Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Chapter 40Product Design and Process Selection in a

Competitive Environment

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

References toTextbook Topics

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Relative Cost of Repair at Stages of ProductDevelopment and Sale

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Average LifeExpectancy for

VariousProducts

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Commercially Available Shapes of Materials

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Cost per Unit Volume for Wrought Metals andPolymers Relative to Cost of Carbon Steel

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Approximate Ranges of Scrap Produced in VariousManufacturing Processes

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Example: Material Changes in Transport Aircraft

Figure 40.1 Advanced materials inthe Lockheed C-5A transport aircraft.(Note: FRP is fiber-reinforcedplastic.)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Manufacturing Capabilities for Minimum Part Dimensions

Figure 40.2 Manufacturing process capabilities for minimum part dimensions.Source: After J. A. Schey.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

DimensionalTolerances andSurface Finish

Figure 40.3 A plot of achievable tolerance versus surface roughness for assortedmanufacturing operations. The dashed lines indicate cost factors where an increase inprecision corresponding to the separations of two neighboring lines gives an increase incost for a given process (for a factor of two). Source: M. F. Ashby, Materials Selectionin Design. Butterworth-Heineman, 1999.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Dependence of Manufacturing Cost onDimensional Tolerances

Figure 40.4 Dependence of manufacturing cost on dimensional tolerances.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Production Time as a Function of Surface Finish

Figure 40.5 Relative production time as a function of surface finishproduced by various manufacturing processes. (See also Fig. 26.34.)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

General Characteristics of ManufacturingProcesses for Various Metals and Alloys

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Methods of Making a Part

Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy,(b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Two Methods of Making Dish-Shaped 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 formingusing one die only.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Relative Costs forMachinery and Equipment