Design for Assembly and Manufacturing Processes

MANUFACTURING
TECHNOLOGY ASSIGNMENT 2

Table of Contents
Design for Assembly.......................................................................................................................2
Analysis of design....................................................................................................................2
Redesign of pressure control sub assembly.............................................................................3
Design Efficiency....................................................................................................................5
Manufacturing processes.................................................................................................................6
Machining parameters.................................................................................................................6
Chip load Calculations.............................................................................................................6
Surface Speed Calculation.......................................................................................................6
Material Removal Rate Calculation.........................................................................................6
Power Required for Machining...............................................................................................6
Machining Time Calculation...................................................................................................7
Manufacturing processes.............................................................................................................7
Key way cutting using 3 axis CNC milling machine..............................................................7
Conventional Machine process for key way cutting................................................................7
Unconventional Machining process for key way cutting........................................................8
3D printing processes..............................................................................................................8
Quality control.................................................................................................................................8
Quality control.............................................................................................................................8
Surface finish and Feed rate....................................................................................................8
Process capability....................................................................................................................9
Control charts...........................................................................................................................9
Acceptance sampling plan.........................................................................................................12
Operational Characteristic Curve..........................................................................................12
Producer’s Risk......................................................................................................................13
Customers Risk......................................................................................................................13
References......................................................................................................................................14
Page 1 of 19

Design for Assembly
Analysis of design
The figure given below shows the various parts of the AC gas control valve. And the
components of the valve are listed below.
Components name Functions
Frame To accommodate all the parts.
Valve plate To control the flow through the valve.
Control stick To actuate the valve plate
Mounting plate Assists to join the valve plate and
mounting plate.
Bushing on upper side To avoid the leakages.
Bushing on lower side To avoid the leakages.
Control handle For adjust the control stick.
O-Rings (2) To avoid the leakage on joints.
Sheet metal tower To close the control valve
Nut (handle) To join the control valve handling with
the control joint.
Bolt (handle) To join the control valve handling with
the control joint.
All the components and their functions are shown in the above given table.
Total number of components – 12
Page 2 of 19

Minimal number of components are the components required for the basic functioning of
the assembly. Here the minimum number of components are 2. And they are listed below.
 Valve plate
 Frame
Redesign of pressure control sub assembly
Components in original design
 Valve plate
 Control stick
 Mounting plate
 Nut (handle)
 Bolt (handle)
 Control handle
Components in modified design
 Valve plate – Here additional inclination added on the control stick holding area. So it
doesn’t requires any mounting plate. Dimensions of the valve plate is given in the
attached figure.
Page 3 of 19