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Process Selection Method
1)
2)
3)
4)
Drawing interpretation
Geometry & Geometry analysis
Manufacturing data
Material Specification & Material Evaluation
Critical processing factors
Consult processing tables
Identify a suitable process
1) Drawing interpretation
Geometry & Geometry analysis
Manufacturing data
Material Specification & Material Evaluation
Geometry
Shape
Size
Weight
Other
Geometry Analysis
Fig 4.6 Shape code
Manufacturing data
Surface finish
Tolerances
Special treatments
Tooling
Other
Material Specification
Material type
Grade
Properties
Other
Material Evaluation
Shape
Material Properties
Fig. 4.7 Mfg. considerations
*Paste a copy of the De
2) Critical processing factors
# Critical process factor description (See Step 1 information)
3) Consult processing tables
Chapter 4 – Process tables
Section Thickness (mm)
Process
Material
Weight (kg)
Shape
Min
Max
Costs
Typical tolerance (mm) Surface finish (um)
L
E
T
EOQ
Prod. rate / hr
4) Identify a suitable process
Selected Process(es)
Reasons
Material Evaluation &
Process selection
READING: PPS CH4 (Pg 109 – 152)
Introduction
• The selection of a specific material ultimately limits the
manufacturing processes that can be used
• Factors that influence the use of material in
manufacturing:
1. The product design must meet the specified need
2. Materials with appropriate properties must be selected
3. Based on both of the above, suitable manufacturing processes
must be selected
4. The response of the material during manufacture and in service
Part 1 – Material Evaluation
Materials
Basic material properties
Metals
Ceramics & Polymers
Material selection process
GENERAL GUIDELINES
1. Specify the performance parameters and translate into
material properties
2. Specify the manufacturing considerations (batch size, part
size, weight, complexity, tolerances, surface finish,
manufacturability)
3. Shortlist the candidates from large database
4. Evaluate & compare each candidate in detail
5. Develop design data and / or a design specification for the
chosen material
Other Material selection methods
Material Evaluation
1.Shape or geometry considerations
2.Material property requirements
3.Manufacturing considerations
1. Shape or geometry considerations
Common questions…
1. Shape or geometry considerations
Fig 4.6 – Geometry classification matrix
1. Shape or geometry considerations
EXAMPLE –
Classify the shapes of the following objects
1. Shape or geometry considerations
EXAMPLE –
Classify the shapes of the following objects
2. Material property requirements
A. Mechanical properties –
• loading, impact loading, cyclic loading, wear
resistance, temperature range, deformation
B. Physical properties –
• electrical, magnetic, thermal, weight, appearance
C. Service environment –
• temperature exposure, most severe environment,
lifetime, maintenance, liability if failure, recyclability
2. Material property requirements
EXAMPLE –
What would be the mechanical, physical &
service properties for the item below?
3. Manufacturing Considerations
PRIMA matrix – see page 127
3. Manufacturing Considerations
EXAMPLE –
Use the PRIMA matrix to identify possible
processes for:
1. Material = Iron, Qty = 150,000
2. Material = Tin, Qty = 3,000
3. Material = Ceramics, Qty = 15,000
Part 2 – Process Selection
Manufacturing processes
Casting process selection
Table 4.4 See pg 131
Labor Equipment Tooling
Economic Order Quantity (EOQ)
order quantity that minimizes total inventory holding costs
and ordering costs
There is also a cost for each unit held in
storage, commonly known as holding cost
there is a fixed cost for each order placed, Ordering Cost
Shaping / Forming
Table 4.5 See pg 134
Machining –
Table 4.7 & 4.8 See pgs 138-139
Joining – Table 4.9 See pg 142
Surface – Table 4.10 See pg 144
Assembly processes
Assembly processes
Factors in Process selection
1. Number of components to be made
2. The component size
3. The component weight
4. The precision required
5. The surface finish & appearance required
+ 6. Workability
Material & process selection factors
Process selection
method
EXAMPLE 4.1 – Pgs 150-151
EXAMPLE 4.1 – Pgs 150-151
A. Geometric Analysis
• Use Fig 4.6
• T1 – Tube with change in
cross-section at the end
EXAMPLE 4.1 – Pgs 150-151
B. Manufacturing considerations
• List important process parameters
EXAMPLE 4.1 – Pgs 150-151
C. Material evaluation
• Cast iron – specified by designer
• Use Fig 4.7 to confirm suitability
EXAMPLE 4.1 – Pgs 150-151
EXAMPLE 4.1 – Pgs 150-151
• Go to the CASTING processing
table (Table 4.4)
• Considering tolerance, surface
finish, batch size etc.
• Shell casting
• Investment casting
• Centrifugal casting
EXAMPLE 4.1 –
Pgs 150-151
• Consider everything from
steps 1-3
• Meets process parameters
while being economical:
SHELL casting + MACHINING
> 100k
3.2
3.3
4.11
6A
3.9 4.1
4.2 4.3
4.4 4.5
4.12
4.13 6A
4.12
6A
4.1 4.2 3.2 3.3 3.4
4.3 4.4 3.9 4.1 4.2 3.3 3.4
3.9 4.2
4.5 4.7 4.3 4.4 4.5 4.1 4.3 3.4 4.2
4.3 4.12 4.8 4.11
4.8 4.12
4.4 4.8 4.3 4.4
6A
4.12 4.13
4.13 6A 4.13 6A 4.5 6A
3.1
3.1 3.6
4.6 4.8
4.9
3.6
4.6
3.1 3.6
4.6 4.8
4.9
ALL
3.1 3.6
4.6 4.8
4.9 7.5
3.1 3.6
4.6
4.8 4.9
3.1
4.6 4.8
4.9
4.6
4.8
4.9
3.2 3.3
3.5 3.7
4.1 4.3
4.10 4.11
3.3
3.3
3.8
3.8
6A 7.2
4.3
4.3
7.3 7.4
7.5
4.10
4.10
3.3
3.4 3.5
3.3
3.4
4.11
3.4
4.3
4.12 4.13
6A
4.3
4.4
7.2
4.4 4.5 4.13
7.5
6A
4.13
3.4
4.3
4.4
6A
Reactive Metals
Precious Metals
3.2 3.5 3.1 3.6 4.7
3.7 4.10 4.10 6M 5.3
6M 7.1 7.1 7.3 7.4 5.5
7.3 7.4 7.5 7.6 7.7 5.7
7.5 8.4
8.4
6M
5.2
5.8
7.7
8.6
6M
7.5
5.2
5.3
6M
4.11
5.2 7.1 7.3
5.3 7.5 7.6
5.8
7.7
7.4
8.4
7.7
6M
7.5
4.1 4.7
4.10
4.11 6A 5.3
5.5 5.2
7.2
7.3 7.4 5.6 5.3
7.5
5.7 5.4
4.1 4.4 5.1
5.3
4.11
5.5
4.12
4.13
5.6 5.1
6A
5.8 5.3
7.2 7.5 5.10 5.10
3.4
4.2
4.3
4.4
6A
4.2
4.3
4.12
6A
4.12
6A
4.6
3.1 3.6
4.6 4.8
4.9
4.8
4.9
Ceramics
3.1
3.8
4.10
6M
7.5
5.5
5.7
6M
8.1
3.5
4.11
7.1 7.5
7.6 7.7
8.3 8.4 3.1
8.5 8.6 7.7
FR Composites
3.5 3.7
4.10 6M
7.1 7.5
7.6 8.4
5.5
5.7
6M
8.3
8.5
8.6
Thermosets
Thermoplastics
3.1
4.10
6M
7.5
3.1 3.6
4.7
4.10 6M
7.1
7.5 7.6
7.7 8.4
Lead
Titanium
3.1
3.7
4.10
6M
7.5
3.1
3.7
3.8
4.10
6M
7.5
Nickel
3.5
3.5
3.5
3.6
3.7
3.1
3.5
3.7
3.1 3.5
3.5 3.7
3.7
3.7
4.10
4.7
4.10
3.7
3.6
4.10
3.7 4.10 4.7 4.10
1-100
6M
4.10
3.7
6M
6M 7.1
6M 7.1
6M
4.10
7.1
6M 7.5
7.1
6M
6M 7.1 7.1 7.5
7.5 7.6
7.5 7.6
7.5
7.5
7.3 7.4
7.6
7.7 8.4
8.2 8.4
8.2
8.4 8.5
3.1
3.2 3.5
3.2 3.5
3.7 4.1
3.2
3.7
3.7 3.8
3.6
4.4
3.2 3.7 3.7 3.8
3.5 3.6 3.2 3.5
4.7 4.10
3.7
3.8
4.5
3.7
3.7 4.10 4.11 6M 4.7 4.10
100-1000
6M 7.3 6.8 4.10 4.10
6M 7.1 6M 7.1
7.2
6M 7.1 4.10 6M
6M
7.3
7.3 7.4
7.1
7.4 7.5
6M
7.3
7.3 7.4
8.4
7.5
7.5
7.4
7.5
7.4 7.5 7.5 8.4 7.3 7.5
3.2
3.3
3.2 3.3 3.2 3.5 3.2 3.5
3.2 3.3
3.5 3.7 3.7 4.1 3.7 4.1 3.2 3.3
3.5
3.3
3.5 3.8
4.1 4.3
3.6
3.8
4.3 4.7 3.5 3.8
4.1 4.3 3.3 3.6
4.4
1,000-10k
4.10 4.11
3.7
4.3
4.11
4.10 4.11 4.1 4.3 4.7 4.10 3.8 4.1
6A 7.2 6A 7.2
4.11
4.10 4.11 4.11 6A 4.3 4.4 4.10
6A
6A
7.3 7.4 7.3 7.4 7.2 7.3 6A 7.2
6A
7.3 7.4 4.10 6A
7.2
7.5
7.5
7.5
7.5
7.4 7.5 7.3 7.4
7.5
3.3
3.9 4.1
3.2 3.4
3.9 4.1 3.2 3.3 3.4
3.3
3.4
4.3 4.4
3.9 4.1
4.3
4.3 4.4 3.9 4.1 4.3 3.4 4.1
4.5 4.11 4.1 4.4
4.3 4.4
3.2
10k-100k
4.4
4.12 4.13 4.5 4.11 4.5 4.11 4.5 4.11 4.4 4.5 4.11 4.3 4.4
3.3
4.12 4.13 4.12 4.13 4.12 4.13 4.12 4.13 4.5 4.13 4.5 4.13
4.11
6A
6A
6A
6A 7.5
6A
6A
7.2 7.5 6A 7.2
6A
Tin and Alloys
Zinc and Alloys
Magnesium
Aluminum
Copper
Stainless Steel
Alloy/Tool Steel
Quantity
Irons
Material
Carbon Steel
Step 1 – Screen for Processes Based on Part Material and Production Volume
5.1
6.3
5.9
4.11
4.12
4.12 4.5
4.13 4.12
5.1
5.3
5.9
4.11
4.12
4.5
4.12 4.12
4.13 6A
5.1
5.1 5.3
5.6 5.4 5.3
5.10 5.10 5.9
4.7
4.11
4.12
4.5
4.12 4.12
7.5
3.6
3.6
Step 2 – Shape Classification
Max.
Typical
bilaterial
Tolerance (in)
Casting Processes
0.10
No Limit
0.040
120‐980
1‐50
All
0.08
2.0
0.010
30‐250
5‐200
0.1‐660
All but T3/5,F5
0.08
2.0
0.006‐0.047
30‐250
5‐50
Non‐ferrous metals
(Al,Mg,Zn,Cu)
0.1‐660
All but T3/5,F5
0.02
0.5
0.002
20‐130
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