Lecture 04

Design For Manufacturing (MANE 4110U)

Selection of Materials and Processes

Instructor: Ahmad Barari

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Compatibility
Between Materials
and Processes

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the following observations help to simplify the overall selection problem:

1. Many combinations of processes and materials are not possible.
2. Many combinations of processes are not possible and, therefore, do
not appear in any processing sequences.
3. Some processes affect only one attribute of the part, particularly
surface treatment and heat-treatment processes.
4. Sequences of processes have a natural order of shape generation,
followed by feature addition or refinement by material removal and then
material property or surface enhancement.

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Three Categories of Processes

Primary processes
Primary/secondary processes
Tertiary processes
primary processes: those used for producing the raw materials for manufacturing
such as flat rolling, tube sinking, and wire drawing. Main shape generating
process, assuming that the material has been purchased in the appropriate
stock form (wire, tube, sheet, etc.). Such processes should be selected to produce
as many of the required attributes of the part as possible and usually appear first in
a sequence of operations. Casting, forging, and injection molding are examples of
primary shape generating processes.

Primary/secondary processes, on the other hand, can generate the main shape of
the part, form features on the part, or refine features on the part. These processes
appear at the start or later in a sequence of processes. This category includes
material removal processes such as machining, grinding, and broaching.

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Tertiary processes do not affect the geometry of the part and always appear after
primary and primary/secondary processes. This category consists of finishing
processes such as surface treatments and heat treatments. The selection of tertiary
processes is simplified, because many tertiary processes only affect a single attribute
of the part. For instance, lapping is employed to achieve a very good surface finish,
and plating is often used to improve the appearance or corrosion resistance.

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Process Capability

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General Shape Attributes

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Depressions
Depressions (Depress): The ability to form recesses or grooves in the surfaces
of the part. The first column entry refers to the possibility of forming
depressions in a single direction, while the second entry refers to the
possibility of forming depressions in more than one direction. These two
entries refer to depressions in the direction of tooling motion and those in other
directions.
The following are some examples of tooling motion directions.
Processes with split moldsthe direction of mold opening.
Processes that generate continuous profilesnormal to the direction of
extrusion or normal to the axis of the cutting medium.
Forging (impact) processesthe direction of impact of the tooling onto the
part.

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UniWall
Uniform wall (UniWall): Uniform wall thickness. Any nonuniformity arising
from the natural tendency of the process, such as material stretching or
buildup behind projections in centrifugal processes is ignored, and the
wall is still considered uniform.

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Other Attributes
Uniform cross-section (UniSect): Parts where any cross-sections normal to a
part axis are identical, excluding draft (slight taper) in the axial direction for
die or mold release if required.
Axis of rotation (AxisRot): Parts whose shapes can be generated by rotation
about a single axis: a solid of revolution.
Regular cross-section (RegXSec): Cross-sections normal to the parts axis
contain a regular pattern (e.g., a hexagonal or splined shaft). Changes in
shape that maintain a regular pattern are permissible (e.g., a splined shaft
with a hexagonal head).
Captured cavities (CaptCav): The ability to form cavities with reentrant
surfaces (e.g., a bottle).
Enclosed (Enclosed): Parts that are hollow and completely enclosed.

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Draft-Fee Surfaces
Draft-free surfaces (NoDraft): The capability of producing constant crosssections in the direction of tooling motion. Many processes can approach
this capability when less than ideal draft allowances are specified, but this
designation is reserved for processes where this capability is a basic
characteristic and no draft can be obtained without cost penalty.

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DFA Compatibility Attributes

Manufacturing processes have varying levels of compatibility with the basic
goals of the DFA of simplified product structure and ease of assembly. This
relative compatibility is measured in the following key areas:
Part consolidation (PConsol): The ability to incorporate several functional
requirements into a single piece, eliminating the need for multipart
assemblies.
Alignment features (Alignmt): The ease of incorporating in the part positive
alignment or location features that aid in the assembly of mating parts.
Integral fasteners (IntFast): The cost-effectiveness and scope of fastening
elements that can be designed into the part. The ability to incorporate features
such as threads, which generally involve separate fasteners, is not given as
much consideration as elements such as snap features.

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General Shape Attributes

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Material Selection by Membership Function

Modification
Ambiguity in the material constraints specified by the designer is modeled by
providing the designer with different levels of accuracy to further describe
the material constraints specified. These levels could correspond, for
example, to the qualifiers approximately, close to, and more or less.
These levels of precision are illustrated in Figure below:

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Selection of sintered powder materials by membership function modification.

(Adapted from Farris, J. Selection of Processing Sequences and Materials During
Early Product Design, Ph.D. Thesis, RI, 1992.)
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Material Selection by Dimensionless Ranking

An aspect of material selection, which is a great source of difficulty, is the
distinction between the fundamental material properties, which are given in
material databases, and the actual design requirements, which are usually
based on a combination of different property values.

Example: for a structural member in

an aerospace product, the designers
may be interested in the maximum
stiffness per unit weight, while for a
high-volume consumer product, the
maximum stiffness per unit material
cost may be more important.

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For a tie bar, the design specification may include the length, l, and the
maximum force, F, to be supported. The design requirement may be to
meet the specifications with the smallest possible part cross-sectional
area, and hence occupy the smallest volume, V. In this case, we require
maximum possible performance per volume from the material. If the yield
or failure stress level in tension is denoted Yt, and the cross-sectional area
is A, then we can write
Minimum volume for the
required force: Design Intent

for minimum volume to support the

required force we require the
minimum value of (1/Yt) or the
maximum value of (Yt)

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for minimum weight to support the required force

and our criterion for material selection is

the maximum possible value of (Yt/).
Finally, if this is a large component, for which material cost is a primary
concern, our focus changes to include the cost of material per unit weight, Cm.
In this case, we replace component weight, W, with component material cost,
C, and write

Now, the material selection requirement is

the maximum value of Yt/(Cm).
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The general procedure for determining derived parameters for particular design
requirements can be recognized from the simple example of the tie bar. The first
step is to find or establish the equation, or set of equations, which define the design
intent. The next step is to decide on a single design parameter which changes when
one material is substituted for another. This is most typically the section thickness or
cross-sectional area.
This design parameter must be eliminated by substitution, since we require a
derived parameter which can be used prior to deciding on the parameters value.
Occasionally this parameter can be eliminated between the equations which
describe the design intent.
In this case the derived parameter represents absolute performance. Most often,
however, it is necessary to introduce an additional equation for the component
volume and eliminate the material-variable design parameter with the volume
equation to establish the derived parameter for maximum possible performance. If,
alternatively, maximum performance per weight or per material cost is desired, then
expressions for component weight or component material cost must, of course, be
introduced into the parameter elimination procedure.

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Example
Assuming that we are interested in producing a light-weight thin-walled stiff
component. For thin-walled components, a primary design requirement is often
the stiffness of the wall.
for a given applied force, F, wall thickness, h, and Youngs modulus, E, the
deflection, , of any region of the wall of a thin part depends upon the shape
of the region and its boundary.
However, the expression can typically be reduced to the form

where C0 is a constant for a particular design.

we write an expression for weight in terms of wall thickness, h, in the
form
where C1 is constant for a
given part geometry.
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Since we wish to minimize weight, we

require the maximum value of (E1/3/) which
is our derived performance parameter.

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Elastic modulus for classes of materials

plotted on linear scales.

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Elastic modulus for classes of materials

plotted on logarithmic scales.
Consider property P and let Pmax, Pmin be the highest and least values in the
database. Thus,taking values 0 and 100 for N gives

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For example, for Youngs modulus, E, the

largest value in the database is likely to be
the value for diamond, which gives
while the least value may be the value for
natural rubber which gives
With these values,
the 100-scale for
Youngs modulus
is given

where E has units of MN/m2.

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It can be seen that they are represented by

the general form
For example, if P1 = Yt, P2 = E, P3 = , m1 = 2, m2 = 1, and m3 = 1, then D
is the derived parameter for best spring performance per weight

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General form of a derived parameters:

And we required D to be presented as:

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the factor cancels in the argument of

both logarithmic expressions. Thus, we
define parameter W as

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This transformation from 100-scale values for individual

parameters to the 100-scale value for any derived parameter is
easily accomplished on a spreadsheet using above Equations.
Next Table is the printout of such a spreadsheet written with
Microsoft Excel.
The bottom row of the spreadsheet contains values for m, the index
values of the derived parameter. The last two columns contain the values
for W and the 100-scale N values for the derived parameter,
respectively.

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Beam Stiffness for

Minimum weight

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Note that the index values entered into the last row are those for the
beam stiffness for minimum weight. It can be seen that for this application
(and no other design constraints), pine is the best choice (N = 100) and
rubber is the worst choice (N = 0).
The 100 score for pine indicates why straight grain wood is still a material
of choice for small aerobatic aircraft structures. Note that manufacturing
feasibility is not a part of this selection process (diamonds scores).

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If we change the index for cost (m) from 0 to 1 (in the equation of D) then the
derived parameter changes to represent the beam stiffness for minimum cost.
The best choice then changes to concrete. Particle board is a close second
with a score of 96, diamond becomes 6, and tungsten carbide is 0 because of
its combination of high cost and high density.
The high scores for concrete and particle board explains their use for low-cost
beams and floor structures, respectively. The main purpose of the 100-scale
method is for such easy visualization of the relative merits of materials for
different applications.
The method can be extended to include combinations of two or more derived
parameters. For example, the primary requirement for an automobile panel
may be bending stiffness for least cost.
However, diaphragm spring quality is a valuable additional material property
since this makes the material more dent resistant. The 100-scale method can
be expanded to cover such situations by using a weighted geometric mean of
the two derived parameters

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Sometimes the choice of a material is based on the inverse of one of the

fundamental properties. Examples would include specific volume representing
lightness instead of density representing heaviness, flexibility instead of stiffness,
softness instead of compressive strength, and so on. Assuming that we are
interested in inverse property (1/P), where P is represented by

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and so the value for M becomes

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Shape Attributes
1. Depressions Yes
2. Uniform wall Yes
3. Uniform cross-section Yes
4. Axis of rotation No
5. Regular cross-section No
6. Captured cavity No
7. Enclosed cavity No
8. No draft Yes
Material Requirements
1. Maximum temperature of 500C
2. Excellent corrosion resistance to
weak acids and alkalis

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Process elimination based

on four geometric
attributes of the part

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Process elimination based on

further four attributes of the part

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Final process selection based on

geometric attributes of the part

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