CHAPTER 40

Competitive Aspects of Manufacturing

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-1
 Commercially Available Materials
TABLE 40.1
Material Available as
Aluminum P, F, B, T, W, S, I
Copper and brass P, f, B, T, W, s, I
Magnesium P, B, T, w, S, I
Steels and stainless steels P, B, T, W, S, I
Precious metals P, F, B, t, W, I
Zinc P, F, D, W, I
Plastics P, f, B, T, w
Elastomers P, b, T
Ceramics (alumina) p, B, T, s
Glass P, B, T, W, s
Graphite P, B, T, W, s
Note: P, plate or sheet; F, foil; B, bar; T, tubing; W, wire; S,
structural shapes; I, ingots for casting. Lowercase letter
indicates limited availability. Most of these materials are also
available in powder form.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-2
 Approximate Amount of Scrap Produced in
Various Manufacturing Processes

TABLE 40.2
Scrap Scrap
Process (%) Process (%)
Machining 10–60 Cold or hot extrusion, forging 15
Hot closed-die forging 20–25 Permanent-mold casting 10
Sheet-metal forming 10–25 Powder metallurgy 5
Rolling, ring rolling <1

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-3
 Advanced Materials
Figure 40.1 Advanced
materials used on the Lockheed
C-5A transport aircraft. (FRP:
fiber-reinforced plastic)

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-4
 Material Changes From C-5A to C-5B Military
Cargo Aircraft
TABLE 40.3
Item C-5A Material C-5B Material Reason for change
Wing panels 7075–T6511 7175–T73511 Durability
Main frame
Forgings 7075–F 7049–01 Stress corrosion resistance
Machined frames 7075–T6 7049–T73
Frame straps 7075–T6 plate 7050–T7651 plate
Fuselage skin 7079–T6 7475–T61 Material availability
Fuselage underfloor end 7075–T6 forging 7049–T73 forging Stress corrosion resistance
fittings
Wing/pylon attach fitting 4340 alloy steel PH13–8Mo Corrosion prevention
Aft ramp lock hooks D6–AC PH13–8Mo Corrosion prevention
Hydraulic lines AM350 stainless steel 21–6–9 stainless steel Improved field repair
Fuselage failsafe straps 6AI–4V titanium 7475–T61 aluminum Titanium strap debond

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-5
 Methods of Making a Simple Part

Figure 40.2 Various methods of making a simple part: (a) casting or powder metallurgy,
(b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-6
 Manufacturing Process Capabilities
Figure 40.3
Manufacturing
process capabilities
for minimum part
dimensions. Source:
J. A. Schey,
Introduction to
Manufacturing
Processes (2d ed.).
McGraw-Hill, 1987.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-7
 Dimensional Tolerance

Figure 40.4
Dimensional tolerance
capabilities of various
manufacturing
processes.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-8
 Dimensional Tolerance and Surface Finish
Figure 40.5 Relationship between relative manufacturing
cost and dimensional tolerance.

Figure 40.6 Relative production time, as a function of surface

finish produced by various manufacturing processes. Source:
American Machinist. See also Fig. 25.33.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-9
 Manufacturing a Sheet Metal Part

Figure 40.7 Two methods of making a dish-shaped sheet-metal part: (a)

pressworking, using a male and female die, (b) explosive forming, using one
die only.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-10
 Approximate Ranges of Machinery Base
Prices
TABLE 40.5
Type of machinery Price range Type of machinery Price range
($000) ($000)
Broaching 10–300 Machining center 50–1000
Drilling 10–100 Mechanical press 20–250
Electrical discharge 30–150 Milling 10–250
Electromagnetic and electrohydraulic 50–150 Ring rolling 500
Fused deposition modeling 60–120
Gear shaping 100–200
Grinding Robots 20–200
Cylindrical 40–150 Roll forming 5–100
Surface 20–100 Rubber forming 50–500
Headers 100–150 Stereolithography 80–200
Injection molding 30–150 Stretch forming 400–> 1000
Boring Transfer machines 100–> 1000
Jig 50–150 Welding
Horizontal boring mill 100–400 Electron beam 200–1000
Flexible manufacturing system > 1000 Spot 10–50
Lathe 10–100 Ultrasonic 50–200
Single- and multi-spindle automatic 30–250
Vertical turret 100–400
Note: Prices vary considerably, depending on size, capacity, options, and level of automation and computer controls.

Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 40-11