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Casting Design and Simulation 2012 (c) B. Ravi, IIT Bombay 1 © Prof. B. Ravi, I.I.T. Bombay Serial Engineering and Quality Need for Design Intervention Design for Manufacturability Design for Manufacturability Casting Design and Simulation E‐Foundry, I.I.T. Bombay © Prof. B. Ravi, I.I.T. Bombay Casting Design and Simulation © Prof. B. Ravi, I.I.T. Bombay Current Practice – ‘Serial Engineering’ Design and Manufacturing work in isolation One way communication Low initial pressure on Design dept. Later high pressure on manufacturing ‘Design is Holy’ (No feedback is solicited) ‘Yes We Can’ (No matter what cost) © Prof. B. Ravi, I.I.T. Bombay Result – Poor Quality Reasons : Very large number of design, material, process parameters Complex interactions between various parameters Poor collaboration between design, tooling, manufacturing Employee turnover: loss of experience‐based knowledge As Proposed As Designed As Manufactured What the User Wanted © Prof. B. Ravi, I.I.T. Bombay Design for Manufacturability Design for Manufacture: “How to efficiently manufacture a design” Typically done by the manufacturing team Reactive Proactive Design for Manufacturability: “How to develop process‐tolerant designs” Should be done by the design team © Prof. B. Ravi, I.I.T. Bombay Design Changes and Cost Design Goal Mfg. Goal Part Cost Cost of Poor Quality Concept proving Prototype High Insignificant Manufacturing Regular Low Baseline Manufacturability Optimal Lowest High Part Development Stage Part Design Tooling Development Manufacturing Design Changes 0 100 Major changes Minor changes

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  • CastingDesignandSimulation 2012

    (c)B.Ravi,IITBombay 1

    Prof.B.Ravi,I.I.T.Bombay

    SerialEngineeringandQualityNeedforDesignInterventionDesignforManufacturability

    DesignforManufacturability

    CastingDesignandSimulation

    EFoundry,I.I.T.Bombay

    Prof.B.Ravi,I.I.T.BombayCastingDesignandSimulation

    Prof.B.Ravi,I.I.T.BombayCurrentPractice SerialEngineering

    DesignandManufacturingworkinisolation

    Onewaycommunication

    LowinitialpressureonDesigndept.

    Laterhighpressureonmanufacturing

    DesignisHoly(Nofeedbackissolicited)

    YesWeCan(Nomatterwhatcost)

    Prof.B.Ravi,I.I.T.BombayResult PoorQuality

    Reasons: Verylargenumberofdesign,material,processparameters Complexinteractionsbetweenvariousparameters Poorcollaborationbetweendesign,tooling,manufacturing Employeeturnover:lossofexperiencebasedknowledge

    AsProposed AsDesigned AsManufactured WhattheUserWanted

    Prof.B.Ravi,I.I.T.BombayDesignforManufacturability DesignforManufacture: Howtoefficientlymanufactureadesign Typicallydonebythemanufacturingteam

    Reactive

    Proactive

    DesignforManufacturability: Howtodevelopprocesstolerantdesigns Shouldbedonebythedesignteam

    Prof.B.Ravi,I.I.T.BombayDesignChangesandCost

    DesignGoal Mfg.Goal PartCost CostofPoorQualityConceptproving Prototype High InsignificantManufacturing Regular Low BaselineManufacturability Optimal Lowest High

    PartDevelopmentStage

    PartDesign ToolingDevelopment Manufacturing

    Design

    Chan

    ges

    0

    100

    Majorchanges Minorchanges

  • CastingDesignandSimulation 2012

    (c)B.Ravi,IITBombay 2

    Prof.B.Ravi,I.I.T.BombayPerfectCasting

    EQUIPMENT TOOLING CONTROL

    PROCESS

    MATERIAL GEOMETRY TOLERANCES

    DESIGN

    Techno

    logy

    Databa

    se

    QUALITY TOTALCOST PRODUCTIVITY

    CASTPART

    Prof.B.Ravi,I.I.T.BombayHolisticApproachtoPerfectCastings

    SolidModeling

    PARTMODEL

    PartDesigner

    Partoptimization1 2FeatureCheck

    OFFLINEF

    EEDB

    ACKL

    OOP OK?

    Feeding/GatingMethods

    Engineer

    5 MethodsoptimizationCasting

    Simulation

    6

    METHODSDETAILS

    ToolingDesign

    TOOLINGMODEL

    ToolMfg.Planning

    ToolDesigner

    Toolingoptimization

    OK?

    4 3

    OK?

    ProcessDesign

    PROCESSDETAILS

    FoundryTrials Process

    Engineer

    Processoptimization8 7PerfectCasting

    Prof.B.Ravi,I.I.T.BombayPartFeaturesandQuality

    ThinribPrematuresolidificaonIncompletefillingColdshut

    SharpcornersTurbulenceMolderosionSandinclusion

    ThickseconSolidificaonhotspotPoorfeedingShrinkageporosity

    UndercutHinderedwithdrawalcoreHightoolingcost

    Prof.B.Ravi,I.I.T.BombayPartFeaturesandQuality

    ThincorePoorheattransferSandfusionRoughsurface

    Bettermetalflow

    Lessthermalconcentration Undercut,

    coldshuteliminated

    Prof.B.Ravi,I.I.T.BombayPartRequirementsVs.ProcessCapability

    Compa

    tibility

    %

    Incompatible

    Normalrange

    420

    100

    MinimumWall Thickness(HPDC),mm0

    Incompatible

    86 1210

    Extremerange Extremerange

    50

    33

    Prof.B.Ravi,I.I.T.BombayDesignforManufacturability

    FUNCTION Selectmaterial Designgeometry Specifytolerances Satisfyfunction

    Optimizepartgeometryormaterialtoimproveitsmanufacturability,elsechangetheprocess

    Geometry

    Material

    Process Manufacturability

    Checkcompatibilitybetweenpartrequirementsandprocesscapabilities

  • CastingDesignandSimulation 2012

    (c)B.Ravi,IITBombay 3

    Prof.B.Ravi,I.I.T.Bombay

    Conventionalproductdevelopment:serialengineeringManufacturabilityissuesarediscoveredlate Bythattime,itistooexpensivetochangethedesign

    Summary

    Designformanufacturability(DFM): PredictandpreventpotentialproblemsearlyinlifecycleMakepartdesigncompatiblewithprocesscapabilities

    Prof.B.Ravi,I.I.T.Bombay

    Whataretheprocesscapabilitiesinyour(aknown)foundry:

    Metal=

    Process=

    Minimumwallthickness: Normal= Extreme=

    Minimumcoredholedia: Normal= Extreme=

    Exercise


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