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The value of a decision matrix is that it forces us to view the various alternatives in a careful and thoughtful manner. The final decision should not be made solely on the results of the decision matrix. The method should help make a proper decision, rather than dictate the decision. For tools like the decision matrix to be viable, rating factors must be assigned as objectively as possible, and weighting factors must be determined to reflect the priority among design criteria. The decision matrix can be an important and useful tool to aid in design decision making, but the designer should be mindful that nothing takes the place of common sense and good judgment. With the weighting factors, the best choice is revealed to be steel, although it is only marginally better than magnesium and titanium. These decision factors are then summed for each option and stored under the Score column. For this example, weighting factors 1–5 are assigned to individual design criteria, with corrosion resistance being 5, machinability and material cost that contribute largely to the overall cost being 4, and weight being 2, as shown in Table 2.3. Therefore, some sort of weighting scale is normally assigned to account for this variation.
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In addition, weight is another important consideration for parts installed on aircrafts. In this example, corrosion and cost are considered to be the two most important criteria. Another issue is that we assume that all design criteria have the same degree of importance. For example, why is the strength factor of aluminum 7075-T6 equal to 3? Can it be 3.5? A slight adjustment in the rating factors could lead to different results. Why does the decision matrix lead to the choice that is either too expensive or comes back to the one that we want to avoid at the first place? Certainly, one of the main issues is rating factors we assigned. The goal is to choose the best possible material to replace the magnesium tubes in order to enhance product reliability and reduce manufacturing lead time, among other design criteria.
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Therefore, it is desirable to manufacture the tubes using a machining process instead of casting. Lead times were excessive and the cost was extremely high for acquiring the tubes. Second, magnesium tubes are currently made by casting, which is extremely uneconomical when only a small quantity is required for the maintenance of the remaining aircraft fleet. First, the current magnesium tubes have poor corrosion resistance, requiring frequent repairs. The tubes are being redesigned to address concerns raised by the maintenance depot. The torque tubes are located in the front leading edge of the airplane wing, three on each side. We use a material selection of airplane torque tubes shown in Figure 2.1 as an example to illustrate the method. A decision matrix consists of rows and columns that allow the evaluation of alternatives relative to various decision criteria.