic feet) needs

to be 14.27 cubic feet in order to ship 1000 parts packed without spacers

5) Processes such as 3D printing can be used to create the same part.

Model 2 – Mounting Bracket

Density: 8.000 g/cm^3

Mass: 3.732 lb

Volume: 12.911 in^3

Surface area: 53.765

A) The mass of the material lost in a typical machining process?6.569 lb –

3.732 lb = 2.84 lb
B) The cost of the lost material based on your calculations above if the cost of
stainless steel is $15.75 per pound is 2.84 lb ($15.75/lb) = $44.7
C) The material cost of the part assuming that the cuttings are remelted and the
cost of aluminum 6061 is $0.62 per pound is $45.99 . The material cost of
the part assuming that the cuttings are not remelted is 6.569 lb ($15.75/lb) =
$103.46.
D) 3.732 lb (1000) ($3.75/lb) = $13,995
E) Another process that could be used to create the same part drawing half of it
then mirroring it.
Model 3 – Support Bracket

Density: 2.700 g/cm^3

Mass: 3.482 lbmass

Volume: 35.747 in^3

Surface Area: 171.890 in^2

a) The material cost of the part assuming that the cuttings are remelted
and the cost of aluminum 6061 is $0.62 per pound is $2.16. Unmelted its
17.558*.62=$10.89.
b) The mass of the material lost in a typical machining process is
17.558-3.482= 14.076lbs
c) the cost of the lost material based on your calculations
above?$10.89-$2.16=$8.73
d) 400*12ft^2/171.890 in^2 = 335 parts can be painted with one gallon of
paint that covers 400 ft2
e) You can either loft or extrude and cut in order to create the same part using
different processes.
Model 4 – Pipe Support

Density: 8.470 g/cm^3

Mass: 3.228 lb mass

Volume: 164,648.363 in^3

Surface Area: 29881.694 in^2

a) The material cost of the part assuming that the cuttings are remelted and the
cost of soft yellow brass is $13.50 per pound is $43.58. Unmelted would be
6.07*13.50=$81.95.
b) The mass of the material lost in a typical machining process is
6.07-3.228=2.84lbs.
c) The cost of the lost material based on your calculations above is
2.84(13.5)=$38.37
d) Another process that could be used to create this part is molding the shape.
Model 1:

Model 2:
Model 3:

Model 4: