Manufacturing Processes for Engineering Materials

Manufacturing Processes for Engineering Materials

1. Achievability • Is the process possible for the selected material?

2. Affordability • What is the cost per part?

3. Properties • What does the process do to the final properties?

4. Shape • How close will the dimensions be to specification?

5. Quality • What are the likelihood of introducing defects? What defects might arise and how can they be fixed?

6. Surface Quality • What does the process do to the surface? Will it look acceptable? Will it accept a coating?

7. Controllable • How consistent is the process? How easy is the process to control?

8. Integration • How does it fit with prior and subsequent processes?

We always want to be able to produce components that meet ALL specifications in terms of properties, surface finish, defects and dimensional accuracy (tolerances). With this in mind:

 What are the limits of the machine/tooling in the process?

 What are the limits of the material in the process?

Most processes will have different issues that affect these, so you generally need to investigate and understand the limits of ‘your’ process

Describes the capability of the molten material to fill mold cavities. It depends on:

Material composition 

• Temperature 

• Surface tension (e.g. presence of oxide films) 

• Surface roughness 

• Inclusions 

 • Solidification range (freezing range)

 • Mold design 

• Mold material and mold surface roughness 

• Pouring rate (higher cooling rate when poured slow)

complete case study is attached below