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Process Selection

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Sundaramali Govindaswamy G
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12 views27 pages

Process Selection

Uploaded by

Sundaramali Govindaswamy G
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Module:5 Process selection

Process selection
Systematic process selection-Process selection charts-Ranking
process cost-Cost modelling
Case studies
Aluminium Connecting Rod, Fan leaf with nylon material,
Airbag canisters, Joining a Steel Radiator, Car bonnet, Spark
Plug Insulators, Ceramic knife, Devices to open corked bottle,
Aircraft wing spar, Forks for a racing bicycle, Spark plug
insulator, Insulation for refrigerator.
Objectives of this unit

How to categorize different manufacturing


processes?

How to choose on of the above manufacturing


process, when the different design parameters of
the product are known to us in general?

Design parameters about a product can be like,


Design parameters about a product can be like,
The MATERIAL the product is made of.

The SHAPE of the product.

The MASS of the product

The Section THICKNESS of the


product

The Dimensional tolerance


requirement of the critical
dimension of the product

The Surface Roughness rqmt of the


product
Variations within a single design parameter

Metals-ferrous
Metals-nonferrous
Ceramics

Glass

Elastomers
The MATERIAL the product is made of. Thermoplastics
Thermosets
Polymer foams

composites
Variations within a single design parameter

•Prismatic
• Circular
• Non circular

The SHAPE of the product. •Sheet


• Flat
• Dished

•3D
• 3-D solid
• 3-D hallow
The MASS of the product MASS of the product range
(1 gm – 10000 gm)

The Section THICKNESS of the The Section thickness of the product


product ranging from (0.1mm – 1000mm) is
considered (practical for all purposes)

The Dimensional tolerance The tolerance range (0.001mm – 10mm)


requirement of the critical is considered.
dimension of the product

The Surface Roughness rqmt of the The Surface Roughness range of


product (0.01 – 100mm) m
How to use PROCESS-SELECTION charts?
The capabilities of different manufacturing processes wrt to different
design parameters of the products are available in the form of Process –
Matrix charts.

The process has to be carefully selected.

Warning: Wrong selection of mfg process leads to excessive manufacturing


costs for any product.

In order to choose the correct manufacturing process, some generic steps


to be followed by the design & the manufacturing engineers are: -
• Keep things standard as far as possible
• Keep things simple
• Design the parts so that they can be ‘easily’ assembled, to reach the
state of a sub assembly or an assembly or a final product.
• Do not specify more performance than needed. (Eg…………..)
The process matrix charts… how they look like?

This is an example for one type of process matrix chart…….


Examples for different random parts………

Aluminum Connecting rod

Fan blade

Radiator assembly

Ceramic knife

Aircraft wing spar


Examples
Part name # Ceramic knife
A ceramic knife is a knife made out of very
hard and tough ceramic, often
zirconium dioxide (ZrO2; also known as
zirconia).[1] These knives are usually
produced by dry-pressing zirconia powder
and firing them through solid-state
sintering.
The resultant blade is sharpened by
grinding the edges with a diamond-dust-
coated grinding wheel. Zirconia is 8.5 on
the Mohs scale of mineral hardness,
compared to 4.5 for normal steel and 7.5
to 8 for hardened steel and 10 for
diamond. This very hard edge rarely needs
sharpening.
Part name # Aircraft wing and ‘wing-spar’

In a fixed-wing aircraft, the spar is often the main


structural member of the wing, running spanwise
at right angles (or thereabouts depending on
wing sweep) to the fuselage.
The spar carries flight loads and the weight of the
wings while on the ground. Other structural and
forming members such as ribs may be attached to
the spar or spars, with stressed skin construction
also sharing the loads where it is used.
There may be more than one spar in a wing or
none at all. However, where a single spar carries
the majority of the forces on it, it is known as the
main spar.[1]
Spars are also used in other aircraft aerofoil
surfaces such as the tailplane and fin and serve a
similar function, although the loads transmitted
may be different from those of a wing spar.
A block to support a bearing

Case a:

Case b:

S
Final selection of the process
It is possible that while selecting the mfg process,
we may end up in more than one process too.
In such cases, evaluate those few processes wrt to ,
• Capital investment required for the production
batch size
• Available skills in our plant,
• Overhead rate.
• Cost per unit product.

And choose the one that is feasible to your factory


environment (mostly, cost per unit product, plays
a major role in the decision of choosing the final
manufacturing process.
Case study: Fan blade of a vacuum cleaner
Setting for the input data from our assumptions in case of student
exercise. (in reality this is decided by the design-engineer)

Function: Fan blade

Constraints:

• Material: nylon
Three dimensional solid
• Shape:

• Mass: 0.1 – 0.2 kg

• Minimum section thickness (mm) 0.4mm

• Tolerances ± 0.5mm

• Maximum allowable surface < 1m


roughness
10,000 nos.
• Batch size:
A factory wants to select manufacturing process for aluminium
alloy fan blade.
• Mass = 100 g,
• Thick at maximum section = 4mm
• Tolerance is in range = 0.2 mm
• surface roughness = 1μ (shown in fig.)

Make use of the five process-matrix charts and do a systematic selection of


the manufacturing process, to produce the same on mass production basis of
10,000 numbers.
Show your List of Manufacturing processes at each stage of using every chart
one by one.
Step Parameter Process
1. Material Shaping: Sand casting,
Aluminium die casting, Investment
alloy casting, Low pressure
casting, Forging
3. Mass is 100 g=0.1kg Die casting, Investment casting and
Forging
2. Thick at maximum Die casting, Investment casting and
section: 4mm, Forging
4. Tolerance is in Die casting and Investment casting
range:0.2 mm
5. Surface roughness: 1μ Die casting
6. Volume: 10,000 Die casting
Step Parameter Process
1. Material Aluminium Shaping: Sand casting, die casting,
alloy Investment casting, Low pressure
casting, Forging
2. Thick at maximum Die casting, Investment casting and
section: 4mm, Forging

3. Mass is 100 g=0.1kg Die casting, Investment casting and


Forging
4. Tolerance is in Die casting and Investment casting
range:0.2 mm

5. Surface roughness: 1μ Die casting

6. Volume: 10,000 Die casting

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