Selecting manufacturing processes

Manufacturing process decisions Deformation processes Casting processes Sheet metalworking Polymer processing Machining Finishing Assembly Material compatibilities / Process capabilities Material costs, Tooling costs, Processing costs

How would we manufacture a mountain bike ?

Seat Post Rear Brake Top Tube Saddle Fork Down Tube Front Brake Handle Bar

Rear Derailleur

Pedal (Courtesy of Trek Bicycle, 2002)

Manufacturing process decisions

How do we choose the specific manufacturing processes? How do the selected materials influence the choice of manufacturing processes? Would product function or performance issues influence our choice of processes? What criteria should we use to select processes? Which criteria are more important? Who will make the final decisions?

Changes?

Parts undergo sequence of processes

Primary - alter the (raw) materials basic shape or form.

Sand casting Rolling Forging Sheet metalworking

Secondary - add or remove geometric features from the basic forms

Machining of a brake drum casting (flat surfaces) Drilling/punching of refrigerator housings (sheet metal) Trimming of injection molded part flash

Tertiary - surface treatments

Polishing Painting Heat-treating Joining

Part / Mfg. Process Considerations

1. Production Volume 2. Part Size (overall) 3. Shape Capability (features) boss/depression 1D boss/depression >1D holes undercuts (int./ext.) uniform walls cross sections - uniform/regular rotational symmetry captured cavities

Types of manufacturing processes

Manufacturing Processes

How is the input material changed?

Deformation

Casting

Sheet Metal

Polymer Processes

Machining

Finishing

Assembly

Extrusion Forging Rolling Bar drawing Wire drawing

Centrifugal Die casting Investment Permanent mold Sand casting

Bending Blanking Drawing Punching Shearing Spinning

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Anodizing Honing Painting Plating Polishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Deformation processes

Rolling Extrusion Drawing Forging

Rolling (of ductile materials)

Rollers in compression thick slab thin sheet Plastic deformation

Rolling

bloom

structural

ingot slab sheet coil

billet

bar

rod

Extrusion
Extrusion die

Ram

Cross sections

Billet

Drawing

Drawing die

Cross sections Pulling force

Billet

Forging (closed-die)
Ram pressure

Blocked preform

Flash

Gutter

Casting Processes

Sand casting Die casting Investment casting

Sand casting (closed-mold)

Cope Core Flask

Riser Sprue

Parting line Drag

Runner Gate

Die casting
Stationary Moving die die

Molten metal

Plunger Sprue

Ejector pins

Parting line

Investment casting
4-part pattern tree Wax pattern is cast Ceramic mold (hardened slurry)

Wax removed by melting

Molten metal solidifies in cast

Ceramic mold is removed

Sheet Metalworking

Bending Blanking Drawing Punching Shearing Spinning

Sheet metal drawing

Punch ram Punch Blank holder Die Blank Drawn part

Clamp force

Polymer Processes
Compression molding Transfer Molding Blow molding Injection molding

Compression molding

Heated mold

Ram Pressure

Charge Part

Transfer molding

Ram pressure

Ram

Heated mold

Sprue

Charge

Part

Blow molding
Molten parison is extruded Extruder air injector Mold halves close Air blown into parison

Part is removed

parison

Injection molding

Cavity half Core half of mold of mold Pellets Feed hopper Barrel Ejector pins

Shear-heating Parting plane/surface

Sprue Mold closure direction Fixed Moving

Example of a box with no undercuts

ejector pins

parting line

core
mold closure direction cavity plastic injection

Internal undercuts

ejector pins

parting line

core closure direction cavity plastic injection

External undercuts

ejector pins

parting line

core

closure direction

cavity plastic injection

Solidification processes
molten material freezing solid Part Casting Processes Polymer Processes Sand Casting Injection Molding Die Casting Blow Molding Investment Casting ThermoForming Centrifugal Compression Molding

Add to your notes

Flow (voids, flash) Cooling time (cycle time) Temperature Mold complexity Warpage Post processing Costs (materials, tooling, processing)

Machining processes
Manufacturing Processes

Deformation

Casting

Sheet Metal

Polymer Processes

Machining

Finishing

Assembly

Extrusion Forging Rolling Bar drawing Wire drawing

Centrifugal Die casting Investment Permanent mold Sand casting

Bending Blanking Drawing Punching Shearing Spinning

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Anodizing Honing Painting Plating Polishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Machining removal of material

Sawing using a toothed blade. Milling from a flat surface by a rotating cutter tool. Planing using a translating cutter as workpiece feeds. Shaping - from a translating workpiece using a stationary cutter. Boring - increasing diameter of existing hole by rotating the workpiece. Drilling- using a rotating bit forming a cylindrical hole. Reaming to refine the diameter of an existing hole. Turning - from a rotating workpiece. Facing - from turning workpiece using a radially fed tool. Grinding - from a surface using an abrasive spinning wheel. Electric discharge machining - by means of a spark.

Surface roughness

Machining process considerations

solid material machining material removed

sawing, turning, boring, milling, drilling, grinding, ECM

Add to your notes

hardness, strength of material shear forces = strong jigs & fixtures tool/bit wear, replacement size of workpiece, fit machine? volume removed rate of removal, hp needed tolerances operator skill, CNC costs (materials, tooling, processing)

Finishing processes
Manufacturing Processes

protection?
Deformation Casting Sheet Metal Polymer Processes Machining Finishing Assembly

Extrusion Forging Rolling Bar drawing Wire drawing

Centrifugal Die casting Investment Permanent mold Sand casting

Bending Blanking Drawing Punching Shearing Spinning

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Anodizing Honing Painting Plating Polishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Assembly processes fastening / joining of 2 or more components

Manufacturing Processes

Deformation

Casting

Sheet Metal

Polymer Processes

Machining

Finishing

Assembly

Extrusion Forging Rolling Bar drawing Wire drawing

Centrifugal Die casting Investment Permanent mold Sand casting

Bending Blanking Drawing Punching Shearing Spinning

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Anodizing Honing Painting Plating Polishing

Automated Bonding Brazing Manual Riveting Soldering Welding

permanent?

Process / Material Screening

Process-First Approach Part Information 1. Production Volume 2. Part Size (overall) 3. Shape Capability (features) boss/depression 1D boss/depression >1D holes undercuts (int./ext.) uniform walls cross sections (uniform /regular) rotational symmetry captured cavities Material First Approach Application Information 1. Applied Loads magnitude cyclic nature (fatigue) rate (slow, impact) duration (creep) 2. Ambient Conditions temperature moisture sunlight (ultra-violet) chemical liquids/vapors 3. Safety/Legal (FDA, UL) 4. Cost

Product function is interdependent

Material Properties

Product Function

Manufacturing Processes

Product Geometry

Are materials compatible with mfg. process?

Material Properties

Manufacturing Processes

compatible materials & processes

Material-Process Compatibility
ME 488 Design for Manufacture & Assembly Materials Compatibility

Magnesium & alloys

Titanium and alloys

Aluminum & alloys

Shape Attributes

Refractory metals

Copper & alloys

Thermoplastics

Stainless Steel

Nickel & alloys

Carbon Steel

Zinc & alloys

Processes Solidification

sand casting investment casting die casting injection molding structural foam blow molding - extr blow molding - inj rotational molding impact extrusion cold heading closed die forging powder metal hot extrusion rotary swaging machined from stock ECM EDM Wire EDM sheet metal bending thermoforming metal spinning
revision 9/02/03

Bulk Deformation

Metal Removal

Profile Generation Sheet Forming

R. J. Eggert, BSU (Based on data from Boothroyd, Dewhurst & Knight) pg 47

Legend

Normal practice Less common Not applicable

thermosets

Alloy Steel

Cast Iron

Is process capable of producing part geometry?

capable geometry & processes

Manufacturing Processes

Product Geometry

Process-first selection approach

Part Information 1. Production Volume (run qty) 2. Part Size (overall) 3. Shape Capability (features)

boss/depression 1D boss/depression >1D holes undercuts (int./ext.) uniform walls

uniform cross sections regular cross sections rotational symmetry captured cavities

Depressions 1D, >1D

1D >1D

Uniform wall (thickness) but

Varying cross section

Constant cross section

Uniform cross section (constant cross section)

Non-uniform wall thicknesses

Axis of rotation (symmetry)

Regular cross section (regular pattern)

Regular (i.e.pattern)

Regular (i.e.pattern)

not-regular

Enclosed (hollow)

And, rotationally molded parts

Draft free surfaces

No draft

With draft
Cope Core Flask

Riser Sprue

Parting line Drag

Runner

Gate

Shape generation capability (of processes)

ME 488/588 Design for Manufacture & Assembly Date: 9/2/03 Engineer: R. J. E. Part Name: no features part Part Data Input: N Process Capabilitites for Shape Generation Design For Assembly N N N N N N N N Process Evaluation

Regular Cross Section

Processes Solidification

sand casting investment casting die casting injection molding structural foam blow molding - extr blow molding - inj rotational molding impact extrusion cold heading closed die forging powder metal hot extrusion rotary swaging machined from stock ECM EDM Wire EDM sheet metal bending thermoforming metal spinning

Y Y Y Y Y Y Y Y Y Y Y Y Y N Y Y Y Y Y Y N

Y Y Y Y Y Y Y Y N N Y N N N Y Y Y N Y Y N

YU YU YU YU YU M M M Y Y Y Y Y N Y Y Y Y M M M

Y Y Y Y Y N N N N N Y YU M N Y Y Y Y Y Y N

Y Y Y Y Y Y Y Y Y Y Y Y Y M Y Y Y Y Y Y M

Y Y Y Y Y Y YU Y YU YU Y Y Y N Y Y Y Y Y Y N

Y Y N N N M M N N N N N N N Y N N N N N Y

N N N N N Y N M N N N N N N N N N N N N N

N N N N N N N N Y Y N YU Y N Y N N Y N N N

4 5 4 5 4 3 3 2 3 3 3 3 2 1 2 3 3 2 4 3 1

3 5 5 5 4 4 4 2 3 3 2 3 2 1 3 4 4 2 3 3 1

1 2 3 5 3 3 3 1 1 1 1 1 3 1 2 1 1 3 4 3 1

8 12 12 15 11 0 0 0 7 7 6 7 0 0 7 8 8 7 0 0 0
revision

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 2 2 2 0 0 0 0 1 1 0 0 0 0 1 1 2

Bulk Deformation

Metal Removal

Profile Generation Sheet Forming

R. J. Eggert, BSU (Based on data from Boothroyd, Dewhurst & Knight)

9/02/03

Accepted / Rejected
A A A A A R R R A A A A R R A A A A R R R

Draft Free Surfaces

Alignment Features

Integral Fasteners

Shape Attributes

Part consolidation

Captured Cavities

Depressions >1D

Uniform-Section

Depressions 1D

Axis of Rotation

Not capable (N)

Feature (M)ust

Uniform-Wall

DFA Index

Enclosed

Manufacturing costs

Total Manufacturing Cost = Material + Tooling + Processing

raw matls molds fixtures jigs tool bits labor electricity supplies O/H (deprec.)

TMC

= M

+T

+ P (6.1)

Material costs per part

Let M = total materials costs (raw, bulk) q = production quantity

Then material costs per part, cM is cM = M/q = (cost/weight x weight) / number of parts Lets reorganize the variables in the equation above cM = [cost/weight] [weight/number of parts] = (cost/weight) (weight/part), and therefore cM = cost/part

Material cost per part (continued)

Let cw = material cost per unit weight, and wp = weight of finished part ww= weight of wasted material, scrap = ratio of wasted material weight / finished weight = ww / wp Then the material cost per part, cM is cM = cw (wp + ww ) = cw (wp + wp ) (6.2) cM = cw wp (1+ ) (6.3) e.g. sand casting cM = ($1/lb)(1lb/part)(1+.05) = $1.05/part

Tooling cost per part

Let

T= total cost of molds, fixtures per production run q = number of parts per run cT= T/q (6.4)

Then

e.g. sand casting cT = ($10,000/run) / (5000 parts/run) = $2.00/part

Processing cost per part

Let

ct = cost per hour, (machine rate + labor) t = cycle time (hours per part) cP = ct t (6.5)

then

e.g. sand casting cP = ($30/hr) (0.3 hrs/part) = $9/part

Total cost per part

Cost per part, c= cM + cT T/q + + cP ct t (6.6) c = cw wp (1+ ) + e.g. sand casting c= $1.05 + $2.00 + $9.00

c=

$12.05 / part

Example costs for 5000 part run

Alternative B Injection molding ABS 3 0.01 0.25 35000 5000 0.03 100 10.7575

Mfg. Process Material Part weight (lb) alpha Material cost ($/lb), cw Tooling cost ($), T Production quantity, q Cycle time (hrs/part), t Machine rate ($/hr) Part cost ($/part)

A Sand casting Aluminum alloy 1 0.05 1 10000 5000 0.3 30 12.05

C Machining Bronze alloy 2 0.2 0.75 1500 5000 0.6 75 47.1

Run quantity is important!

1000

Cost ($/part)

100

10

1 0 1000 2000 3000 4000 5000 6000 Production quantity

A-Sand casting B-Inj.Molding C-Machining

How can we lower the cost of parts?

c = cw wp (1+ ) + T/q + ct t (6.6) 1) purchase less expensive materials, 2) keep our finished part weight low 3) produce little manufactured waste 4) design simple parts that result in less expensive tooling 5) make many parts production run (i.e. batch) 6) choose a manufacturing process that has a low cycle time & cost per hour Goal: minimize the sum of the terms! (not any one term in particular)

Summary

Manufacturing process decisions Deformation processes Casting processes Sheet metalworking Polymer processing Machining Finishing Assembly Material compatibilities / Process capabilities Material costs, Tooling costs, Processing costs