1. 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

2. How would we manufacture a mountain bike ? Top Tube Rear Derailleur Front Brake Rear Brake Saddle Seat Post Pedal Handle Bar Down Tube Fork (Courtesy of Trek Bicycle, 2002)

3. 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?

4. Parts undergo sequence of processes Primary - alter the (“raw”) material’s 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 Changes?

5. 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

6. Types of manufacturing processes How is the input material changed?

7. Deformation processes Rolling Extrusion Drawing Forging

8. Rolling (of ductile materials) Plastic deformation Rollers in compression thick slab thin sheet

9. Rolling slab bloom billet sheet coil barrod structural ingot

10. Extrusion Ram Cross sections Extrusion die Billet

11. Drawing Pulling force Cross sections Drawing die Billet

12. Forging (closed-die) Blocked preform Gutter Ram pressure Flash

13. Casting Processes Sand casting Die casting Investment casting

14. Sand casting (closed-mold) Core Riser Sprue Runner Drag Flask Cope Gate Parting line

15. Die casting Parting line Plunger Sprue Moving die Stationary die Ejector pins Molten metal

16. Investment casting Wax pattern is cast Wax removed by melting Molten metal solidifies in cast Ceramic mold is removed Ceramic mold (hardened slurry) 4-part pattern tree

17. Sheet Metalworking Bending Blanking Drawing Punching Shearing Spinning

18. Sheet metal drawing Blank Drawn part Clamp force Blank holder Die Punch Punch ram

19. Polymer Processes Compression molding Transfer Molding Blow molding Injection molding

20. Compression molding Charge Heated mold Part Ram Pressure

21. Transfer molding

22. Blow molding Extruder air injector parison Part is removed Air blown into parison Mold halves close Molten parison is extruded

23. Injection molding Shear-heating Cavity half of mold Core half of mold Ejector pins Moving Feed hopper Sprue Fixed Barrel Pellets Mold closure direction Parting plane/surface

24. Example of a box …with no undercuts core cavity parting line mold closure direction plastic injection ejector pins

25. Internal undercuts core cavity parting line closure direction plastic injection ejector pins

26. External undercuts core cavity parting line plastic injection ejector pins closure direction

27. Solidification processes Casting Processes Sand Casting Die Casting Investment Casting Centrifugal Polymer Processes Injection Molding Blow Molding ThermoForming Compression Molding solid Partmolten materialfreezing Flow (voids, flash) Cooling time (cycle time) Temperature Mold complexity Warpage Post processing Costs (materials, tooling, processing) Add to your notes

28. Machining processes

29. 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.

30. Surface roughness

31. Machining process considerations sawing, turning, boring, milling, drilling, grinding, ECM material removed solid materialmachining 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) Add to your notes

32. Finishing processes protection?

33. Assembly processes – fastening / joining of 2 or more components permanent?

34. Process / Material Screening

35. Product function is interdependent Material Properties Product Function Manufacturing Processes Product Geometry

36. Are materials compatible with mfg. process? Material Properties Manufacturing Processes compatible materials & processes

37. Material-Process Compatibility

38. Is process capable of producing part geometry? Manufacturing Processes Product Geometry “capable” geometry & processes

39. 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

40. Depressions 1D, >1D 1D >1D

41. Uniform wall (thickness) but… Varying cross section Constant cross section

42. Uniform cross section (constant cross section) Non-uniform wall thicknesses

43. Axis of rotation (symmetry)

44. Regular cross section (regular pattern) not-regular Regular (i.e.pattern)

45. Enclosed (hollow) And, rotationally molded parts

46. Draft free surfaces Core Riser Sprue Runner Drag Flask Cope Gate Parting line With draft No draft

47. Shape generation capability (of processes)

48. Manufacturing costs Total Manufacturing Cost = Material + Tooling + Processing raw mat’ls molds labor fixtures electricity jigs supplies tool bits O/H (deprec.) TMC = M + T + P (6.1)

49. Material costs per part Let M = total materials costs (raw, bulk) q = production quantity Then material costs per part, c M is c M = M/q = (cost/weight x weight) / number of parts Let’s reorganize the variables in the equation above c M = [cost/weight] [weight/number of parts] = (cost/weight) (weight/part), and therefore c M = cost/part

50. Material cost per part (continued) Let c w = material cost per unit weight, and w p = weight of finished part w w = weight of wasted material, scrap  = ratio of wasted material weight / finished weight = w w / w p Then the material cost per part, c M is c M = c w (w p + w w ) = c w (w p +  w p ) (6.2) c M = c w w p (1+  ) (6.3) e.g. sand casting c M = ($1/lb)(1lb/part)(1+.05) = $1.05/part

51. Tooling cost per part Let T= total cost of molds, fixtures per production run q = number of parts per run Then c T = T/q (6.4) e.g. sand casting c T = ($10,000/run) / (5000 parts/run) = $2.00/part

52. Processing cost per part Let c t = cost per hour, (machine rate + labor) t = cycle time (hours per part) then c P = c t t (6.5) e.g. sand casting c P = ($30/hr) (0.3 hrs/part) = $9/part

53. Total cost per part Cost per part, c = c M +c T +c P c = c w w p (1+  ) + T/q+c t t (6.6) e.g. sand casting c = $1.05+$2.00+$9.00 c = $12.05 / part

54. Example costs for 5000 part run

55. Run quantity is important! A-Sand casting B-Inj.Molding C-Machining

56. How can we lower the cost of parts? c = c w w p (1+  ) + T/q+c t 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)

57. 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