Key Processes in Machining and Design for Manufacturability of Components
If you want to be successful in your assignments and improve your grades, use our case study at Native Assignment Help. Our team of proficient assignment help experts is knowledgeable and experienced enough to produce outstanding papers that meet academic standards. Thus, come together with us at Native Assignment Help for sure success in everything.
Introduction
The numerous systems are being developed mainly for varied purposes with applications like assisting in machine-based tool designs, improving machine tool-based simulation such as the monitoring of performance and regulating the machine tool by the essential network. “Design for manufacturing (DFM)” or DFA mainly consists of integration regarding the product design as well as process-based planning, particularly into the one similar activity. The main objective is to design the required product which could be easy and conformation by economical to manufacturers.
Review of Existing Knowledge / Design Development
The important new-based sensing technology has been implemented for a recent new form of development mainly in machining-related technology as well as machine design-based tools. There is a critical type element formed for obtaining the essential manufacturing-based automation along with great products as well as enhanced accuracy with higher controls are the capability to the various process-based variables which could impact the given products-based qualities associated with the reliable based sending of the techniques and analysis of technologies (Zhang et al. 2019). Thus, the importance of manufacturing-based designing is to be lined by the important fact that near about 70% of the various manufacturing based on the product such as the materials costs, different assembly as well as processes is to be determined through the certain decision along with the production like the process-based planning and machine-based tool selection would be responsible for the just of 20%.
Hence this model is designed mainly to enhance the given machine-based component of the grouping type process to consider the various material-based handling that consist mainly as the basis of the selection regarding the various threshold kind values and to take along with issues if the several bottleneck-based machines to modify the production associated cells (Verl et al. 2019). The main objective is the develop the cost-based benefit type analysis for the different duplication of the process. The ultimate aim is to determine the actual threshold-based value.
DFM
Machine tools are mainly operated through the manual process and also with various automatic-based controls. Therefore, the previous machines-based flywheels have been used mainly to stabilize the different motions with the most severe and complex based system linked with gears or levels for regulating the different machines that worked on. The machines then continued to be developed and enhanced (Zhang et al. 2019). The NC-based machines have been used in the numbers of the punched-in cards for controlling the various motions.
Plain turning
The plain-based turning consisted of operations for eliminating the excess quantity of the materials mainly from their surfaces adjacent to the cylindrical-based jobs.
Figure 1: Plain turning process
Step Turning
Step turning is the process that produces certain troops for the various diameters involved in the products.
The facing is associated with the machining-based operation mainly by that end of the surface for the pieces have to be made with the flat surfaces and then removed the metal, particularly from them.
Figure 2: plain turning process
Knurling
Knurling is a famous process for embossing the impression mainly in the diamond base shape and with a straight based line of the design patterns mainly in the workpiece of the surfaces. Thus, the knurling-based process mainly begins with the surface-based roughing and hence to be done with the great gripping related surfaces (Vafadar et al. 2021).
Threading
Threading is the activity for cutting down the needed type of threads mainly on internal as well as external of the various cylindrical based surfaces.
Figure 3: plain turning process
Chamfering
This process particularly removes the various burrs as well as sharp type edges and hence makes the process handling a safe manner. Thus, the chamfering could be also done by the essential tools that is the consort of the chamfer for equality and kept mostly at an angle of 45 degrees.
Results and Analysis
“Top Cap XYZ PROTURN SLX 355”
It would need to take into account the manufacturing process of the part and assess its design without relation to the manufacturing and assembly elements to properly conduct a "DFM (Design for Manufacturability)" analysis on the "Top Cap XYZ PROTURN SLX 355".
Figure 4: DFM analysis of “Top Cap XYZ PROTURN SLX 355”
During a DFM analysis, some things to keep in mind are the Employees now acquire the information and abilities required to minimize errors, which leads to fewer mistakes. Because employees, administrators, and support staff are comfortable with the current systems, startup expenditures are decreased. Because programming has indeed occurred, at least partially, accuracy is higher, lead times are shorter, and efficiency is improved. When tools are already in existence from the fabrication of earlier, similar items, labour costs may be minimized (Bui et al. 2023).
Figure 5: DFM analysis event 1 for Z END
Desirable Sequence of DFM Activities Effective DFM involves two aspects: (1) an analysis of the complete product to simplify its design (reduce the parts count, etc.), and (2) an analysis of each individual part to maximize its manufacturability. It makes sense to perform the overall product analysis first—before individual components are analysed—for several reasons:
This figure shows the simulation of the components of the “DFM” where the “Top Cap XYZ PROTURN SLX 355” have to be created to be simple to produce, affordable, robust, and effective. Therefore, the process of production, assembly procedure, accuracy analysis, and design for testing has to all be considered throughout the design phase. After that the product may be built effectively and adhere to the necessary criteria by optimising the design for these characteristics.
Design for assembly (DFA) seems to provide a greater potential return—probably due to opportunities to simplify the whole product and eliminate parts—than analysing individual component parts.
The configuration of the overall assembly, decided on after a DFA analysis, will determine whether certain parts exist and what configuration they must have. It does not make sense to analyse the component parts until their existence and configuration are determined.
Higher production volumes enable numerous scale savings, including justification of spending in automation and other more productive equipment and tools. Because of the module's greater importance and volume of use, just-in-time arrangements are simpler because producers can spend more readily on ordering and supplying the commodity.
Material choice
The "Top Cap XYZ PROTURN SLX 355" should be constructed from a material that is acceptable for production and is suitable for the intended application.
Design approach
To reduce the possibility of errors and boost production efficiency, the structure should be as straightforward as feasible, including fewer features or stages.
Tolerances and dimensions
The dimensions of the “Top Cap XYZ PROTURN SLX 355” should be within acceptable tolerances to ensure a good fit with other components and minimize the need for adjustments during assembly. The "Top Cap XYZ PROTURN SLX 355" should have dimensions that are within reasonable tolerance levels in order to offer a good fit with other parts and reduce the need for modifications during installation.
Manufacturing procedure
To assure quality uniformity and minimize the risk of component failures, a manufacturing procedure should be modified.
Assembly
In order to cut down on the time and effort needed to finish the assembly process, the "Top Cap XYZ PROTURN SLX 355" should be designed for simplicity.
The "Top Cap XYZ PROTURN SLX 355" can be designed to be more readily made, lowering production costs, and assuring quality consistency by addressing the following criteria.
“Bottom Cap XYZ PROTURN SLX 355”
The "Bottom Cap XYZ PROTURN SLX 355" can be put together in a number of ways:
Material Prep work: Choose the raw materials needed for the part and cut the required amount of material to size.
Group fabrication is another area where production costs can be lowered. It is very doable to develop machinery once equipment sets have been established. Utilizing a unique adapter, group instruments like group fittings may analyse all the members of a family or a sizable number of them. As a result, equipment costs would go down and different component configuration times would no longer be needed. Traditionally, each piece in the planning and control of production is thought of as an autonomous unit as during the scheduled stage (Delic and Eyers, 2020). As a corollary, a planner must handle a lot of units. This vast array of parts is reduced by cluster scheduling to a vastly smaller range of families of related elements.
Using a spindle of a milling gear, the machining project entails reshaping raw material into the desired shape.
Drilling and Tapping
To make it easier to attach similar components, openings/threads should then be made in the component. Therefore, drilling a hole in a component is what drilling entails, whereas cutting threads into the hole's walls is what tapping entails. These procedures are crucial for facilitating the attachment of comparable components and ensuring a safe and trustworthy connection. Hereafter to guarantee correct fit and functionality of the components, the size, depth, and type of the apertures and screws must be carefully chosen.
Deburring
To assure a flat finish and get rid of any sharp corners, the component needs to be deburred.
Cleaning: To get rid of any dirt or other impurities, the component needs to be totally cleaned. Prior to moving to the following phase, the item should be checked for any flaws or non-conformities. The first step in applying innovative tools to a manufacturing method is to determine the part families and create the corresponding cells. There are multiple methodologies to calculate all essential aspects of machine designs.
Calculations
TURN (FACE COMPONENT)
X BEGIN 0.0
Z BEGIN 40.0
X END 60.0
Z END 60.0
CHAMFER 0
TOOL OFFSET RIGHT
SURFACE SPEED 250
FEED PER REV 0.1
TOOL # 1
CYCLE (MACHINE OUTER OF COMPONENT)
X BEGIN 0.0
Z BEGIN 40.0
DEPTH OF PASS 2
APPROACH Z 5.0
SURFACE SPEED 250
FEED PER REV 0.15
TOOL # 1
FIN CUT 0.5
Z FIN CUT 0.1
FIN SURFACE SPEED 300
FIN FEED PER REV 0.1
FIN TOOL # 1
GROOVE (PARTING OFF)
OD/ID or FACE OD/ID
X BEGIN 0.0
Z1 60.0
Z2 65.0
X END 60.0
Z3 70.0
Z4 75.0
CHAMFER TOP 0
CHAMFER BOTTOM 0
RPM 1000
FEED PER REV 0.1
FIN CUT 0
TOOL # 2
Some of these algorithms depend on data gathered from route cards, whereas others based their calculations on the computer chart. Most equipment part group techniques that depend on a comprehensive examination of circuit card details are derived from a Burbidge-developed continuous production analysis approach. There are 2 techniques for organizing machines into cells using the data there in the equipment diagram.
Finishing
To increase the module's look and minimize its impact, a covering, including anodizing or paints, should indeed be applied. It is important to analyse the "Bottom Cap XYZ PROTURN SLX 355" at various phases of the production system. For instance:
Examination of materials: It is important to check the feedstock for flaws like cracks, warping, or mismatched measurements. Throughout the machining, the item should indeed be inspected to make sure it adheres to the necessary specifications and dimensions Final Inspection is the complete component must be examined for flaws,
In conclusion, there are many various procedures involved in manufacturing the "Bottom Cap XYZ PROTURN SLX 355", including sample preparation, sanding, piercing and tapping, sandblasting, cleaning, checking, and final. All through various phases of the manufacturing operation, the part can be inspected to ensure it complies with necessary norms and standards.
Discussion
Consider the above to help manage the design project CAD/CAM. A good Computer-aided design platform, which is a component of computer-integrated manufacturing, is such a tool that can help the concurrent engineering company. To ensure each member of the team is using the same data, a core design database that the design team or other squad members can access is a good idea (Yadav et al. 2020). This indicates that a functional internet is also required, and that is needed if the team members are spread apart. These amenities lessen the need for team members to conduct all team activity personally in the same location. Centralization and Standardization is a crucial strategy. The system used to manage engineering and manufacturing should have as many aspects as possible.
Think about unifying things like design blueprints and design elements Elements (New components should ideally look and function just like older ones. Moreover, the total percentage of parts kinds employed ought to be kept to a minimum. The usability, quality, pricing, and reliability of parts that have previously been purchased or put into production have already been established. Materials, market parts, and fasteners “Modules Create frameworks” and procedures. Practices Standardized have a multitude of advantages. If components can be used, production costs are avoided. Workers only need to learn a method once, which makes it helpful in other circumstances and lowers training expenses. There is no longer a need for extra training regarding additional projects, regions, or goods.
To lower costs, shorter setup times, better process optimization, fewer tooling requirements, quicker throughput times, and more effective use of expensive gear. The use of Computer Design as in fields of production schedule results in the highest price reductions. The control, methods of production, and tool design and production of machine tools.
The materials of a selection of the appropriate order are transported from one working area to a different one for different activities in batch-type manufacturing. The majority of the pieces must wait for a lot to develop before migrating to this other workstation because these people working are 11 when far away. Using group technology is one way to get rid of these added traveling expenses and time delays (Leach, 2019)
Use Native Assignment Help to make your engineering dreams come true! Our skilled writers are specialised in delivering high-quality engineering assignment help that is accurate, well-researched, and tailored to satisfy your educational objectives. We have you in mind regarding civil, mechanical, electrical, or any other engineering field!
Conclusion
The most accurate indicator of manufacturability is manufacturing cost. You can approach it using a significant cost factor, such as labour hours’ time, or you can represent it as the sum of the costs for the item or component in question. Design for assembling has seen the most advanced of all (DFM). In comparison to evaluating the injection moulded parts for individual parts, where issues like tool cost, yield, and output quantity all weigh greater heavily when compared with assemblies, presenting an evaluation on assembly designs is also somewhat simpler. Systems for assembling assessments can make it quick and simple to compare several options. Together and with price, common metrics include components count, layout efficacy, and view to meet. Labour cost time is a simple measure of the cost of production that has the potential to be utilized on its own.
References
Amith, M., Lin, R.Z., Cui, L., Wang, D., Zhu, A., Xiong, G., Xu, H., Roberts, K. and Tao, C., 2020. Conversational ontology operator: patient-centric vaccine dialogue management engine for spoken conversational agents. BMC Medical Informatics and Decision Making, 20(4), pp.1-17.
Bui, H.K., Phan, V.M., Nguyen, H.Q., Nguyen, V.D., Nguyen, H.V. and Seo, T.S., 2023. Function of the Speech Recognition of the Smartphone to Automatically Operate a Portable Sample Pretreatment Microfluidic System. ACS sensors, 8(2), pp.515-521.
Delic, M. and Eyers, D.R., 2020. The effect of additive manufacturing adoption on supply chain flexibility and performance: An empirical analysis from the automotive industry. International Journal of Production Economics, 228, p.107689.
Kuhail, M.A., Farooq, S., Hammad, R. and Bahja, M., 2021. Characterizing visual programming approaches for end-user developers: A systematic review. IEEE Access, 9, pp.14181-14202.
Leach, R.K., Bourell, D., Carmignato, S., Donmez, A., Senin, N. and Dewulf, W., 2019. Geometrical metrology for metal additive manufacturing. CIRP annals, 68(2), pp.677-700.
Mars, J., 2022. The Case for a Wholistic Serverless Programming Paradigm and Full Stack Automation for AI and Beyond--The Philosophy of Jaseci and Jac. arXiv preprint arXiv:2206.08434.
Martin, A.A., Calta, N.P., Khairallah, S.A., Wang, J., Depond, P.J., Fong, A.Y., Thampy, V., Guss, G.M., Kiss, A.M., Stone, K.H. and Tassone, C.J., 2019. Dynamics of pore formation during laser powder bed fusion additive manufacturing. Nature communications, 10(1), p.1987.
Mehrpouya, M., Dehghanghadikolaei, A., Fotovvati, B., Vosooghnia, A., Emamian, S.S. and Gisario, A., 2019. The potential of additive manufacturing in the smart factory industrial 4.0: A review. Applied Sciences, 9(18), p.3865.
Vafadar, A., Guzzomi, F., Rassau, A. and Hayward, K., 2021. Advances in metal additive manufacturing: a review of common processes, industrial applications, and current challenges. Applied Sciences, 11(3), p.1213.
Verl, A., Valente, A., Melkote, S., Brecher, C., Ozturk, E. and Tunc, L.T., 2019. Robots in machining. CIRP Annals, 68(2), pp.799-822.
Yadav, G., Luthra, S., Huisingh, D., Mangla, S.K., Narkhede, B.E. and Liu, Y., 2020. Development of a lean manufacturing framework to enhance its adoption within manufacturing companies in developing economies. Journal of Cleaner Production, 245, p.118726.
Zhang, D., Qiu, D., Gibson, M.A., Zheng, Y., Fraser, H.L., StJohn, D.H. and Easton, M.A., 2019. Additive manufacturing of ultrafine-grained high-strength titanium alloys. Nature, 576(7785), pp.91-95.
Zhou, J., Gandomi, A.H., Chen, F. and Holzinger, A., 2021. Evaluating the quality of machine learning explanations: A survey on methods and metrics. Electronics, 10(5), p.593
Share this
Cite This Work
Go Through the Best and FREE Case Studies Written by Our Academic Experts!
