Manufacture and Materials

Essay by AlcojimUniversity, Bachelor'sA, April 2004

download word file, 20 pages 4.2

Question 1: - Why automotive manufactures are seeking to employ new manufacturing techniques in component manufacture - you should give additional examples. [10]

Manufacturing Process Comparison Table:

Manufacturing Process Raw Material Utilisation (%) Energy Requirement per kg of finished part (MJ)

Casting 90 30-38

PM - Sintering 97 29

Cold or Warm Extrusion 85 41

Hot Drop Forging 75-80 46-49

Machining Processes 40-50 66-82

- To produce the highest quality part at the lowest possible cost, to produce a 'WIN WIN' situation where the customer gets a low cost high quality part that is economical and profitable to produce.

- To save money - PM can be a cheaper process than alternative methods. A part of a commercial irrigation sprinkler made from brass alloy was die-cast but is now produced using PM at a 60% cost saving.

- Generally cutting costs through innovation will save money.

- Generally companies are looking to produce a manufacturing process that is more automated / efficient / time saving / etc.

- To make an increase in Raw material utilisation (see table above).

- A decrease in the energy required producing the part (see table above).

- To make production more energy efficient.

- To produce a higher quality part.

- To produce o process that will require less labour.

- Require minimal time of unskilled labour - unskilled because of cheaper wages and ease of recruitment.

- Have a reduction in lead times this so supply to the customer is more guaranteed.

- Create ways of producing cheaper tools / equipment.

Typical example of Improved Process Technique:

PM Metal Injection Moulding (MIM) process

- Uses very fine powders mixed with polymers or wax-based materials (extra costs due to smaller grain sizes and the addition of the polymer to help powder flow).

- The...