cycle of manufacturing exercise

[@ndreaR]

Good morning, I wanted to ask you about this exercise (see attachment).
I leave you some of my first considerations:
- the electro-erosion is a process too slow is in fact possible for a production of 100'000 pieces, but I would also exclude it for the batch of 10 pieces.
- both punching/drawing that requires matrices, so I would only associate them with very large batches, but in this case I think it is still a compulsory choice for the 10 pieces.
- Hydroforming I have several doubts, it also needs a mold, but I read that it can also be applied to small batches
I said this I thought that for the lot of 100'000 pieces with ribs you can:
1) starting from a rolled sheet of suitable thickness
2) sheet metal rectangle cutting
3) hydroforming of the melt and ribs (I think it's the only way to get ribs)
4) punching holes and melt
5) external perimeter hairstyle
and here I have a question: how uncomfortable it is to do the chopping and punching operations after a funnel? is it done in companies?

for the batch of 10 pieces without ribs:
1) starting from a rolled sheet of suitable thickness
2) laser cutting of sheet metal rectangle
3) casting funnel (in this case I would propose to better cushion the costs a rubber funnel matrix)
4) laser cutting holes and melt
5) laser trim outside perimeter

n.b. we use the terms hairstyle and punching according to the finished product we want to get. For example if we want to pierce a sheet we call punching, lying if we want to get a disk from a sheet we say hairstyle. I don't know if this distinction is also used in the workplace.

said qusto let me know about my solution and if you have to share advice or work experiences your personal are very welcome.
Thank you!

 

[MassiVonWeizen]

punching is used for drilling, as you have rightly said, but mainly for those with deformation i.e. for hollow holes, threaded holes, this does not prohibit that simple holes can be made if the production department considers it convenient.

It is necessary to understand whether the piece must be compulsory a single stink or can be welded keeping the aesthetic quality.
for a lot of 100,000 pieces you could also think of making a special punch so as to obtain with one operation the desired shape (the punch would remain useful for the next batch)
for a lot of 10 pieces I would do, if possible, the laser cutting and pressing case, the hexagon from fold and finally welding and grinding.

scattered observations:
I don't know her and I don't say about it.
on large batches make hairstyle and then drilling/punishing does not suit, laser cutting does in one shot only both.
a good welder makes the union of the two pieces that we don't even notice that he's in two parts.

 

[Vittorio]

a lawful question
Does the piece in question have to be made of steel?
can be die cast aluminium?

 

[MassiVonWeizen]

rereading the track well I realized I was superficial giving advice that are not provided by the track. Sorry about the magazine
I would opt for a stinging, but it lets me perplex the plague closed on the hexagonal part and that from the beginning I had not seen. I try to think about it better in the meantime do not consider how much I wrote before

 

[Fabietto]

I have no experience about it, but as a boulders I would make a step mold, like:

for the production of 100,000.
for the 10 pieces, I do not know the size of the details, but if we are in the range 40x40x40, I would not exclude the electro-erosion a priori. .

 

[PIETRO2002]

if I had to make 10 pieces:

laser base plate cutting.
laser cutting of octagon development.
octagon bending
octagon flap welding.
octagon welding on the base plate.

for 100,000 pieces:

by studying well I would see a hand-drawing mold and step-by-step funnel, first evaluating the material filling coefficient, in the sense if the piece is imbutable on the whole length without needing an intermediate heat treatment between the phases of funnel, so as not to have a piece too rough with cracks.

 

[Fabietto]

Good morning...

a curiosity. .
Why are some processes repeated? and the number in parentheses what does it mean?

 

[PIETRO2002]

for 10 pieces could also be:

milling and running holes upper side on cnc.

milling in the lower side (where the piece was clamped)

internal electroerosion to obtain the octagonal hole.

 

[Vittorio]

I understood it so
best production system to get 10 pieces prototypes.
and subsequently better production system to produce 100,000.
taxing the choice of work in the table?
steel tax? (as it would seem from the image)

 

[@ndreaR]

a lawful question
Does the piece in question have to be made of steel?
can be die cast aluminium?

preferably rolled steel

 

[@ndreaR]

rereading the track well I realized I was superficial giving advice that are not provided by the track. Sorry about the magazine
I would opt for a stinging, but it lets me perplex the plague closed on the hexagonal part and that from the beginning I had not seen. I try to think about it better in the meantime do not consider how much I wrote before

Thank you! si indeed the plague on the melt leaves puzzled also me

 

[@ndreaR]

I have no experience about it, but as a boulders I would make a step mold, like:

for the production of 100,000.
for the 10 pieces, I do not know the size of the details, but if we are in the range 40x40x40, I would not exclude the electro-erosion a priori. .

So you say that if the piece is not too large, it can also be electro-erosion?

 

[@ndreaR]

if I had to make 10 pieces:

laser base plate cutting.
laser cutting of octagon development.
octagon bending
octagon flap welding.
octagon welding on the base plate.

for 100,000 pieces:

by studying well I would see a hand-drawing mold and step-by-step funnel, first evaluating the material filling coefficient, in the sense if the piece is imbutable on the whole length without needing an intermediate heat treatment between the phases of funnel, so as not to have a piece too rough with cracks.

we say that for the exercise we assume that the material is imbutable

 

[@ndreaR]

a curiosity. .
Why are some processes repeated? and the number in parentheses what does it mean?

I think it's because you can use both lots the same process

 

[@ndreaR]

I understood it so
best production system to get 10 pieces prototypes.
and subsequently better production system to produce 100,000.
taxing the choice of work in the table?
steel tax? (as it would seem from the image)

Exactly, the exercise asks exactly that. the work must be put in tables because the professor wants us to reason limited to those. does not want, for example, to use welding or machining of particle removal

 

[@ndreaR]

Thank you! si indeed the plague on the melt leaves puzzled also me

Maybe you can get from a laser trim

 

[Davide98]

according to me:

for 10 pieces -> laser cut holes, laser trim and funnel

for 100000 -> funnel, punching 1 (for nerves), punching 2 (for holes) and hairstyle

other processing is not relevant

 

[PIETRO2002]

for 10 pieces

embutitura del piece e contemporanea tranciatura del foundllo octagonale. this implies the construction of a block mold, simple but that of course has a cost to spread on 10 pieces, if the professor does not want welding... If you like.

threading and executing holes by laser.

 

[Fabietto]

So you say that if the piece is not too large, it can also be electro-erosion?

bye, give these premises:
- material c45
- hypothesized dim 40x40x40
- particular to deform so that it can be obtained from erosion in a single setup
- acceptance of roughness given by the process

Let's try to make the bills of the servant. .
we can get the 10 pieces all together,
from a single crude dim 250x100x40 (2 rows of 5 pieces each).

material cost
8kg material * 3€/kg = 24€
cost graphite (only electrode that gets the 10 prints)
1kg graphite * 70€/kg = 70€*2 = 140€ (consider building 2 equal electrodes)
material 24+140=164€

production costs
10h cad-cam-industrialization-work cycle etc.
10h*2=20h electrode construction
20h electroerosion
5h cleaning post processing.
tot. production 55h*30€/h=1650€ (considered average cost of all 30€/h)

total costs
164+1650=1814€/10 pz=181,4€/cad pz.

 

[PIETRO2002]

according to me:

for 10 pieces -> laser cut holes, laser trim and funnel

for 100000 -> funnel, punching 1 (for nerves), punching 2 (for holes) and hairstyle

other processing is not relevant

bye, give these premises:
- material c45
- hypothesized dim 40x40x40
- particular to deform so that it can be obtained from erosion in a single setup
- acceptance of roughness given by the process

Let's try to make the bills of the servant. .
we can get the 10 pieces all together,
from a single crude dim 250x100x40 (2 rows of 5 pieces each).

material cost
8kg material * 3€/kg = 24€
cost graphite (only electrode that gets the 10 prints)
1kg graphite * 70€/kg = 70€*2 = 140€ (consider building 2 equal electrodes)
material 24+140=164€

production costs
10h cad-cam-industrialization-work cycle etc.
10h*2=20h electrode construction
20h electroerosion
5h cleaning post processing.
tot. production 55h*30€/h=1650€ (considered average cost of all 30€/h)

total costs
164+1650=1814€/10 pz=181,4€/cad pz.

I like it, but given the fold that's on top of the octagon, you can't get in one set up.