1 / 19

Environmentally Conscious Design & Manufacturing

Environmentally Conscious Design & Manufacturing. Class 14: Cost Factors in Machining Operations . Prof. S. M. Pandit. Manufacturing Economics & the Environment. Life cycle view Raw material Manufacturing Design Production (Scheduling, Planning, Machining) Use Post-use

santo
Download Presentation

Environmentally Conscious Design & Manufacturing

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Environmentally Conscious Design & Manufacturing Class14: Cost Factors in Machining Operations Prof. S. M. Pandit

  2. Manufacturing Economics & the Environment Life cycle view • Raw material • Manufacturing • Design • Production (Scheduling, Planning, Machining) • Use • Post-use • Materials handling • Energy production

  3. Manufacturing Economics & the Environment • Product Life Cycle • Use Power Generation • “Waste” • Energy • Materials • Fluids Post Use Manufacturing Material Handling and Logistics Raw Material Extraction

  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)

  5. Post Use • Reuse / Remanufacture / Recycle / Disposal Environmental Impact “Cost” Material cost Design costs Option chosen

  6. Material Handling Cost Item Choice (Design) Equipment A B C Tractor truck 34 583 239 Forklift truck 21 1779 338 Hand truck 19 * 203 Data from Material & Design choice Add to total cost Manufacturing Facilities Location, Planning and Design D.R. Sule (PWS Kent Publ. Co., 1988)

  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

  8. Machining Costs • Machine Tool • Power requirements • Initial costs • Depreciation • Flexibility • Maintenance • Expected use

  9. Machining Costs Tool type Work - piece Fluid application Quality requirements Productivity needed • Process parameters • Speed • Feed • Depth of cut Tool wear Power consumed Power=Feed Rate(Feed Force+Friction Force)/ (hMech* hMech) Engineering Formulas (7th Ed.,1998) K.Gieck & Reiner Gieck., Mc Graw Hill

  10. Machining Costs • Process Parameters • Tool type • Insert • Rake, • Non - Insert Cost Material, Dry/wet Material • Cutter Type (turning, milling, ..) • Single point / Multi point / Form tool

  11. Machining Costs Work - piece • Volume of material removed (m3) • Tool type needed (insert …) • Cutting fluid needed (Y/N, flow rate) Cost

  12. Machining Costs L Volume removed:

  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

  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

  15. Machining Costs • Tool • Excessive wear rate v/s cost • Catastrophic failure • inclusions in work • incorrect parameters • shock loading (temperature / load induced)

  16. Machining Costs • Fluid Use • Mist collectors • Pumps and tanks (circulation) • Filtration • Maintenance system • Additives / Initial cost • Disposal (bioremediation / chemical treatment)

  17. Scheduling Scheduling L.P. formulation Cost Quality Environment Cost Difference

  18. Case Study Alternative 1 Alternative 2 • Machining • Tool • Work • Cutting Fluid • Power, labor, m/c tool • Environment ? Cost items

More Related