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Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:1
Environmentally Conscious Design & Manufacturing
Class 14: Cost Factors in Machining Operations
Prof. S. M. Pandit
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:2
Manufacturing Economics & the Environment
Life cycle view Raw material Manufacturing
Design Production (Scheduling, Planning, Machining)
Use Post-use Materials handling Energy production
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:3
Manufacturing Economics & the Environment
Product Life Cycle Use
Power Generation
•“Waste”
•Energy
•Materials
•Fluids
Post Use
Raw Material ExtractionMaterial Handling and Logistics
Manufacturing
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:4
Raw Material
• Design requirements– With/ without environmental considerations– Quality factor
• Quality deterioration/ improvement• Inspection
• Cost of raw material– Natural (extraction cost)– Man-made (development costs - temporal)
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:5
Post Use
Environmental Impact
• Reuse / Remanufacture / Recycle / Disposal
“Cost”
Material cost
Design costs
Option chosen
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:6
Material Handling Cost
Equipment A B C
Tractor truck 34 583 239Forklift truck 21 1779 338Hand truck 19 * 203
Item Choice (Design)
Manufacturing Facilities Location, Planning and DesignD.R. Sule (PWS Kent Publ. Co., 1988)
Data from Material & Design choice Add to total cost
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:7
Manufacturing Cost Factors
• Machine Tool• Machining
– Process parameters wear rate– Tool / Workpiece interaction
• Work (job) chips• Tool wear / failure debris
– Fluid use mist, disposal• Process scheduling energy use• Production planning productivity factors
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:8
Machining Costs
• Machine Tool
– Power requirements– Initial costs– Depreciation– Flexibility– Maintenance– Expected use
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:9
Machining Costs
• Process parameters – Speed– Feed– Depth of cut
Power=Feed Rate(Feed Force+Friction Force)/ (Mech* Mech)
Engineering Formulas (7th Ed.,1998)K.Gieck & Reiner Gieck., Mc Graw Hill
Tool wear
Power consumed
Tool typeWork - pieceFluid applicationQuality requirementsProductivity needed
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:10
Machining Costs
• Process Parameters– Tool type• Insert – Rake,
• Non - Insert
• Cutter Type (turning, milling, ..)• Single point / Multi point / Form tool
Material
Cost
Material, Dry/wet
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:11
Machining Costs
– Volume of material removed (m3)– Tool type needed (insert …)– Cutting fluid needed (Y/N, flow rate)
Work - piece
Cost
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:12
Machining Costs
L
/12dddd3dπLV
)22(2
0 isis
Volume removed:
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:13
Machining Costs
• Chips– Continuous (bad)
• Interferes in machining - Flush with cutting fluid ?
– Discontinuous (good) • Need to adjust
– Work material– Machining parameters– Tool geometry
– Dust
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:14
Machining Costs
• Factors influencing fluid application costs– Type of fluid
• Synthetic / natural oils / semi-synthetic• Straight oils• Air / inert gas
– Flow rate– Heat transfer requirements– Lubrication & chip transport– Chip adhesion
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:15
Machining Costs
• Tool
– Excessive wear rate v/s cost– Catastrophic failure
• inclusions in work• incorrect parameters• shock loading (temperature / load induced)
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:16
Machining Costs
• Fluid Use– Mist collectors– Pumps and tanks (circulation)– Filtration– Maintenance system– Additives / Initial cost– Disposal (bioremediation / chemical treatment)
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:17
Scheduling
Scheduling L.P. formulation
Cost EnvironmentQuality
Cost Difference
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:18
Environmentally Conscious Design & Manufacturing (ME592)
Date: April 5, 2000 Slide:19
Case Study
• Machining– Tool– Work– Cutting Fluid– Power, labor, m/c tool– Environment ?
Cost items
Alternative 1 Alternative 2