CHAPTER 40

Competitive Aspects of Manufacturing

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-1

Commercially Available Materials

TABLE 40.1
Material
Available as
Aluminum
P, F, B, T, W, S, I
Copper and brass
P, f, B, T, W, s, I
Magnesium
P, B, T, w, S, I
Steels and stainless steels
P, B, T, W, S, I
Precious metals
P, F, B, t, W, I
Zinc
P, F, D, W, I
Plastics
P, f, B, T, w
Elastomers
P, b, T
Ceramics (alumina)
p, B, T, s
Glass
P, B, T, W, s
Graphite
P, B, T, W, s
Note: P, plate or sheet; F, foil; B, bar; T, tubing; W, wire; S,
structural shapes; I, ingots for casting. Lowercase letter
indicates limited availability. Most of these materials are also
available in powder form.
Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-2

Approximate Amount of Scrap Produced in

Various Manufacturing Processes
TABLE 40.2
Process
Machining
Hot closed-die forging
Sheet-metal forming
Rolling, ring rolling

Kalpakjian Schmid
Manufacturing Engineering and Technology

Scrap
(%)
1060
2025
1025
<1

Process
Cold or hot extrusion, forging
Permanent-mold casting
Powder metallurgy

2001 Prentice-Hall

Scrap
(%)
15
10
5

Page 40-3

Advanced Materials
Figure 40.1 Advanced
materials used on the Lockheed
C-5A transport aircraft. (FRP:
fiber-reinforced plastic)

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-4

Material Changes From C-5A to C-5B Military

Cargo Aircraft
TABLE 40.3
Item
Wing panels
Main frame
Forgings
Machined frames
Frame straps
Fuselage skin
Fuselage underfloor end
fittings
Wing/pylon attach fitting
Aft ramp lock hooks
Hydraulic lines
Fuselage failsafe straps

C-5A Material
7075T6511

C-5B Material
7175T73511

Reason for change

Durability

7075F
7075T6
7075T6 plate
7079T6
7075T6 forging

704901
7049T73
7050T7651 plate
7475T61
7049T73 forging

Stress corrosion resistance

4340 alloy steel

D6AC
AM350 stainless steel
6AI4V titanium

PH138Mo
PH138Mo
2169 stainless steel
7475T61 aluminum

Corrosion prevention
Corrosion prevention
Improved field repair
Titanium strap debond

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Material availability
Stress corrosion resistance

Page 40-5

Methods of Making a Simple Part

Figure 40.2 Various methods of making a simple part: (a) casting or powder metallurgy,
(b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-6

Manufacturing Process Capabilities

Figure 40.3
Manufacturing
process capabilities
for minimum part
dimensions. Source:
J. A. Schey,
Introduction to
Manufacturing
Processes (2d ed.).
McGraw-Hill, 1987.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-7

Dimensional Tolerance
Figure 40.4
Dimensional tolerance
capabilities of various
manufacturing
processes.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-8

Dimensional Tolerance and Surface Finish

Figure 40.5 Relationship between relative manufacturing
cost and dimensional tolerance.

Figure 40.6 Relative production time, as a function of surface

finish produced by various manufacturing processes. Source:
American Machinist. See also Fig. 25.33.
Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-9

Manufacturing a Sheet Metal Part

Figure 40.7 Two methods of making a dish-shaped sheet-metal part: (a)
pressworking, using a male and female die, (b) explosive forming, using one
die only.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-10

Approximate Ranges of Machinery Base

Prices
TABLE 40.5
Type of machinery

Price range
($000)
10300
10100
30150
50150
60120
100200

Type of machinery

Price range
($000)
501000
20250
10250
500

Broaching
Machining center
Drilling
Mechanical press
Electrical discharge
Milling
Electromagnetic and electrohydraulic
Ring rolling
Fused deposition modeling
Gear shaping
Grinding
Robots
20200
Cylindrical
40150
Roll forming
5100
Surface
20100
Rubber forming
50500
Headers
100150
Stereolithography
80200
Injection molding
30150
Stretch forming
400> 1000
Boring
Transfer machines
100> 1000
Jig 50150
Welding
Horizontal boring mill
100400
Electron beam
2001000
Flexible manufacturing system
> 1000
Spot
1050
Lathe
10100
Ultrasonic
50200
Single- and multi-spindle automatic
30250
Vertical turret
100400
Note: Prices vary considerably, depending on size, capacity, options, and level of automation and computer controls.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 40-11