Design for Manufacture and Assembly Selection of Processes Function and 4 consumer requirements / Component design Manufacturing processes Material properties Relation between functions, material and manufacturingProperties of stock material Behavior of ‘material in the ‘component / ‘. y x ‘Component Effect of geometry and fabrication external forces method Relation between material properties, geometry and manufacturing The choice of sequence / combination of manufacturing processes can be narrowed down based on the following: 1. Sereening based on component material group because not all processes are suitable for all materials 2. Screening based on component shape because manufacturing processes also have limitations on the shapes they can produce. 3. Screening based on the required number of components because most economical batch size varies from one manufacturing process to another 4. Many processes form a natural sequence for shape generation, surface finish or dimensional accuracy. a. Primary processes — sand casting, die casting, investment casting, forging, rolling, extrusion, ete. b. Primary/secondary processes — welding, sheet metal work, heat treatment, metal cutting, etc. c. Tertiary or finishing processes ~ surface treatment, grinding, coating, ete. 4Table 1: Compatibility between some Widely Used Metallic Materials and Processes ‘Compatibility between Some Widely Used Metallic Materials and Processes ‘Cabon Stainless Cast Aluminum Copper Magnesium nc and) Hasta Steel Steel tron loys and loys andAlloys Alloys andlloys Superalloys Sand casing Xx XX KX, xx xx x N xx Dic casting No NN x Xx XX N Ne Foring XX XK NK xx xx Ne x x Rating XX XK NK xx Xx x x xx Exrusion x x ow xX xx xx x x x 5 Table 2: Economic batch size and Compatibility between Product Shape and Manufacturing Processes Economic Baich Size and Compatibility between Product Shape and Manufacturing Proceses AD Gimiar Dimensions Prismatic (1D Much Lorger Sheet (ID Mach Shorter in All Directions) than the Other 2Ds) than the Other 203) Economic Circular Noncireular Ritch Size Solid Hollow Crove Section Creme Section Flat Cupped Sand casting 14000 xx xx Xx Xxx Ne N Investment casting S100 XX. xx XX xx Nr Ne Die casting sino XX. xx xx xx Ne ™ Pm 35000 XK Xx Xx xx Ne Ne Rolling NA N Ne Xx xx xx N Shoot metal wok >soom Nr Ne Xx xx xx xx Cold beading L100 xx Ne Xx xx x x Meu cutting NA ax xx Xx xx xx xx Fusion welding NA Xx xx Xx xx xx xx Injection molding >100 Xx xx Ne Ne Ne ™ Compression moling —>8.000 Note: N/A=does not ply. XX common postice,X=les common or performed with ifiaty, Ne=not recommended,Case study: Process selection for a connecting rod Analysis: The most important mechanical property required is fatigue resistance. Wrought components have better fatigue properties than cast components. AIST 4340 and C-70 steels are normally used for making motor car connecting rods. For weight reduction, Aluminum, Titanium and Magnesium alloys are used in racing 1. Based on tables 1 and 2 the most suitable processes for 3D solid components are casting, powder metallurgy and forging. 2. No cast iron — eliminates casting, both powder metallurgy and forging processes are suitable for steel connecting rods. 3. Powder metallurgy — higher cost — less waste — less machining — less eergy consumption Case study: Process selection for a connecting tod Finishing processes and assembly Machining and grinding ~ s Drilling and broaching — small end and big end Drilling and tapping the bolt holes of the big end Ic faces. Machining bolt head seats Machining the fracture splitting groove Assembly of the connecting parts Finish grinding of the side faces Milling of bearing positioning grooves, inserting big end shells and small end bush 9. Honing the internal surfaces of the big end shell and the small end bush ey AHRWnRR 10. Inspection and packaging