Faculty Publications


Machining experiments for establishment of parameters for deviation-based cost of manufacturing formulations

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Proceedings of the ASME Design Engineering Technical Conference



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Realistic modeling of cost of manufacturing is essential for estimating cost of a product as well as for optimizing alternate manufacturing strategies. There are many factors that affect cost of manufacturing but the single most important parameter for estimating the cost of manufacturing is tolerance (deviation from the nominal size). In the past, most of the cost formulations were based on some inverse power function of a single tolerance parameter. However, it has been shown in our earlier work that when geometric tolerances are used to control the features, it is very difficult (and may not always be feasible) to establish a single tolerance parameter that can be used for estimating the cost. In our earlier work, we have established generic cost formulations based on the deviations of all features of a part and the mating relations between parts. It has been shown that the deviation based cost formulations could be used to establish cost of manufacturing at various geometric tolerancing conditions and the deviation parameters could be mapped to the geometric tolerancing specifications as per ASME Y14.5. In this paper results from manufacturing experiments carried out to establish process-specific machining parameters for the cost functions are presented. The parameters that have been considered are: turning operations at various combination of speed, feed and depth of cut on cylindrical rods (planar circular face) of specified nominal size and tolerances. The deviations of the machined surfaces (surface roughness) are then measured using a digital profilometer and the data from these measurements are analyzed for generation of best fitted planes for establishing the deviation parameters for the specified tolerance conditions. Results from these experiments are presented and applicability and limitations of these cost models are discussed. Future research steps for development of parameters for other remaining features (conical, spherical, etc.) are discussed. Copyright © 2011 by ASME.


Department of Industrial Technology

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