Question

One million (1000000) cylindrical pen holders are to be fabricated using a 6061-T6 aluminum base plate and a pipe. Following are the specifications and data pertaining to this project:

Base Metal: 6061-T6 Aluminum for plate and the pipe

Filler Metal: 5356 Aluminum Alloy

Density of Aluminum: 0.098 lb/inch³

Base Plate: Circular, Diameter = 4 inch; Plate Thickness = 0.25 inch

Tubular Segment: 3 Inch Nominal Diameter Schedule 40 Pipe (OD and ID can be found through internet).

Pipe Height: 4 inch

Welding Process: Gas Metal Arc Welding (GMAW)

Metal Transfer Mode: Spray

Weld Type and Size: Circumferential, 0.25 Inch Fillet Weld (each leg 0.25 inch)

Shielding Gas: Mixture of Argon and Helium gas

Perform the following tasks:

1. Develop a 2D drawing of plate and pipe assembly (include front and top views)
2. Develop a 3D model using Solidworks (include front, top and isometric views)
3. Include weld symbol that indicates weld type, weld size, and circumferential weld
4. Estimate the quantity of weld metal required to make the weld assuming welding process deposition efficiency 90%.
5. How many wire spools would be required if each spool weighs 20 pounds?
6. What would the total cost of the electrode wire be if each spool costs $138?
7. What would be welding wire cost per weld?

Answer 1