The electric plug is perhaps the commonest of electrical products. It has a number of components: the casing, the pins, connectors, a cable clamp, fasteners, and, in some plugs, a fuse. The task is to investigate processes for shaping the two-part insulating casing, which, for safety reasons, is to be made of a thermosetting plastic. Each part weighs about 30 grams and is to be made in one step from with a planned batch size of \(2 \times 10^{6}\). The required tolerance of \(0.3 \mathrm{~mm}\) and surface roughness of \(1 \mu \mathrm{m}\) must be achieved without using secondary operations.

a. Itemize the function and constraints, leave the objective blank and enter 'Choice of process' for the free variable.

b. Use the charts of Figs. 7.3, 7.4 and 7.6 to identify processes to shape the casing.

Data From Fig, 7.3

Data From Fig, 7.4

Data From Fig, 7.6

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Metals, ferrous Metals, nonferrous Ceramics Glasses Elastomers Thermoplastics Thermosets Polymer foams Composites Sand casting Die casting Investment casting Centrifugal casting Forging Extrusion Sheet forming Powder methods Electro-machining Machining O Injection moulding Blow moulding Compression moulding Rotational moulding Thermo-forming Polymer casting Resin-transfer moulding Filament winding Lay-up methods Vacuum bag Additive manufacture 0 0 OOOO lo o Shaping