Lecture 32: Process

Selection

Jayant Jain

Assistant Professor,
Department of Applied Mechanics,
IIT Delhi, Hauz Khas, 110016

Recap
Classification of processes
Important process attributes

Process selection flow chart

Classification of shapes

Process charts
Material-process chart, Shape-process chart, Processmass chart, Process-section thickness chart
Physical limits to size: casting

Very thin objects: Forging

Metal shaping processes such as rolling, forging, or
extrusion involve flow solid metals flow by plastic
deformation or by creep

The minimum thickness that

can be achieved from these
processes is limited by plastic
flow very thin sections
cause substantial friction forces
and stick to the tools, even at
very large pressures

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Tolerance and Roughness

No process can shape a part exactly to a specified dimension. Manufacturing
processes vary in the levels of tolerance and roughness they can achieve
economically.

Tolerance
Dimension y specified
as y = 100 0.1 mm

Roughness
Measure of the irregularities
of a surface specified as an
upper limit such
as R < 100 m

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Process-Tolerance
Real process allow
tolerances between
a range of 10R and
1000R R being
surface roughness
See the colored band

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Process-Roughness
Processing cost for precision and surface finish increase
exponentially as the requirements are made more severe

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

The next step is to rank the survivors by

economic criteria. To do this we need to
examine process cost.

Ranking: process cost

The manufacture of a
component consumes
resources, each of which
has an associated cost
the final cost is the sum
of those of the
resources it consumes
Trying to build the cost
model: Already in CES,
it will help you in ranking
on the basis of cost
comparison

Cost model

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Shaping Cost Per Unit

Material: material cost and mass
per unit; f is the scrap fraction
for unused material

Tooling: cost is dedicated and written

off for production of n units;
nt represents life of tool
in case replacement is necessary

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Shaping Cost Per Unit

Capital: non-dedicated cost; written
off against time for a given hourly
rate; two is the write-off time, L is
the load factor, and is the
production rate
Overhead: gross overhead costs
divided by the production rate

Total cost have three components

Material cost independent of batch size and

production rate
n = Batch size/production volume
= Production rate