Assignment 3

Name:
Matric No:

Find the most suitable process

and materials to produce this PC
front cover
Requirements
1. Lightweight, Low density is critical, higher strength-to-weight ratio
2. Maximum temperature can stand 500°C
3. Excellent corrosion resistance

Do the Material and Manufacturing Process Selection Analysis to find the most
suitable material and process for this part.
 Table A – Shape Attributes
No. Shape Attribute Yes / No

1 Depressions

2 Uniform wall

3 Uniform cross-section

4 Axis of rotation

5 Regular cross-section

6 Captured cavity

7 Enclosed cavity

8 No draft
 Table B – Shape Generation Capabilities

Uniform Regular
Depress- Uniform Axis of Captured Enclosed No
cross- cross-
ions wall rotation cavity cavity draft
section section

Shape Att. (Yes / No)

1 Sand casting Y Y Y Y Y Y N N
2 Investment casting Y Y Y Y Y Y N N
3 Die casting Y Y Y Y Y N N N
4 Injection molding Y Y Y Y Y N N N
5 Structural foam Y Y Y Y Y N N N
6 Blow molding (extr) Y M N Y Y M Y N
7 Blow molding (inj) Y M N Y Y M N N
8 Rotational molding Y M N Y Y N M N
9 Impact extrusion Y Y N Y Y N N Y
10 Cold heading Y Y N Y Y N N Y
11 Closed die forging Y Y Y Y Y N N N
12 Power metal parts Y Y Y Y Y N N Y
13 Hot extrusion Y Y M Y Y N N Y
14 Rotary swaging N N N M N N N N
15 Machining (from stock) Y Y Y Y Y Y N Y
16 ECM Y Y Y Y Y N N N
17 EDM Y Y Y Y Y N N Y
18 Wire-EDM Y Y Y Y Y N N Y
19 Sheet metal stamp/bend Y M Y Y Y N N N
20 Thermoforming Y M N Y Y N N N
21 Metal spinning N M N M N Y N N

Note:
Y – this process is CAPABLE to produce this attribute
Y – this process is CAPABLE and also EASIER to produce this attribute
N – this process is NOT CAPABLE of producing this attribute
M – this process is FOR SURE WILL produce this attribute
Table C - Materials and Processes Compatibility
Analysis & Conclusion
 Table of Manufacturing Process Capabilities Range

Shapes Produced
No. Process Part Size Tolerances a Surface Finish Process Limitations Typical Application Material Comments
Competitively b

Secondary machining usually required

General: ±0.02 (1
Large parts with walls and Production rates often lower than that for other casting
in.), ±0.1 (24 in.) Engine blocks Very flexible manufacturing process in
internal passages of complex processes
Weight: 0.2 lb–450 ton For dimensions Engine manifolds 1, 2, 3,4, 5, 6, terms of possible geometries, part size,
1 Sand casting 500–1000 μin. geometry requiring good Tolerances, surface finish coarser than other casting
Minimum wall: 0.125 in. across parting line Machine bases 7d, 8, 12 and possible materials
vibration damping processes
add ±0.03 (50 in.2), Gears pulleys Pattern in reusable and mold expendable
characteristics Requires generous draft (approximately 3 deg) and radii
±0.04 (200 in.2)
(approximately equal to thickness)

Expendable pattern and mold

Turbine blades
Greater flexibility in material choices or
Most investment castings are less than 12 in. long and Burner nozzles
Weight: 1 oz–110 1b Small intricate parts part geometry than die casting, but much
less than 10 1b L/D ratio of through or blind holes less Armament components
Major dimension: To 50 in. General: ±0.002 (1 requiring good finish, good 2, 3, 4d,5, 6, 8, higher production costs
2 Investment casting 63–25 μin. than 4:1 and 1:1, respectively Lock components
Minimum wall: 0.025 in.) ±0.004 (6 in.) dimensional control, and 9d, 12 Less susceptible to porosity than most
Tooling cost and lead time generally greater than for Sewing machine
(ferrous), 0.060 (nonferrous) high strength casting process
other casting processes except die casting components
Multiple parts may be cast simultaneously
Industrial handtools bodies
around central sprue

Produces thin-set walls of all casting

Minimum wall (in.): 0.025 General: ±0.002 (1 process
(Zn), 0.05 (Al, Mg) in.) ±0.005 (6 in.) Trimming operations required for flash and overflow Similar to injection molding in Production rate approximately 100 parts
Minimum hole diameter (Zinc) ±0.003 (1 in.), removal part geometry, but particularly per h in alum and approximately 200 parts
3 Die casting (in.): 0.04 (Zn), 0.08 (Mg), ±0.006 (6 in.) 32–85 μin. Similar to injection molding Porosity can be present suited where higher mechanical 5, 6d, 7, 8 per h in zinc
0.1 (Al) (Alum, Mg) Add Die life limited to approximately 200k shots in Al or Mg properties or the absence of Tooling cost and lead time similar to that
Maximum weight (lb): 35 ±0.004 across parting or 1 million in Zn creep are required for injection molding but trimming and
(Zn), 20 (Al), 10 (Mg) line or moving core surface treatment can make process less
economic

General ±0.003 (1
in.), ±0.008 (6 in.)
Typical cycle time 20–40 s
Hole diameter:
Details such as living hinges, insert
±0.001 (1), ±0.002 (1
molding, and snap features allow
diameter)
significant opportunity for part
Flatness: ±0.002 in. Tooling is costly and requires greater lead time than
Small-to-medium sized parts Numerous applications, often consolidation
Injection molding Envelope: 0.01 in.3–80 ft3 per in. most alternative processes
4 8–25 μin. with intricate detail and replacing the die casting or 10, 11 Injection molding of thermoset materials
(thermo- plastics) Wall: 0.03–0.250 in. Increase tolerance 5% Poor design can result in high levels of molded-in stress,
good surface finish sheet metal assemblies also possible: Longer cycle time, no
for each additional resulting in warpage or failure
reprocessing of waste, generally harder,
mold cavity
more brittle, but more stable material
Increase tolerance:
which can be used at higher service
±0.004 for
temperatures
dimensions across
parting line

Tooling approximately 20% less than for

injection molding
Solid skin approximately 0.03–0.8 in.
Large, somewhat intricate
thick; entire wall cross section has
Poor; paint parts, requiring high Details as sharp as those of injection molding not
Structural foam Weight: 25–50 lb Approximately that of Pallets, housing, drawers, TV densities between 50% and 90% of solid
5 generally required stiffness and/or thermal or possible 10
molding Wall: 0.09–2.0 in. injection molding cabinets, fan shrouds weight
properties acoustical insulating Cycle time is long (2–3 min)
Process generates a low level of internal
properties
stress RIM is a similar foaming process
utilizing thermosets (generally
polyurethane)
 Injection blow molding: Smaller parts,
General: ±0.02 (1
With extrusion blow molding, some geometries produce more accurate necks
in.), ±0.04 (6 in.) Most polymer containers to 5
Envelope: Up to 800 gal Hollow, well-rounded thin- a high level of material scrap Extrusion blow molding: More
Blow molding Wall: ±50% of gal
6 containers (105 ft3) 250–500 μin. walled parts with low degree Integral handles possible with extrusion blow molding 10 asymmetrical parts, less costly tooling
(extrusion) nominal wall Toys
Wall: 0.015–0.125 in. of asymmetry only High production rates, particular for
Neck: ±0.004 Auto heater ducting
Poor control of wall thickness injection blow molding (as low as 10 s per
(injection only)
cycle)

Injection blow molding: Smaller parts,

General: ±0.02 (1
With extrusion blow molding, some geometries produce more accurate necks
in.), ±0.04 (6 in.) Most polymer containers to 5
Envelope: Up to 800 gal Hollow, well-rounded thin- a high level of material scrap Extrusion blow molding: More
Blow molding Wall: ±50% of gal
7 containers (105 ft3) 250–500 μin. walled parts with low degree Integral handles possible with extrusion blow molding 10 asymmetrical parts, less costly tooling
(injection) nominal wall Toys
Wall: 0.015–0.125 in. of asymmetry only High production rates, particular for
Neck: ±0.004 Auto heater ducting
Poor control of wall thickness injection blow molding (as low as 10 s per
(injection only)
cycle)

Cycle time 8–20 min

General: ±0.025 (1
Envelope: Up to 5000 gal Inserts for securing or stiffening are
in.) ±0.05 (6 in.), Poor; parts Large containers with Abrupt wall changes, long, thin projections, and small Toys
8 Rotational molding Containers: (670 ft3) 10 possible
±0.01 (24) generally textured minimal detail separations between opposing part surfaces not possible Containers
Wall: 0.06–0.40 in. Less detail possible than with blow
Wall: ±0.015
molding
Outer diameter
Approximately, 1–2 in.
(O.D.): ±0.002 (0.5
diameter
in) Generally chosen over screw machined
Part with a closed end Flat inner bottom requires additional operation
Inner diameter (I.D.): part if material savings are significant
thicker than side walls Tooling costs are high
Impact extrusion ±0.003 (5 in.) Fasteners (approximately 25% or more)
Diameter: 0.075–2.5 in. (backward) Maximum L/D ratio for backward extrusion is 10 (in
9 (forward and Bottom diameter: 20–63 μin. Sockets for socket wrench 2, 3d, 5, 6, 7, 8 Significant improvement in mechanical
Length: 3–4 in. Headed parts with large L/D some aluminum alloys)
backward) ±0.005 (5 in.) Gear blanks with shank properties due to cold working, allowing
ratio and zero draft (forward L/D ratio almost unlimited in forward extrusion
Tolerances further material reduction
extrusion) Tolerances not as good as machining
approximately 50% Limited asymmetry possible
Combination of forward/
greater for
backward common
rectangular parts
Head height: ±0.006
(0.025 shank
diameter) ±0.008 Small symmetrical, or near Nails Minimization of shank diameter and upset
Seldom used for diameters greater than 1.25 in.
Shank diameter: 0.03–2.0 (0.50 shank diameter) symmetrical, headed Fasteners volume important
Must allow much more generous radii than with 2, 3, 4d, 5, 6,
10 Cold heading in. Head diameter ±0.01 32–85 μin. cylindrical parts, with shank Spark plug pot Production rates 35–120 parts per min
machining 12d
Length: 0.6–9.0 in. (0.25 shank diameter, length greater than shank Ball Joint Process can also be carried out warm
Significant asymmetry difficult
±0.018 (0.50 shank diameter Shafts (800–1200°F)
diameter)
Length: ±0.03 (1 in.)

By controlling material flow, grain

Perpendicular to die structure may be applied with the
motion: ± 0.7% of Parts of moderate Holes may not be produced directly Crankshafts direction of principal stress
dimension complexity, in a wide range Flash must be removed and secondary machining is often Airframe components Closed die forgings nearly always pass
Closed die forging 2, 3, 4, 5, 6, 8,
11 Weight: 0.1–500 lb Parallel to die 125–250 μin. of sizes, whose failure in required Tools through series of impressions before
(Hot forging) 9, 12d
motion: ±0.03 (10 service would be Die wear and die mismatch can be significant Nuclear components completion
in.2 area), ±0.12 (100 catastrophic Generous draft angles and radii are suggested Agricultural components In decreasing order of forgability: A1,
in.2 area) Mg, steel, St Steel, titanium, high-
temperature

Production rates approximately 700 parts

Minimum wall: 0.06 in. Perpendicular to press per h
Generally lower mechanical properties than wrought Small gears
Minimum hole diameter: direction: ±0.15% of Impregnation with lubricants gives self-
metals Lock mechanisms
0.06 in. dimension (±0.05% if Small parts of uniform lubrication properties
Powder metal Undercuts, off-axis holes, and threads cannot be components 1, 2, 3, 4, 5, 6,
12 Maximum length (in repressed) 8–50 μin. height with parallel, but Density range 75%–95% (compared to
processing produced directly Small arms parts 9d, 12d
direction of press): 4.0 in. Parallel to press fairly intricate walls raw material)
Thin sections and feature edges should be avoided Filters
Maximum projected area: direction: ±0.30% of Maximum compression ratio (powder
Maximum L/D ratio approximately 3 Bearings
40 in.2 dimension volume before and after pressing and
sintering) approximately 2.5:1
 Plastic working produces favorable grain
General: ±0.01 (1 in.)
structure
±0.03 (6 in.) (±0.005
Dimensional accuracy and part-to-part consistency Maximum extrusion ratios are 40: 1
Cross-sectional area: 0.1– if cold drawn after Straight part with constant
63 μin. (Alum), generally not an high as competing processes. Warp and Heatsinks (Alum), 5: 1 (LC steel)
225 in.2 (Alum), 0.5–4.0 extrusion) cross section that is fairly
125 Micro twist can be troublesome Structural corner and edge 2, 3d, 4d, 5, 6, Shorter setup time than rolling, but a
13 Hot extrusion in.2 (LC steel) Angles ±2 deg. complex, but balanced,
includes (LC Use of materials other than aluminum and copper alloys members 7d, 8, 9d lower production rate (1–8 ips) crossover
Minimum wall: 1.5% of Twist: 1° per foot for without extreme change in
steel) can cause some shape restrictions Decorative trim point at approximately 50,000 ft
circumscribed diameter width less than 2 in. wall thickness
Avoid knife edges and long, unsupported projections Low tooling costs, therefore short runs
Flatness: 0.004 in. per
can often be justified if part consolidation
in.
and integral fastening is considered.

Tooling costs are generally less than those

for cold extrusion or cold heading
Tube: Gold club shafts, table
20% of original Tapper should be 6° or less included angle for manual Noncylindrical part can be swaged in
Diameter: 0.01–5.0 in. (bar), Diameter: ±0.003 (1 Tapered cylindrical rod or legs, exhaust pipes 2, 3, 4, 5, 6,
14 Rotary swaging stock finish (five- feeding and up to 14° for power feed stationaly die machines
14 in. (tubing) in.) tubing Bar: Punches, screwdriver 7d, 8d, 12
fold improvement) Shoulders perpendicular to part axis not possible Production rates can range from 100–3000
blades
parts per h
Shapes like splines can be produced

Turning ±0.001,
boring ±0.0005,
Rotational: Axisymmetrical
Milling ±0.002,
Turning 63–125 part with L/D ratio of 3 or
Drilling ±0.008– Little opportunity for part consolidation
Boring 32–125 less and major diameter of 2
0.002, Most parts produced by a sequence of several operations 1, 2, 3, 4, 5, 6, Closer to true CAD/CAM link than most
Machining (from Limited only by machine Milling 63–125 in. or less
15 Broaching ±0.005, and machines Widely varied applications 7d, 8, 9d, 10d, other processes
stock) capability Drilling 63–250 Nonrotational: Rectangular
Grinding +0.002 Need for multiple operations can impact part quality 11d, 12d Most flexible of manufacturing processes
Grinding 8–32 part with all feature parallel
(diameter); ±0.008 Tool wear is significant
Reaming 63 and open in the same
(surface), Reaming,
direction
±0.001 (all for
dimensions of 1 in.)

Highly accurate complex, or Material removal rates much greater than

finely detailed shapes in EDM (approximately 5 in. 3 per min.)
hardened materials or those although tooling, equipment, and energy
Minimum hole diameter:
susceptible to damage due to Some taper of walls costs are much higher
Electrochemical 0.01 in
16 General: ±0.001 8–63 μin. heat build-up Minimum radius of 0.002 all around Various jet engine parts 1d, 3, 6d, 9, 12 Surface finish not nearly as closely tied to
machining (ECM) Maximum hole depth: 50 ×
Production of high aspect or Material most be electrically conductive removal rates as with EDM
diameter
bur-free holes and Generally more cost-effective than
processing of flimsy precision machining and grinding for all
materials but the most easily machined materials

Due to low production rates,

Electrode wear impacts accuracy and requires periodic
Minimum hole diameter: EDM is generally used in
8–250 μin. replacement
Eectrical discharge 0.002 toolmaking rather than part 2d, 3d, 5d, 6, These components are often used in
17 General ±0.001 (dependent on Same as ECM Material removal rate is extremely slow (0.01–0.5 in. 3
machining (EDM) Minimum slot width: 0.002 production, or for deburring, 9d, 12d drawing, extruding, or stamping dies
removal rate) per h)
in. where other methods are not
Additional limitations identical to ECM
satisfactory

Due to low production rates, A very different variation of conventional

Electrode wear impacts accuracy and requires periodic
Minimum hole diameter: EDM is generally used in EDM, wire EDM is used to cut highly
Wire electrical 8–250 μin. replacement
0.002 toolmaking rather than part 2d, 3d, 5d, 6, accurate, and sometimes complex profiles
18 discharge General ±0.001 (dependent on Same as ECM Material removal rate is extremely slow (0.01–0.5 in. 3
Minimum slot width: 0.002 production, or for deburring, 9d, 12d in hardened materials up to 6 in. thick
machining (EDM) removal rate) per h)
in. where other methods are not These components are often used in
Additional limitations identical to ECM
satisfactory drawing, extruding, or stamping dies
 Mechanical reciprocating presses operate
at 35–500 strokes per min.
Punching or CNC Turret presses achieve 55–265 hits
Material thickness 0.001– Holes with diameter lest than stock thickness need to be
stamping: ±10% of per min. at 1 in. centers
0.75 in. (normally 0.050– Moderate complexity parts drilled
material thickness For cold rolled Often when the cost of dies exceeds the
Sheet metal 0.375 in.) of constant material Since 1/2–2/3 of material thickness is fractured, rather Numerous consumer and 2, 3, 4, 5, 6,
19 (2.0 in.) sheet or coil: 32– total cost of parts, die sets are no longer
stamping/bending Area: 80 ft2 with turret thickness with flanges in a than sheared, secondary operation or fineblanking is industrial applications 7d, 8d, 12d
Press brake: ±2° On 125 μin. cost-effective (approximately 20,000 pcs
press and press brake, 10 ft2 single direction needed for good edge finish or parallel sides
bend, ±0.015 in. hole- for common geometries)
with die sets Finishing and material scrap costs are often substantial
to-bend Progressive dies can often be justified if
they can save two or more secondary
operations on individual die sets

Tooling less expensive than other plastic

processing, methods
High production rates possible (drinking
Various consumer packaging
General: ±0.05% of Low degree of part complexity cups: 2000–3000 pcs.min.)
Bus, aircraft interior panels
dimension Large, shallow, thin wall Low dimensional accuracy Material properties can be improved due
20 Thermoforming Area: 1 in.2–300 ft2 60–120 μin. Refrigerator linings 10
Wall: ±20% of parts with generous radii Minimal opportunity for integral fasteners or attachment to molecular orientation
Signs
nominal points Reinforcing fibers may also be added to
Boat hulls
improve strength of several processes
available (vacuum, pressure, drape),
vacuum is most popular

Conventional spinning and displacement

spinning differ in that displacement
Stiffening beads should be formed externally rather than
spinning moves material back along
Diameter: 25 in.–26 ft internally
Cooking utensils forming member refining grain structure
Material thickness: (Alum), Diameter: ±0.01 (1 Thin-walled conical shape Cylindrical sections and reentrant angles are possible but
Lamp bases 2, 3d, 4, 5, 6, in ddirection of flow
21 Metal spinning 0.004–1.5 (LC steel), in.), ±0.03 (24 in.) 32–65 μin. with diameter greater than more costly
Nose cones 7d, 8d, 12d Tooling costs are much less than for
(0.025– 0.05 in. most Angle: ±3 deg twice depth Minimal radius 1.5 × thickness
Reflectors stamping or deep-drawing, very small
common) Maximum thickness for hand spinning: 0.25 in. (A1),
quantities may be economically produced
0.187 (LC steel), 0.125 (S steel)
Tube spinning reduced I.D., O.D., or
lengthens tubes or performs

a Limits shown represent fine tolerances. More stringent requirement will significantly increase cost.

b Part types that can be produced cost effectively in comparison to other processes.

c Materials.
Used on a limited basis: 1, cast iron; 2, carbon steel; 3, alloy steel; 4, stainless steel; 5, aluminum and
d alloys; 6, copper and alloys; 7, zinc and alloys; 8, magnesium and alloys; 9, titanium; 10,
thermoplastics;11, thermosets; 12, nickel and alloys.