Process Selection ExamplesProcess Selection Examplesver. 1ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20091OverviewOverview• Rocker arm•HIP vesselHIP vesselME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20092Rocker ArmRocker ArmME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20093Alternative ConfigurationsME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20094Process choicesProcess choices• Casting•Drop stampingDrop stamping• Hand forgingW ldi•Welding• (Assume all capital equipment is available)ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20095)Process EconomicsME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20096HIP Pressure VesselHIP Pressure VesselME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20097Design RequirementsDesign Requirements•Internal radius = 0 5 m•Internal radius = 0.5 m• Outside radius = 0.7 m• Height = 2 m•Caps must be removablep• Internal pressure = 100 MPa•Steel withσ= 500 MPa•Steel with σy= 500 MPaME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20098Design RequirementsDesign Requirements• Surface area = 15 m2•Volume=15m3Volume 1.5 m• Weight = 12 tonnesIdid b•Inner radius and pressure may vary by a factor of 2ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 20099Possible ProcessesPossible ProcessesMhii•Machining• Hot working• Casting•FabricationFabricationME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200910MachiningMachining• Machine from solid (rolled or forged) billet• Much material discarded•Might select for oneoff•Might select for one-offME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200911Hot WorkingHot Working• Steel forged to thick walled tube•Finished by machiningFinished by machining• Preferred route for economy of material useuseME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200912CastingCasting•Cast cylindrical tube•Cast cylindrical tube• Finish by machining• Casting defects a problem– requires elaborate NDT• ultrasonic• x-rayME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200913FabricationFabricationWld i l h d lt•Weld previously shaped plates• Used for very large pressure vessels, nuclear reactors• Welds are defect-pronep– elaborate NDT required• ultrasonic• x-rayME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200914Final SelectionFinal Selection• Forging or machining of previously forged metalg– large compressive deformation • heals defects• aligns oxides and other such in harmless, strung-out waysME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200915SummarySummary•Process selection depends on many•Process selection depends on many issues:t–cost– quantitydditi l t–additional process steps– quality–available equipment and expertise–etc.ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 200916ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT
View Full Document