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

Rear Pedal
Derailleur

(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”) 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
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

M a n u fac tu rin g
How is the input
P ro cesses material changed?

Sheet P o ly m er
D e fo rm a tion C a sting M e tal P ro cesses M a c h in in g F in ish in g A s s e m b ly

E x tru s io n C e n trif u g a l B e n d in g B lo w m o ld ing B o rin g A n o d iz in g A u to m a ted

F o rg ing D ie ca s ting B la n k in g C a s tin g D r i l li n g H o n in g B o n d in g
R o llin g In v e stm e nt D raw in g C o m p r e s s io n m o l d i n g F a c in g P a in tin g B ra z ing
B a r d ra w in g P e r m a n e n t m o ld P u n c h in g E x tru s io n G rin d ing P la ting M an u al
W ire d raw in g S a n d c a s tin g S h e a rin g I n j e c ti o n M o l d i n g M i ll i n g P o lish in g R iv e ting
S p in n in g T h e rm o fo rm ing P la n in g S o ld e rin g
T ra n sfe r m o ld in g T u rn in g W e ld ing
S a w ing
ECM ,EDM
Deformation processes

 Rolling
 Extrusion
 Drawing
 Forging
 Rolling (of ductile materials)

Rollers in compression

thick
slab

thin
sheet

Plastic deformation
 Rolling

bloom
structural

ingot
coil
slab sheet

billet bar rod

Extrusion

Extrusion
die

Cross
sections
Ram

Billet
Drawing

Drawing die

Cross
sections

Pulling
Billet force
 Forging (closed-die)

Ram pressure

Flash
Blocked
preform

Gutter
Casting Processes

 Sand casting
 Die casting
 Investment casting
 Sand casting (closed-mold)

Cope
Riser
Core
Flask Sprue

Parting Runner
line
Drag Gate
Die casting

Stationary Moving
die die

Molten
metal

Plunger Ejector pins

Sprue

Parting line
Investment casting
Ceramic mold
4-part pattern tree (hardened slurry)

Wax pattern
is cast

Wax removed Molten metal Ceramic mold is

by melting solidifies in cast removed
Sheet Metalworking

 Bending
 Blanking
 Drawing
 Punching
 Shearing
 Spinning
Sheet metal drawing

Punch ram
Punch

Blank
holder
Clamp
Die force

Blank
Drawn part
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

Air
Molten Mold blown
parison is halves into Part is
extruded close parison removed

Extruder
air injector

parison
 Injection molding

Cavity half Core half

of mold of mold

Pellets

Feed hopper
Barrel

Ejector pins

Shear-heating Sprue

Mold closure direction

Parting
plane/surface Fixed Moving
 Example of a box …with no undercuts

ejector parting
pins line

core

mold cavity
closure
direction
plastic
injection
 Internal undercuts

ejector parting
pins line

core

closure cavity
direction
plastic
injection
 External undercuts

ejector parting
pins line

core

cavity
closure
direction
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

Flow (voids, flash)

Cooling time (cycle time)
Temperature
Mold complexity
Warpage
Post processing
Costs (materials, tooling, processing)
Add to your
notes
 Machining processes

M a n u fac tu rin g
P ro cesses

Sheet P o ly m er
D e fo rm a tio n C a s tin g M e tal P ro cesses M a c h in in g F in ish in g A s s e m b ly

E x tru s io n C e n trif u g a l B e n d in g B lo w m o ld in g B o rin g A n o d iz in g A u to m a ted

F o rg in g D ie ca s tin g B la n k ing C a s tin g D r i l li n g H o n in g B o n d in g
R o llin g In v e stm e nt D raw in g C o m p r e s s io n m o l d i n g F a c in g P a in tin g B ra z ing
B a r d ra w in g P e r m a n e n t m o ld P u n c h in g E x tru s io n G rin d in g P la ting M an u al
W ire d raw in g S a n d c a s tin g S h e a rin g I n j e c ti o n M o l d i n g M i ll i n g P o lish in g R iv e tin g
S p in n in g T h e rm o form in g P la n ing S o ld e rin g
T ra n sfe r m o ld in g T u rn ing W e ld in g
S a w ing
ECM ,EDM
 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

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
Add to your
costs (materials, tooling, processing)
notes
 Finishing processes

M a n u fac tu rin g
P ro cesses
protection?
Sheet P o ly m er
D e fo rm a tio n C a s tin g M e tal P ro cesses M a c h in ing F in ish in g A s s e m b ly

E x tru s io n C e n trifu g al B e n d in g B lo w m o ld in g B o ring A n o d iz in g A u to m a ted

F o rg ing D ie ca s tin g B la n k in g C a s tin g D r i l li n g H o n ing B o n d in g
R o llin g In v e stm e n t D raw in g C o m p r e s s io n m o l d i n g F a c in g P a in tin g B ra z in g
B a r d ra w in g P e r m a n e n t m o ld P u n c h in g E x tru s io n G rin d ing P la tin g M an ual
W ire d raw ing S a n d c a sting S h e a rin g I n j e c ti o n M o l d i n g M i ll i n g P o lish in g R iv e tin g
S p in n in g T h e rm o fo rm in g P la n in g S o ld e rin g
T ra n sfe r m o ld in g T u rn in g W e ld ing
S a w in g
ECM ,EDM
 Assembly processes
– fastening / joining of 2 or more components

M a n u fac tu rin g
P ro cesses

Sheet P o ly m er
D e fo rm a tio n C a s tin g M e tal P ro cesses M a c h in in g F in ish in g A s s e m b ly

E x tru s io n C e n trif u g a l B e n d in g B lo w m o ld in g B o ring A n o d iz in g A u to m a ted

F o rg in g D ie ca s tin g B la n k in g C a s tin g D r i l li n g H o n in g B o n d in g
R o llin g In v e stm e nt D raw ing C o m p r e s s io n m o l d i n g F a c in g P a in tin g B ra z in g
B a r d ra w in g P e r m a n e n t m o ld P u n c h in g E x tru s io n G rin d in g P la tin g M an u al
W ire d raw in g S a n d c a s tin g S h e a ring I n j e c ti o n M o l d i n g M i ll i n g P o lish in g R iv e tin g
S p in n in g T h e rm o fo rm in g P la n in g S o ld e rin g
T ra n sfe r m o ld in g T u rn in g W e ld in g
S a w in g
ECM ,EDM permanent?
Process / Material Screening
Product function is interdependent

Material
Properties

Product
Function

Manufacturing Product
Processes Geometry
Are materials compatible with mfg. process?

Material
Properties

Manufacturing compatible
Processes materials & processes
 Material-Process Compatibility

M a g n e s i u m & a ll o y s
T i t a n iu m a n d a l lo y s
A lu m in u m & a llo y s
S h a p e A ttr ib u te s

R e f r a c t o r y m e t a ls
C o p p e r & a ll o y s

T h e r m o p la s t ic s
S t a in l e s s S t e e l

N ic k e l & a llo y s
ME 488 Design for Manufacture & Assembly Materials Compatibility

C a rb o n S te e l

Z i n c & a l lo y s

th e rm o s e ts
A llo y S t e e l
C a s t Iro n
Processes
Solidification sand casting
investment casting
die casting
injection molding
structural foam
blow molding - extr
blow molding - inj
rotational molding

Bulk impact extrusion

Deformation cold heading
closed die forging
powder metal
hot extrusion
rotary swaging

Metal machined from stock

Removal ECM
EDM

Profile Generation Wire EDM

Sheet sheet metal bending

Forming thermoforming
metal spinning
© R. J. Eggert, BSU (Based on data from Boothroyd, Dewhurst & Knight) pg 47 revision 9/02/03

Legend Normal practice

Less common
Not applicable
Is process capable of producing part geometry?

“capable”
geometry & processes

Manufacturing Product
Processes Geometry
Process-first selection approach

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

boss/depression 1D uniform cross sections

boss/depression >1D regular cross sections
holes rotational symmetry
undercuts (int./ext.) captured cavities
uniform walls
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 Regular
(i.e.pattern) not-regular
(i.e.pattern)
Enclosed (hollow)

And, rotationally molded

parts
 Draft free surfaces

No draft

With draft

Cope
Riser
Core
Flask Sprue

Parting Runner
line
Drag Gate
Shape generation capability (of processes)
 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)
 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

Let’s 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

Then
cT= T/q (6.4)

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)

then cP = ct t (6.5)

e.g. sand casting

cP = ($30/hr) (0.3 hrs/part) = $9/part
 Total cost per part

Cost per part,

c= cM + cT + cP
c = cw wp (1+ ) + T/q + ct t (6.6)

e.g. sand casting

c= $1.05 + $2.00 + $9.00
c= $12.05 / part
Example costs for 5000 part run
 Run quantity is important!
1000

100
Cost ($/part)

10

1
0 1000 2000 3000 4000 5000 6000
Production quantity

A B C

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