Process Selection - From Design to Manufacture Episode 1 Part 1 potx

[...]...//SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 10 – [1 16 /16 ] 13 .5.2003 7:42PM //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 11 – [1 16 /16 ] 13 .5.2003 7:42PM Preface to first edition In order to facilitate the achievement of the required quality and cost objectives for the manufacture of a component design solution it is necessary to carry out... providing Design for Manufacture (DFM) and cost related information for the designer (1. 11 1. 20) A review of cost estimation techniques for the early stages of design and a method for relating product cost to material cost, total batch size and level of underlying technology can be found in References 1. 21 1. 24 //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 3 – [1 18 /18 ] 8.5.2003 9 :11 PM... Compounds Bulk Molding Compounds //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 1 – [1 18 /18 ] 8.5.2003 9 :11 PM Part I A strategic view Some background to the problem and placing process selection and costing into the context of modern product introduction and the application of techniques in design for manufacture and assembly 1. 1 Problems In today’s environment, manufacturing businesses... into the context of modern product introduction processes and the application of techniques in design for manufacture Part II presents the manufacturing process information maps (PRIMAs) and their selection Part III is concerned with methods and data for costing design solutions //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 12 – [1 16 /16 ] 13 .5.2003 7:42PM xii Preface to. .. relative cost coefficient assigned to a component design T ¼ process time in seconds for processing an ideal design of component by a specific process V ¼ volume of material required in order to produce the component Vf ¼ finished volume of the component Wc ¼ waste coefficient A //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 14 – [1 16 /16 ] 13 .5.2003 7:42PM xiv Notation used... concerned with process capability and design costing K G Swift and J D Booker //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 13 – [1 16 /16 ] 13 .5.2003 7:42PM Notation used List of terms ¼ total average cost of setting up and operating a specific process, including plant, labor, supervision and overheads, per second in the chosen country B ¼ average annual cost of tooling for processing... the associated risks are not properly understood Understanding the effects of variability and the severity/cost of failure is crucial to risk assessment and its management * Numbers in parentheses indicate References These are found on p 309 //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 2 – [1 18 /18 ] 8.5.2003 9 :11 PM 2 A strategic view Fig 1. 1 Commitment and incursion of costs during... Ultrasonic Seam Welding Wave Soldering Manufacturing process key (for Part III) AM CCEM CDF CEP CF CH CM2.5 Automatic Machining Cold Continuous Extrusion (Metals) Closed Die Forging Continuous Extrusion (Plastics) Cold Forming Cold Heading Chemical Milling (2.5 mm depth) //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 16 – [1 16 /16 ] 13 .5.2003 7:42PM xvi Notation used CM5 CMC CNC... primarily designed for use with company specific data, approximate data on a sample of common manufacturing processes and material groups is included to illustrate the design costing process and quantify the effect of design choices and alternative process routes on manufacturing cost The work is presented in three main parts Part I addresses the background to the problem and puts process selection. .. opportunity to exploit any benefits from alternative processes may be lost The greatest opportunity in design for manufacture occurs at the initial design stage, for while there are also possibilities for a product in production to be modified, there are many additional constraints This is also illustrated in Figure 1. 1 On top of the problems of tooling and equipment, it is not uncommon to find that . Selection //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 2 – [1 16 /16 ] 13 .5.2003 7:42PM //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 3 – [1 16 /16 ] 13 .5.2003 7:42PM Process Selection From design to manufacture Second. //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 1 – [1 16 /16 ] 13 .5.2003 7:42PM Process Selection //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D. forming 11 7 3 .10 Spinning 12 1 3 .11 Powder metallurgy 12 4 3 .12 Continuous extrusion (metals) 12 8 4 Machining processes 13 1 4 .1 Automatic and manual turning and boring 13 2 4.2 Milling 13 6 4.3 Planing