Process Planning bPROCESS PLANNING STEPS Study the overall shape of the part. Use this information to Classify the part and determine the type of workstation needed. Thoroughly study the drawing. Try to identify every manufacturing features and notes. If raw stock is not given, determine the best raw material shape to use. Identify datum surfaces. Use information on datum surfaces to determine the setups. Select machines for each setup. For each setup determine the rough sequence of operations necessary to create all the features.PROCESS PLANNING STEPS (continue) Sequence the operations determined in the previous step. Select tools for each operation. Try to use the same tool for several operations if itis possible. Keep in mind the trade off on tool change time and estimated machining time. Select or design fixtures for each setup. Evaluate the plan generate thus far and make necessary modifications, Select cutting parameters for each operation. Prepare the final process plan document.COMPUTER-AIDED PROCESS PLANNING ADVANTAGES 1. It can reduce the skill required of a planner. b 2. It can reduce the process planning time. 3. It can reduce both process planning and manufacturing cost. 4, It can create more consistent plans. 5, It can produce more accurate plans. 6. It can increase productivity.WHY AUTOMATED PROCESS PLANNING + Shortening the lead-time + Manufacturability feedback + Lowering the production cost + Consistent process plansRapid PrototypingRapid Prototyping ‘© What is rapid prototyping? ~ Itis a process that creates parts in an additive, layer-by- layer manner. ~ Aspecial class of machine technology that quickly produces models and prototype parts from 3-D data using an additive approach to form the physical models.Rapid Prototyping (RP) + Introduction of RP — Generate a prototyping by Laying Manufacturing Technology - composite material layer by layer Rapid Prototyping (RP) + Development of RP — First Phase : Manual (or Hard) Prototyping + Age-old practice for many centuries + Prototyping as a skilled craft is traditional and manual and based on material of prototype + Natural prototyping technique- Second Phase : Soft (or Virtual) Prototyping + Mid 1970's + Increasing complexity + Can be stressed, simulated and tested with exact mechanical and other properties — Third Phase : Rapid Prototyping + Mid 1980's + Hard prototype made in a very short turnaround time (relies on CAD modelling) + Prototype can be used for limited testing + 3times complex as soft prototyping — Building computer model + Model is building by CAD/CAM system + Model must be defined as enclosed volume or solid— Converting model into STL file format + STereoLithography (STL) file is a standard format to describe CAD geometry used in RP system + STLfile file approximates the surfaces of the model by polygons + Fundamentals of RP — Fabricating the model + Building model layer by layer + Forming a 3D model by solidification of liquid/powder+ Applications of RP - For design evaluation + Touch and holding a physical prototype — For function verification + eg, assembly, kinematics performance, and aerodynamic performance — Models for further manufacturing processes + eg. Vacuum casting, spray metal moulding, investment casting, etc.+ Advantages and Disadvantages 4 No planning of process sequences 4No specific equipment for handling materials 4 No transportation between machining 4 Features-based design and feature recognition are unnecessary 4 Defining a blank geometry is unnecessary 4 Defining different setups or complex sequences of handling material is unnecessary» Role of RP in Product Development Cycle — Product design + Increase part complexity and diversity with little effect on lead time and cost + Minimise time-consuming discussion and evaluations of manufacturing possibilities - Tool design and manufacturing + Minimise design, manufacturing and verification of tooling + Reduce parts count and eliminate tool wearRapid Prototyping (RP) + Role of RP in Product Development Cycle — Assembly and test + Reduce labour content of manufacturing (e.g. machining, casting, inspection and assembly, etc.) + Reduce material costs (e.g. handling, waste, transportation, spare and inventory, etc.) — Function testing + Avoid design misinterpretations, i.e. what you design is what get) bDue to the newness of the technology, there are already so many words for RP used today: —RP( most commonly used) - Rapid Prototyping —RPTM(inc. new development trends) - Rapid Prototyping, Tooling and Manufacture — Direct CAD Manufacturing/Desktop Manufacturing/Instant Manufacturing/CAD Oriented Manufacturing = RP+ Classification of RP Systems By the initial form of its material, RP systems can be categorised into: — Liquid-based Liquid-based material => Curing Process > Solid (e.g. SLA, SGC, SOUP, etc.) + Classification of RP Systems — Solid-based Encompass all forms of material in the solid form, such as in the form of wire, a roll, laminates and pellets. — Powder-based ® Grain-like material = Joining/Binding => Solid (e.g. SLS and 3DP, etc.)+ Features of RP Systems — Layer thickness(mm) - 0.05 - 0.3(SLA); 0.1 4(LOM.); ~0.05(FDM); ~0.08(SLS); 0.04 - 0.15(SGC) —Accuracy(mm) - 0.01- 0.2(SLA); 0.1 - 0.2(LOM); 0.127 - 0.254(FDM); 0.03 - 0.38(SLS); 0.05 - 0.5(SGC) — Manufacturer - 3D System, Stratasys, Helisys, DTM, EOS, etc. &Stereolithography (SLA) Stereolithography (SLA) is the most widely used rapid prototyping technology. It can produce highly accurate and detailed polymer parts. It was the first rapid prototyping process, introguced in 1988 by 3D Systems,” Inc., based on work by inventor Charles Hull. It uses a low-power, highly focused UV laser to trace out successive cross-sections of a three-dimensional object in a vat of liquid photosensitive polymer. As the laser traces the layer, the polymer solidifies and the excess areas are left as liquid. ‘When a layer is completed, a leveling blade is moved across the surface to smooth it before depositing the next layer. The platform is lowered by a distance equal to the layer thickness (typically 0.003-0,002 in), and a ‘subsequent layer is formed on top of the previously completed layers. This process of tracing and smoothing is repeated until the build is complete. Once complete, the part is elevated above the vat and drained. Excess polymer is swabbed or rinsed away from the surfaces. In many cases, a final cure is given by placing the part in a UV oven. After the final cure, supports are cut off the part and surfaces are polished, sanded or otherwise finishedStereolithography (SLA) Abbreviation: Material type: Materials: Max part size: Min feature size: Min layer thickness: Tolerance: Surface finish: Build speed: Applications: sla Liquid (Photopolymer) Thermoplastic (Elastomers) 59.00% 29.50% 19.70in. 0.0041n. o.0010 in, 0.00501, smooth Average Form/fittesting, Functional testing, Rapid ‘tooling patterns, Snap fits, Very detailed parts, Presentation models, High heat applicationsFused Deposition Modeling (FDM) eee ——, Fused Deposition Modeling (FDM) was developed by Stratasys in Eden Prairie, Minnesota. In this process, a plastic or wax material is extruded through a nozzle that traces the part's cross sectional geometry layer by layer. The build material is usually supplied in filament form, but some setups utiize plastic pellets fed from a hopper instead, The nozzle contains resistive heaters that keep the plastic at a temperature just above its melting point so that it flows easily through the nozzle and forms the layer. The plastic hardens immediately after flowing from the nozzle and bonds to the layer below. Once a layer is built, the platform lowers, and the extrusion nozzle deposits another layer. The layer thickness and vertical dimensional accuracy is determined by the extruder die diameter, which ranges from 0.013 to 0.005 inches. In the X-Y plane, 0.001 inch resolution is achievable. A range of materials are available including ABS, polyamide, polycarbonate, polyethylene, Polypropylene, and investment casting wax.Fused Deposition Modeling (FDM) Abereviation Materaltype: Materials: Max part sie: Min feature size: Min ayer thickness: Tolerance: Surfacefinish Build speed: Applications: Fo Solid (Flaments) ‘Thermoplasticssuch as ABS, Polycarbonate, and Polyphenyisulfone; Elastomers, 36.00%24.00%36.00%n. 0.008in, 0.0050in. 0.0080in. Rough Slow Form/fit testing, Functional testing, Rapid tooling patterns, mall detalled parts, Presentation models, Patient and food applications, High heat apalicationsSelective Laser Sintering (SLS) Selective Laser Sintering (SLS) was developed at the University of Texas in ‘Austin, by Car! Deckard and colleagues ‘The technology was patented in 1989 and was originally sold by DTM Corporation DTMwas acquired by 8D Systems in 2001 The basic concept of SLS is similarto that OfSLA. Ittuses a moving laser beam to trace and selectively sinter powdered polymer and/or metal composite materials into successive cross-sections of a three- dimensional part. As in all rapid prototyping processes, the parts are built upon a platform that adjusts in height equal to the thickness of the layer being built, Additional powder is deposited on top of each solidified layer and sintered. This powder is rolled onto the platform from a bin before building the layer. The powder is maintained at an elevated temperature so that itfuses easily upon exposure to the laser. Unlike SLA, Special support structures are not required because the excess powder in ach layer acts as 2 support to the part being built. With the metal composite material, the SLS process solidifies a polymer binder material around steel powder (100 micron diameter) one slice at a time, forming thé part. The part is then placed in a furnace, at temperatures in excess of 900 °C, where the polymer binder is burned off and the part is infiltrated with bronze to improve its density. The burn-off and infiltration procedures typically take about one day, after which secondary machining and finishing is performed. Recent improvements in accuracy and resolution, and reduction in. stair-stepping, have minimized the need for secondary machining and finishing. SLS allows for a wide range of materials, including nylon, sglass-filed nylon, SOMOS (rubber-like),Selective Laser Sintering (SLS) Abbreviation: Matenaltype: Materials: Maxpart size: Min feature size Minlayer thickness: Tolerance: Surface finish Bulldspeed: Applications: sis Powder Polymer) Thermoplasticssuch as Nylon, Polyamide, ‘and Polystyrene; Elastomers; Composites 22.00% 22.00 x30.00 in. * 0.005 in. 0.0080 in. 0.0100 in. Average Fast Form/fit testing, Functional testing, Rapid toolingpatterns, Less detailed parts, Parts with snap-fits & living hinges, High heat applicationsLaminated Object Manufacturing The first commercial Laminated Object ‘Manufacturing (LOM) system was shipped in 1991. LOM was developed by Helisys of Torrance, CA. The main components of the system ar a feed mechanism that advances a sheet over a build platform, a heated roller to apply pressure to bond the sheet to the layer below, and a laser to cut the outline of the part in each sheet layer. Parts are produced by stacking, bonding, and cutting layers of adhesive-coated ‘sheet material on top of the previous one. A laser cuts the outline of the part into each layer. After each cut is completed, the platform lowers by a depth equal to the sheet thickness (typically 0.002-0,020 in), and another sheet is advanced on top of the previously deposited layers. The platform then rises slightly and the heated roller applies pressure to bond the new layer. The laser cuts the outline and the process is repeated until the part is completed. After a layer is cut, the extra material remains in place to support the ppart during build3-D Printing ‘The 3D printing process begins with Three Dimensional Printing (2P) the powder supply being raised by a technology was developed at the piston and a leveling roller distributing Massachusetts Institute of Technology & thin layer of powder to the top of the and licensed to several corporations. build chamber. A multi-cHannel ink-jet The process is similar to the Selective print head then. ‘deposits "a liquid Laser Sintering (SLS) process, but adhesive to targeted regions of the instead of using @ laser to sinter the Sowder bed. These regions of powder vwaimracmaterial, an ink-jet printing head” are bonded together by the adhesive deposits aliquid adhesive that binds the nd form one layer of the part. The ‘material. Material options, which include femaining freestanding powder metal or ceramic powders, ate Supports the part during the build somewhat limited but are inexpensive after a layer is built, the build platform relative to other additive processes. 3D js lowered and a new layer of powder Printing offers the advantage of fast added leveled, and. the printing build speeds, typically 2-4 layers per repeated. After the part is completed, minute. However, the accuracy, surface {he loose supporting powder can be finish, and part strength are not quite aS brushed away and the part removed good as some other additive processes. 3D printed parts are typically infiltrated 3D Printing is typically used for the rapid with a sealant to improve strength and prototyping of conceptual models surface finish. (limited functional testing is possible).Abbreviation: Material type: Materials: Max part sie: Min feature size: Min ayer thickness Tolerance: Surface irish Build speed: Applications 30° Powder Faroutmatals such as Stainless Non‘grouemetlsuch Bron tose composts rms '59.00%28.50x27.50in, 0.008 in, 0.0020in. 2.0080}. Rough Very Fast Concept models, Limited functional testing, Architectural& landseape models, (Color industrial design models, Consumer goods & packagingProduct Life Cycle ManagementProduct Life Cycle Management >What is the Product-Life Cycle and PLM? >The aim of PLM > Components and figures Influential factors Solutions of PLM » Sub — Softwares Advantages of this systemProduct Data Management (PDM) ig Director of macnn x SSProduct life cycle + Design phase + Manufacturing phase + Product usage phase + Disposal phase The design phase is the most critical + Determines the product success or failur the market place. + Has a direct impact on product cost, quality, manufacturing, maintenance cost, and disposal cost. + Approximately 80% of the product cost is fixed at the design stage; it is easier and less costly to change the design in early phases. Reduction in cost and lead time and improvements in product quality must be sought from all areas of a product-life cycle.Research and DevelopmentResearch and Development In that level; Companies decide for cost of product and problems of Service.%80 of product costs are determined at this stage. Products are designed, made a prototype and tested for needs of various users. The most appropriate marketing method is doing nothing about the product sales. Because; there is not a product yet. Introduction (Offer) In that level; large budgets must be separated for promotion because it is the first time of product — market meeting. So word of mouth marketing is not possible even the productis so qualified. The size of the budget influences the length of product life cycle. The new product does not produce profit due to costs of supply and promotion.Growth If the product is fit for market, companies can pass this level. In that level; Companies begin to obtain revenue. The price of the product can be the same at the beginning or it can be change. The cost of marketing should be stable and also you have to invest for improving your product's features. Expansion of distribution lines reach to the new customers profile. After all that, rate of profit is going to pick-up. Maturity This level starts from the rate of sales decline. Competition increases between sellers. The rivals try to reduce prices while the cost of production is falling. In this way weak opponents pull out from the market.Decline In that level; the rate of sales reduces visibly. The reasons of decline are technological developments, opponents who gain experience and strong etc. At the end of this stage the companies need to know the idea of customers about product. Because they need that feedback system to improve their product.‘The Main Figures Figuee 1: Product Life Cycle Phases Introduction (from conception to disposal) % Product life cycle management process % Business (the money dimension) % Heart beat of changes (the time dimension) % Complexity (huge number of configurations) ConclusionWhich factors have an impact on PLM? External Factors v Scale: Companies want to grow continuously. ¥ Complexity: The diversity of product increases because of product and the process of production. ¥ Time of cycle: It’s important for competition. ¥ Lean production: It's about using less energy and material. ¥ Global competition: The competition has increased significantly. ¥ The arrangements made by governments and international agreements: It's about environmental degradation, work and arrangement of job security.What are the sub-softwares? + Product Portfolio Management (PPM) + Computer Aided Design / Engineering / Manufacturing {CAx) + Product Data Management (PDM) + Manufacturing Process Management (MPM) + Digital Manufacturing (DM)What are the solutions of PLM? © PLM Solutions are organs. It has been developed for the improvement of organization by IT(Information Technology) © Work to rely on customer © Responding quickly to changing market conditions © Shortening the duration of the market to offer new products © Workflow that allows optimization of product © Reduction in the cost of prototype © Continuous innovation process and implement new technologies effectively Reduction of waste Being in closer contact with customers and suppliers ° °» Because of all these solutions and advantages, the volume of PLM was 10.2 billion dollars in the world according to the last user license’