DEVELOPMENT OF COMPUTER-AIDED MATERIALS AND MANUFACTURING PROCESS SELECTION SOFTWARE USING BOOTHROYD-DEWHURST METHODOLOGY ZAEIME BIN ZAKARIA

Transcription

1 DEVELOPMENT OF COMPUTER-AIDED MATERIALS AND MANUFACTURING PROCESS SELECTION SOFTWARE USING BOOTHROYD-DEWHURST METHODOLOGY ZAEIME BIN ZAKARIA A project report submitted in partial fulfilment of the requirements for the award of the degree of Master of Engineering (Mechanical Advanced Manufacturing Technology) Faculty of Mechanical Engineering Universiti Teknologi Malaysia MAY 2010

2 iii To my beloved parent, Zakaria B. Sulaiman, Rukiah Bt. Abdullah. My siblings, Zaidi, Zaiham, Siti Zamilah, Siti Zaeidah, Siti Zaiton, Mohd Zaharuddin, Siti Zaila, Zaffi, Zahir, Siti Zahira, Mohd Zaeim, Mohd Fitri. And especially to my wife Haryanti, my daughters Zulaeiqa Ayume and Zunnur Aizayurie. Thank for all your support.

3 iv ACKNOWLEDGEMENT First of all, I would like to thank to Allah S.W.T for giving me strength and guidance to complete this project. I would like to express my sincere thanks to my supervisor Dr. Ariffin Bin Haji Abdul Razak for the constant guidance, invaluable knowledge, and constructive ideas in leading me to accomplish this project. I am indebted to Majlis Amanah Rakyat (MARA) for grating me the scholarship to pursue my study at the Universiti Teknologi Malaysia. Finally, I would like to extend my heartful thank you to all my lecturers in Department of Manufacturing and Industrial Engineering of the Universiti Teknologi Malaysia, friends and family members who have given me moral support during my studies.

4 v ABSTRACT The interest of this thesis is about the application system developed by selection in engineering materials and manufacturing process using the Boothroyd Dewhurst methodology as a main guidance. The implementation of this application gives opportunity to the designer to improve the best materials by using the best process during the early steps of product design. A prototype application system called CAM-MaPS and the uses of Visual Basic software had implemented the proposed methodology. By selecting the parts on knowing the common materials and process, in which to produce will be compared to the future result by using the CAM-MaPS for optimization.

5 vi ABSTRAK Tujuan menghasilkan tesis ini adalah untuk membangunkan satu sistem aplikasi di dalam melakukan pemilihan bahan kejuruteraan dan juga proses pembuatan yang menggunakan kaedah Boothroyd Dewhurst sebagai rujukan. Pada peringkat awal reka bentuk sesuatu pengeluaran, penggunaan sistem aplikasi ini juga memberikan peluang kepada pereka bentuk untuk meningkatkan lagi penggunaan bahan yang dikira terbaik malahan juga bagi proses pembuatan. Maka terhasilah satu prototaip aplikasi sistem yang menggunakan keadah Boothroyd Dewhurst dan perisian Visual Basic dan dikenalli sebagai CAM-MaPS. Perbandingan keputusan hasil daripada aplikasi sistem akan dibandingkan dengan bahagian produk yang telah dipilih di mana bahan dan juga proses di dalam menghasilkannya adalah diketahui dan perbandingan ini dilakukan bagi mengoptimumkan sistem aplikasi tersebut.

6 vii TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS AND ABBREVIATION LIST OF APPENDICES ii iii iv v vi vii xi xii xvi xvii 1 INTRODUCTION 1.1 Project Introduction Project Objective Scope Problem Statement Selected Parts Thesis Structure Summary 7

7 viii 2 LITERATURE VIEW ON MATERIAL AND MANUFACTURING PROCESSES 2.1 Introduction Manufacturing processes Sand Casting Investment Casting Die Casting Extrusion Impact Extrusion Hot Extrusion Cold Heading Closed Die Forging Powder Metallurgy Rotary Swaging Machining Process Electrochemical Machining (ECM) Electric Discharge Machining (EDM) Wire EDM Sheet Metal Process Metal Spinning Engineering Materials Metals Study Material Cast Iron Carbon Steel Alloy Steel Stainless Steel Aluminium and Alloys Copper and Alloys Zinc and Alloys Magnesium and Alloys Titanium and Alloys 46

8 ix Nickel and Alloys Refractory Metals Materials Properties Review on previous study Simultaneous Design for Manufacturing Process Selection of Engineering Plastics Computer Aided Design for Manufacturing Process Selection Computer-aided manufacturing planning for mass customization:part1,framework Summary 70 3 BOOTHROYD DEWHURST METHODOLOGY 3.1 Introduction General Shape Attributes Selection of Manufacturing Process Selection of Material Final Eliminating Process Reason of Eliminating Summary 83 4 TOOL FOR SOFTWARE DEVELOPMENT 4.1 Introduction Visual Basic Summary 88 5 DEVELOPMENT OF PROTOTYPE SOFTWARE 5.1 Introduction Structure of Prototype Software Graphic User Interface (GUI) 95

9 x Main Interface Credit Interface Input Data Graphic User Interface Result Graphic User Interface Info Guide Graphic User Interface Help Graphic User Interface Summary VERIFICATION OF CAM-MaPS SOFTWARE 6.1 Introduction Case Studies Prismatic Part Rotational Part Summary DISCUSSIONS 7.1 Introduction Discussion on Prismatic Part Case Study Discussion on Rotational Part Case Study Summary CONCLUSIONS 8.1 Introduction Future Work Recommendations Concluding remark 122 REFERENCES 124 Appendices A- E

10 xi LIST OF TABLES TABLE NO. TITLE PAGE 2.1 Hot extrusion temperature for various metals The selected of part attribute The selected of part material requirement Example flow of process selection in manufacturing processes Example how to rank the process by rating system Shape attributes for stapler handler Requirements of production factors for the stapler handler Requirements of properties factors for the stapler handler Shape attributes for the gear Requirements of production factors for the gear part Requirements of properties factors for the gear 112

11 xii LIST OF FIGURES FIGURE NO. TITLE PAGE 1.1 Survey of designers knowledge of manufacturing process Survey of designers knowledge of polymer materials The handle of stapler gun The selected gear for case study Schematic diagram for sand casting mold Sequences to produce a metal casting in sand mold Schematic sequences producing the part using investment casting Hot chamber die casting Cold chamber die casting The illustration for extrusion of a roundness bar Forward extrusion open die Example of hot extrusion die for Aluminium The illustration for cold heading process and the sample product Sequences of closed die forging in produced piston rod Sequences in powder metallurgy process and the sample of product Components of rotary swaging, Sequences in rotary swaging process and the sample of product The turning process and milling process The schematic of electrochemical machining process 25

12 xiii 2.15 The schematic of EDM process, the EDM milling and sample of products using EDM process The schematic of WEDM process in cutting the workpiece The schematic of stamping operation Common die-bending operations, using V and wiping die Schematic illustration of the conventional spinning process Types of parts conventionally spun. All parts are antisymm The schematic of DCA Master input card in HyperQ/PP Envelope size specification card Internal geometry specification cards Process ranking card Detailed DCA for selected process Design dependency diagram this diagram views process selection Master input card in DFPS Surface roughness/ tolerances specification card Part shape classification/ envelop sizes specification Process ranking card Detail DCA for selected process DCA online help for process/material compatibility Architecture of computer-aided manufacturing planning (CAMP) system for mass customization Flow chart to performed selection material and 72 process 3.2 Depressions in a single direction and Depressions in more than one direction Example of uniform wall thickness 74

13 xiv 3.4 Uniform cross section and Non-uniform cross section Different area for cross section in non-uniform part Part that can be generated by rotation of a single axis and Part that cannot be generated by rotation of a 75 single axis 3.7 The splined shaft A bottle of water with captured cavities attribute The plastic ball with enclosed attribute part with draft, part with draft free surfaces Process Elimination by Geometric Attributes Process Elimination by Part Application Information Final process elimination by process/material combination Front page GUI of Visual Basic The structure of prototype software Form of part attributes Example data keep in by user in production factors section Example the input data by user for materials properties factor The sequence step of software Proposed graphic user interface for main page of CAM-MaPS Appearance GUI of credit page The proposed input data graphic user interface The graphic user interface for the result Selection for shape attributes, processes, materials and material properties The interface of Helps page Image of stapler gun The view of input data GUI for stapler holder 108

14 xv 6.3 Result generated for stapler holder Example of application gears The view of input data GUI after user fill the requirement data for gear Result generated for gear part 113

15 xvi LIST OF SYMBOLS AND ABBREVIATION ECM EDM Kg mm MPa Ø Ti-O WEDM Electro chemical machining Electro discharge machining Kilogram Millimetre Mega Pascal Diameter Titanium Oxide Wire electro discharge machining

16 xvii LIST OF APPENDICES APPENDIX TITLE PAGE A1 Properties of each material involved in database systems 127 A2 Descriptions for the material 128 B Manufacturing processes and their attributes 130 C The relation between manufacturing processes to engineering materials 133 D Shape generation capabilities of processes 134 E1 Capability of Sand Casting process 135 E2 Capability of investment casting process 136 E3 Capability of die casting process 137 E4 Capability of impact extrusion process 138 E5 Capability of cold heading process 139 E6 Capability of hot forging (closed die) process 140 E7 Capability of pressing and sintering (power metal parts) process 141 E8 Capability of rotary swaging process 142 E9 Capability of hot extrusion process 143 E10 Capability of machining (from stock) process 144 E11 Capability of electrochemical machining (ECM) process 145 E12 Capability of electrical discharge machining (EDM) process 146 E13 Capability of sheet metal stamping/ bending process 147 E14 Capability of metal spinning process 148

17 CHAPTER 1 INTRODUCTION 1.1 Project Introduction In the era of industrial of manufacturing of products or parts, the most important parts is the systematic in earlier selection of engineering materials and manufacturing processes combinations. With the right choice of selection in materials and processes it will increase the profit by reducing the manufacturing cost, time, labor and other involved activities in producing the products. At the same time it will increase the quality and the quantity of the products and parts. By those advantages in right selection of materials and processes during manufacturing activity, an application of a prototype system is developed to select processes and material that can be generated automatically. This application uses programming Visual Basic version 2005 and it is user friendly. The developed application is hope on having graphic user interface (GUI) which can intriguing user to use it. It s also should be designed with low rate entry data from user and on the other hand user could selects any appropriate prepared data from the application. Adopted time for processing data by using this application is expected speedier by using manual method which made by one design engineer or whosoever which included in

18 2 selection of materials and processes. Symbols or icons also will be asserting in this application to facilitate user to choose according desirable suitability parts. 1.2 Project Objective The objective of this project is to develop a prototype software system for selection of material and manufacturing processes based on Boothroyd-Dewhurst DfM methodology. By using this application it will help user to do selection in materials and manufacturing processes in a short time. The data or parameter key in by the user to be generated by computer to get the result and it is an intelligent method, comparing with the manual method. 1.3 Scope To accomplish this project, there are some scopes or limitation given by the supervisor. Following are the scopes project proposed: 1. Review on Boothroyd-Dewhurst DfM methodology. 2. Use Microsoft Visual Basic programming language for prototype system development. 3. Develop a prototype software system for selecting the proper material and manufacturing process. 4. Select the mechanical products for case study. 5. The materials selection limit to metal only.

19 3 1.4 Problem Statement There are many process manufacturing resides within industries nowadays. It comprise of conventional, CNC and advance processes. Similarly material resides within markets now, which are found in several kinds. Sometime a designer tends to conceive parts in terms of processes and materials which they are most familiar and exclude those which proved more economic. Then the opportunities for major manufacturing improvements may be lost through such limited selections of manufacturing processes and associated materials in the early stage of the product design. Figure 1.1 and Figure 1.2 show on survey were made on designers in Britain on their knowledge on material and processes occur in industry [1]. 120% 100% 80% 60% 40% 20% 0% 86% 87% 94% 69% 34% 33% 31% 6% 93% 58% 49% 51% 42% 7% 97% 76% 73% 24% 27% 3% 92% 8% Figure 1.1 Survey of designers knowledge of manufacturing process:, great deal/ fail amount:, little or nothing

20 4 90% 80% 74% 74% 84% 84% 80% 74% 78% 70% 60% 59% 50% 40% 30% 20% 26% 26% 16% 16% 41% 20% 26% 22% 10% 0% Figure 1.2 Survey of designers knowledge of polymer materials:, great deal/ fail amount:, little or nothing [1] By using Boothroyd-Dewhurst DFM methodology it will solve the problem in choosing appropriate material and processes. But nowadays it was done manually by referring the tables and it would be quite time-consuming to choose what kinds of material and processes suitably in producing product or part. Sometimes error also occurs during referring the tables because it has been lots items within one table. Due to this, by developing a prototype software application, it is able to solve problems easily. 1.5 Selected Parts To ensure the different in result after generated by prototype software, two different types in shape was selected. The first is prismatic part and the second one is

21 5 rotational part. The part has been selected to do the selection by using the Boothroyd Dewhurst methodology by states all the parameter of the part such as shape attributes, material properties, production factor, dimension and image of parts. After that the parameters will be key in into the prototype software application system. For the selected prismatic part, it was a handle of gun stapler. Figure 1.3 shows the actual view of the part. In actual situation, this handle made from steel where it requires strong and rustless. The main function of handle is to acting as a medium to transfer forces from hand gripping to active the knuckle system of gun stapler. Finally, the selection of material and manufacturing process of this part will do it by using the Boothroyd Dewhurst methodology. Figure 1.3 The handle of stapler gun For the second part with rotational shape, was a selected part which is gear. Figure 1.4 shows the actual gear to do the analysis by using Boothroyd Dewhurst methodology. The main function of this gear is to acting as medium of power transmission to ensure some system is functioning. The power sources might come from motor, human forces or nature energy like water or wind. The requirement of material properties is in high strength; resist to high temperature and other factor will be discussed in more detail in chapter 6.

22 6 Figure 1.4 The selected gear for case study 1.6 Thesis Structure Chapter 1 explains more on introduction, objective, scope, problem statement and the selected material as a case study. Chapter 2 is more focused on the literature view to complete this project. This chapter explains more on manufacturing processes, metal materials and the previous studies of related with this field. In chapter 3, the selection material and processes by using Boothroyd-Dewhurst DFM methodology was explained. Steps of selection and related factors were described. The related factors which will discuss in this chapter is more on shape attributes, material properties and production factors.the related software as a tool develop this system will be explained in detail in chapter 4. In this case the use of software is Visual Basic version In chapter 5, the topic discusses more on about the Structure of Prototype Software. The figure of guide user interface (GUI) has been shown to give more understanding for the reader. Verification of prototype software will be done in chapter 6 by using prismatic and rotational parts. The results generated by software will be discussed in chapter 7. In chapter 8, all progress and

23 7 suggestions will conclude and the chapter of sources on the materials studies will be listed at references. 1.7 Summary The main purpose of this research carried out in developed a prototype system was to facilitated user in making selection of manufacturing processes and metal material. There were elected a few scopes and will be focused on the directions to determine the results. Most important is how to used Boothroyd and Dewhurst s method which will be core in production software application later. To ensure the result by using developed prototype software is right, comparison will be made by using selected parts which are material and process are already know.