More Process Selection Case Studies Elevator Control Quadrant

„ Aerospace part - Elevator control quadrant „ Elevator control quadrant: The quadrant is part of the
„ Casing for an electric plug control system for the wing-elevator of a commercial
aircraft. It is to be made of a light alloy (aluminum or
„ Ceramic valve magnesium) with the shape shown in the figure. It
„ Plastic bottle weighs about 5 kg. The minimum section thickness is 5
mm, and – apart from the bearing surfaces – the
requirements on surface finish and precision are not
strict: surface finish ≤ 10 μm and precision ≤ 0.5 mm.
The bearing surfaces require a surface finish ≤ 1 μm and
a precision ≤ 0.05 mm. A production run of 100 – 200 is
planned.
a) Itemize the function and constraints, leave the objective
blank and enter “Choice of process” for the free variable.
b) Use copies of the charts of Chapter 7 in succession to
identify processes to shape the quadrant.
c) Use the CES software to identify in more detail the
viable processes.
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Elevator Control Quadrant Elevator Control Quadrant

„ Using the Process Attribute Charts

Function Shape an elevator quadrant „ The material constraint limits the selection to those shown in the first column
Constraints Material class: aluminum or of the next chart.
magnesium alloy „ The shape constraint eliminates two, leaving those in the second column. All
Shape class: 3D-solid of these can meet the constraints on size and section, which are not
restrictive.
Mass: 5 kg
„ The tolerance and roughness constraints on the body are not met by sand
Minimum section: 5 mm casting, though it is worth asking if they have been overspecified.
Tolerance: 0.5 mm, (0.05mm on „ Those on the bearing surfaces are much more restrictive – only machining
bearing surfaces) from solid achieves them.
Surface roughness: 10 μm (1 μm „ The answer here is not to reject the others, but to add a finishing step, shown
on bearing surfaces) at the bottom of the Process-Roughness and Process-Tolerance charts
Planned batch size of 100 - 200 „ The result is the list shown in the third column.
Objective -- „ Economics are important here – the batch-size chart suggests that only the
three listed in the last column are economic at a batch size of 100 – 200.
Free variables Choice of process

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Elevator Control Quadrant Elevator Control Quadrant

Processes passing Processes that Processes meeting the Processes that are
the material survive the shape tolerance constraint economic at a batch of „ Repeat with CES software – Level 2
constraint constraint 100 - 200 „ Are the choices different?
Sand casting Sand casting FAILS
Die casting Die casting Die casting plus machining FAILS
Investment Investment Investment casting plus Investment casting plus
casting casting machining machining
Low pressure Low pressure Low pressure casting plus FAILS
casting casting machining
Forging Forging Forging plus machining Forging plus machining
Extrusion FAILS
Sheet forming FAILS
Powder methods Powder methods Powder methods FAILS
Machine from solid Machine from solid Machine from solid Machine from solid

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 Casing for an electric plug Casing for an electric plug

„ The electric plug is perhaps the commonest of

electrical products. It has a number of components, Function Shape an electric plug casing
each performing one or more functions. The most
obvious are the casing and the pins, though there are Constraints Material class: Material class:
many more (connectors, a cable clamp, fasteners, and, thermoplastic or thermosetting
in some plugs, a fuse). The task is to investigate
Shape class: 3D-solid
processes for shaping the two-part insulating casing,
the thinnest part of which is 2 mm thick. Each part Mass: 0.03 kg
weighs about 30 grams and is to be made in a single
step from a thermoplastic or thermosetting polymer with Minimum section: 2 mm
a planned batch size of 5 x 104 – 2 x 106. The required Tolerance: 0.3 mm
tolerance of 0.3 mm and surface roughness of 1 μm
must be achieved without using secondary operations. Surface roughness: 1μm
(a) Itemize the function and constraints, leave the objective Planned batch size of 5 x104 – 2 x106
blank and enter “Choice of process” for the free
variable. Objective --
(b) Use the charts of Chapter 7 successively to identify Free variables Choice of process
possible processes to make the casing
(c) Use the CES software to select processes for making
the casing.
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Casing for an electric plug Ceramic valves for faucets

„ Many household faucets now have ceramic valves replacing faucets

„ Here we seek a net-shape process – the casing must be shaped in one
operation without the need for any further finishing.
„ Applying the constraints as shown in the Process Attribute Charts and
eliminating processes that fail a constraint leaves two candidates:
„ Injection molding and compression molding
„ CES-EduPack results in the same choices
ME 474-674 Winter 2008
in which rubber washers tended to wear or brass surfaces tended to
corrode
„ Ceramics wear well, and they have excellent corrosion resistance in
both pure and salt water.
„ A ceramic valve consists of two disks mounted one above the other,
spring-loaded so that their faces are in contact. Each disk has a
diameter of 20 mm, a thickness of 3 mm and weighs about 10
grams. In order to seal well, the mating surfaces of the two disks
must be flat and smooth, requiring high levels of precision and
surface finish; typically tolerance < 0.02 mm and surface roughness
< 0.1 μm. The outer face of each has a slot that registers it, and
allows the upper disc to be rotated through 90o (1/4 turn). In the
“off” position the holes in the upper disc are blanked off by the solid
part of the lower one; in the “on” position the holes are aligned. A
production run of 105 –106 is envisaged.
„ List the function and constraints, leave the objective blank and enter
“Choice of process” for the free variable.
„ Use the charts of Chapter 7 to identify possible processes to make
the valve.
„ Use the CES software to select processes for making the valve.
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Ceramic valves for faucets Ceramic valves for faucets

Function Shape a ceramic valve for faucets „ Applying the constraints using the Process Attribute Charts, and
Constraints Material class: technical ceramic eliminating processes that fail a constraint leaves only one candidate:
powder methods.
• Shape class: prismatic
• Mass: 0.01 kg
„ The CES selection distinguishes several powder processes. The two
meet all the requirements except those on precision and tolerance are
• Minimum section: 3 mm
„ Pressing and sintering
• Tolerance: 0.02 mm
„ Powder injection molding
• Surface roughness: 0.1μm
• Planned batch size of 105 –106
„ A separate grinding and polishing operation must be added to
meet the precision and tolerance requirements
Objective --
Free variables Choice of process

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 Shaping plastic bottles Shaping plastic bottles

„ Plastic bottles are used to contain fluids as various as milk and engine „Applying the constraints as shown
Function Shape a polyethylene bottle on the Charts eliminating processes
oil. A typical polyethylene bottle weighs about 30 grams and has a
Material class: Polyethylene (or that fail a constraint in the manner of
wall thickness of about 0.8 mm. The shape is 3-D hollow. The batch Constraints the table shown previously leaves only
size is large (1,000,000 bottles). What process could be used to make thermoplastic)
two candidates: blow molding and
them? • Shape class: 3-D hollow injection molding.
• Mass: 0.02 – 0.04 kg „At Level 1 and 2 the CES selection is
„ List the function and constraints, leave the objective blank and the same as that derived from the
enter “Choice of process” for the free variable. • Minimum section: 0.7 - 1 mm charts.
„ Use the Process Attribute charts to identify possible processes to • Tolerance: 1 mm „At Level 3 CES distinguishes two
make the bottles. variants of blow molding, identifying
• Surface roughness: 10 μm injection blow molding, as the best
„ Use the CES software to select processes for making the bottles. • Planned batch size >106 choice because it can provide the
desired change of section.
Objective -- Commercially, plastic bottles are
made using injection blow molding.
Free variables Choice of process

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