Arjstme 02 001

Advanced Research Journals of Science and Technology

ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY

(ARJST)

OPTIMIZING THE PRODUCT DEVELOPMENT TIME BY USING ADVANCE MANUFACTURING SOFTWARE’S

2349-1845

K.Rajanikanth1, J.Ranjith Kumar2, Gyadari Ramesh3, Dr.VVRLS.Gangadhar4, 1 2 3 4

Research Scholar, Department of Mechanical Engineering,Princeton college of Engineering and Technology,Hyderabad,India.

Assistant Professor , Department of Mechanical Engineering, Princeton college of Engineering and Technology,Hyderabad,India.

Associate professor , Department of Mechanical Engineering, Princeton college of Engineering and Technology,Hyderabad,India.

Professor , Department of Mechanical Engineering, Princeton college of Engineering and Technology,Hyderabad,India.

Abstract In business and engineering, new product development is the complete process of bringing a new product to market. A product is a set of benefits offered for exchange and can be tangible or intangible. There are two parallel paths involved in the NPD process: one involves the idea generation, product design and detail engineering; the other involves market research and marketing analysis. Companies typically see new product development as the first stage in generating and commercializing new product within the overall strategic process of product life cycle management used to maintain or grow their market share.

At present, product development is done by the companies using trial and error method which increases the total lead time, wastage of material. The product developers are not using the advanced software’s effectively. In this thesis, the time taken to manufacture the main housing used in weighing machine is estimated. Main Housing is drawn in 3D Modeling and feature based software Pro/Engineer. The time taken for modeling, part programming and machining time using software’s Pro/Engineer and Delcam is compared and analyzed in this thesis.

*Corresponding Author:

ABOUT THE PROJECT

K.Rajanikanth, Research Scholar, Department of Mechanical Engineering, Princeton college of Engineering and Technology,Hyderabad,India.

Nevertheless, reaping the benefits of effective development often requires a large irrevocable investment. For some complex products, the product development process can take years and require millions of person-hours of effort.

Accordingly, measures of performance of the development process, such as product development cycle-time, also known as lead-time , and engineering effort are widely applied and tracked.

Published: August 22, 2015 Review Type: peer reviewed Volume: II, Issue : I Citation: K.Rajanikanth,Research Scholar (2015) OPTIMIZING THE PRODUCT DEVELOPMENT TIME BY USING ADVANCE MANUFACTURING SOFTWARE’S

INTRODUCTION Development is the set of activities that transform a concept for satisfying perceived needs into a product or service that is ready for the market. Innovative firms use development to increase demand or even create entirely new markets through novel product design. In today’s technology driven marketplace, the importance of design and, therefore, development seems unquestioned. This importance is further reinforced because development not only establishes the functional performance of a product, but also drives the economic characteristics of that product.

In fact, it is widely cited, that between 70% and 90% of total project costs are determined during the early stages of the development process. Furthermore, recent research has reinforced the importance of development in the context of other available options for firm spending. Specifically, the return on research and development spending via capital expenditure has been shown to be much more effective at boosting operating margin, market value, and sales growth

In contrast to its impact, the cost of development is generally assumed to make up a small portion of the total development effort cost, but this portion is rarely quantified. Recent trends have further raised the importance of development, making the lack of information regarding development costs increasingly unacceptable. In particular, the demands of consumers for product variety have increased considerably in the past and are expected to continue to do so in the future. These effects are magnified by the accompanying trend toward decreasing product lifetimes.

SCOPE Conventional machining usually involves changing the shape of a work piece using an implement made of a harder material. Using conventional methods to machine hard metals and alloys means increased demand of time and energy and therefore increases in costs; in some cases conventional machining may not be feasible.

So the process of using advanced manufacturing software’s in field of manufacturing reduces the lead time and improves the product development time and we achieve good dimensional accuracies .

Computer-aided manufacturing (CAM) is the use of computer software to control machine tools and related machinery in the manufacturing of work pieces.

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Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, which then controls the machine tool.

An advanced manufacturing production system is capable of furnishing a mix of products in small or large volumes, with both the efficiency of mass production and the flexibility of custom manufacturing, to respond rapidly to customer demand and desired quality Advanced manufacturing results from substantive advancements (whether incremental or breakthrough) over the current state of art in the production of materials and products; these advancements include improvements in manufacturing processes and systems and the use of advance manufacturing softwares.

turing, in distinction from processes of controlled material addition, which are known as additive manufacturing.

Exactly what the "controlled" part of the definition implies can vary, but it almost always implies the use of machine tools (in addition to just power tools and hand tools).

The precise meaning of the term machining has evolved over the past one and a half centuries as technology has advanced. In the 18th century, the word machinist simply meant a person who built or repaired machines.

This person's work was done mostly by hand, using processes such as the carving of wood and the hand-forging and hand-filing of metal. At the time, millwrights and builders of new kinds of engines (meaning, more or less, machines of any kind), such as James Watt or John Wilkinson, would fit the definition.

Turning operation:

EXISTING SYSTEM

Turning operations are operations that rotate the work piece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning

DESCRIPTION:

Milling operations:

The existing traditional manufacturing processes by using available manufacturing software’s are resulting in more machining time and increasing product development time,Increased productivity and cost reduction are preeminent goals of modern manufacturing enterprises machining time, surface quality and workpiece accuracy, machine tool controls must therefore be capable of making an approach optimized for the milling machine and the manufacturing process.

Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling.

PROBLEMS: 1. Current manufacturing software’s do not address all parameters of machining time 2. Dealing with more cutting operations and selection of cutters be problematic because of time complexity; PROPOSED SYSTEM An accurate estimate of machining time is very important for predicting delivery time, manufacturing costs, and also to help production process planning. Most commercial CAM software systems estimate the machining time in milling operations simply by dividing the entire tool path length by the programmed feed rate. This time estimate differs drastically from the real process time because the feed rate is not always constant due to machine and computer numerical controlled (CNC) limitations.

In this thesis, the time taken to manufacture the main housing used in weighing machine is estimated. Main Housing is drawn in 3D Modeling and feature based software Pro/Engineer. The time taken for modeling, part programming and machining time using software’s Pro/ Engineer and Delcam is compared and analyzed in this thesis.

MACHINING Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The many processes that have this common theme, controlled material removal, are today collectively known as subtractive manufac-

Drilling operations: Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but sometimes on lathes or mills.

OVERVIEW OF MACHINING TECHNOLOGY An unfinished workpiece requiring machining will need to have some material cut away to create a finished product.

A finished product would be a workpiece that meets the specifications set out for that workpiece by engineering drawings or blueprints For example, a workpiece may be required to have a specific outside diameter. A lathe is a machine tool that can be used to create that diameter by rotating a metal workpiece, so that a cutting tool can cut metal away, creating a smooth, round surface matching the required diameter and surface finish.

CONVENTIONAL vs NON CONVENTIONAL MACHINING Manufacturing processes can be broadly divided into two groups and they are primary manufacturing processes and secondary manufacturing processes. The former ones provide basic shape and size to the material as per designer’s requirement. Casting, forming, powder metallurgy are such processes to name a few. Secondary manufacturing processes provide the final shape and size with tighter control on dimension, surface characteristics etc. Material removal processes are mainly the secondary manufacturing processes.

Material removal processes once again can be divided into mainly two groups and they are “Conventional Machin19

Advanced Research Journals of Science and Technology

ing Processes” and “Non-Traditional Manufacturing Processes”.

Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc. Similarly, Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Water Jet and Abrasive Water Jet Machining (WJM and AWJM), Electro-discharge Machining (EDM) are some of the Non Traditional Machining (NTM) Processes.

The three main forms of energy used in non-conventional machining processes are as follows: • Thermal energy • Chemical energy • Electrical energy MODERN MANUFACTURING SYSTEMS Every manufacturing system normally undergoes several phases. The system must be planned, implemented and controlled, generally by trained and competent manufacturing and management personnel. During the planning phase, consideration must be given to critical factors such as potential market for the product, its design, processes to be employed, facilities, equipment and materials needed for production. In the implementation phase, these resources are acquired and put in place so that production can begin. The implementation phase goes with the controlling phase, in that the system must be controlled or managed both at the time of its implementation and during production.

Whenthe planning, implementation and controlling phases have been safely and successfully undertaken, it is necessary that the personnel follow up with continuous improvement, to meet the emerging demands, and also to ensure that the company will remain in business for a long time. It is at this stage that many technical managers, like Manufacturing Systems graduates, use their initiative to study and improve the different areas of their manufacturing systems for continued and improved productivity.

Importance of Improving Manufacturing Systems The works of improvement gurus like F. W. Taylor, who spearheaded research on work measurement, helped to sustain the American manufacturing industry through the twentieth century. Later, the combined forces of such manufacturing philosophies as total quality management (TQM), just-in-time (JIT) manufacturing, lean manufacturing and computer integrated manufacturing (CIM) created an important improvement in U. S. manufacturing, setting the stage for the economic growth of the 1990s (Wright, 2001). These philosophies and the powerful technologies that supported them provided the impetus that sustained the U.S. as the world’s number one economic super power.

DESIGN AND MANUFACTURING SOFTWARE DESIGN OVERVIEW Software has become an essential component of the product lifecycle. The combination of CAD, analytical tools and finite element programs speeds the entire design process and allows engineers to better optimize products. Manufacturing programs improves part quality and in some cases adds capabilities not possible with software.

Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of adesign. CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing. CAD output is often in the form of electronic files for print, machining, or other manufacturing operations.

Computer-aided manufacturing (CAM) is the use of computer software to control machine tools and related machinery in the manufacturing of workpieces. This is not the only definition for CAM, but it is the most common; CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is now a system used in schools and lower educational purposes.

Typical areas of concern • High Speed Machining, including streamlining of tool paths • Multi-function Machining • 5 Axis Machining • Feature recognition and machining • Automation of Machining processes • Ease of Use Overcoming historical shortcomings Over time, the historical shortcomings of CAM are being attenuated, both by providers of niche solutions and by providers of high-end solutions. This is occurring primarily in three arenas: 1. Ease of usage 2. Manufacturing complexity 3. ntegration with PLM and the extended enterprise Ease in use For the user who is just getting started as a CAM user, out-of-the-box capabilities providing Process Wizards, templates, libraries, machine tool kits, automated feature based machining and job function specific tailorable user interfaces build user confidence and speed the learning curve.

User confidence is further built on 3D visualization through a closer integration with the 3D CAD environment, including error-avoiding simulations and optimizations.

Manufacturing complexity The manufacturing environment is increasingly complex.

The need for CAM and PLM tools by the manufacturing engineer, NC programmer or machinist is similar to the need for computer assistance by the pilot of modern aircraft systems. The modern machinery cannot be properly used without this assistance.

Today's CAM systems support the full range of machine tools including: turning, 5 axis machining and wire EDM. Today’s CAM user can easily generate streamlined tool 20

Advanced Research Journals of Science and Technology

paths, optimized tool axis tilt for higher feed rates, better tool life and surface finish and optimized Z axis depth cuts as well as driving non-cutting operations such as the specification of probing motions.

MODELING, CORE AND CAVITY EXTRACTION The main housing used in weighing machine is manufactured by metal die casting process this component modeling core and cavity extraction is carried in Pro/ENGG and DELCAM software’s and the manufacturing time is compared The process involves design and manufacturing of the following parts • • • •

Core holder plate Cavity holder plate Core insert Cavity insert

Actual part of main housing

Model of Main Housing

Die for main housing part

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Advanced Research Journals of Science and Technology

Core holder plate

Core insert

Cavity holder plate Cavity insert

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MANUFACTURING PROCESS USING DEL CAM Core Holder Plate

Select Machining Process For Roughing Has A Offest Area Clear Model

Import model

Program Window

Open Model

Create Work Piece

Cutting Tool

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After Machining

Selecting cutting tool Before changing parameters

Tool path statistics

From the above window total machining time are 4hours 36min.

After Changing Advanced Parameters From the above tool path statistic window after controlling tool parameters and lead in outs machining time 2hours 6minits.

From the above procedure we reduced almost half machining time.

For cavity holding plate before parameter 3h40m after parameter 2h Core insert before8h36m after parameters 6h20m Cavity insert before 25minits after 16minits For Finishing Operation Select marching procedure has a constant Z level finishing and remove side material

Before parameters editing machining time 2h43m After Parameters editing machining time 2h28m

Sample NC code for cavity holder plate G71 O0001 (ncl.1) (07/24/15-16:13:10) N0010T1M06 S1500M03 G01G43X-21.601Y89.182Z5.F3000.H01 Z2.

Z-1.F200.

X74.17Y89.168F1000.

G02X79.088Y87.926I-.603J-12.744F500.

X83.092Y84.287I-6.649J-11.339 G01X83.177Y84.171F1000.

G02X83.943Y82.776I-4.769J-3.525F500.

G01X85.077Y79.334F1000.

X85.123Y78.511 X85.133Y69.352 X65.109 G02X68.519Y60.384I-10.084J-8.967F500.

G01Y49.522F1000.

X85.145 X85.158Y29.692 X68.519 Y9.862 X85.158 X85.15Y-9.968 X68.519 Y-29.798 X85.141 X85.132Y-49.628 X68.519 24

Advanced Research Journals of Science and Technology

CONCLUSION

Y-53.937 G02X61.974Y-65.505I-13.495J-.001F500.

G01X55.396Y-69.458F1000.

X85.124

In this thesis, a die for a casting component used in weighing machine is designed in Pro/Engineer. The die parts core holder plate, cavity holder plate; core insert and cavity insert are to be machined.

EXPERIMENTAL RESULTS

The manufacturing process is done in both Pro/Engineer and Delcam. The machining time is analyzed and compared for both the softwares. By observing, by performing manufacturing process in Delcam, the machining time is reduced when compared with that of Pro/Engineer. This is because, in Delcam, the non cutting paths are not considered. The machining time for roughing and finishing are still reduced by changing the original parameters.

The finishing process in Pro/Engineer takes more time since it considers the time of roughing also which is a disadvantage. So using manufacturing software Delcam reduces the machining time and is a better tool than Pro/ Engineer.

REFERENCES 1. Clark, K.B. & Fujimoto, T., 2012. Product development performance: Strategy, organization, and management in the world auto industry Boston, MA: Harvard Business School Press 2. Datar, S., Jordan, C.C., Kekre, S., Rajiv, S. & Srinivasan, K., 2011. The advantages of timebased new product development in a fast-cycle industry. Journal of Marketing Research, 34, 36-49.

3.Griffin, A., 2008. Metrics for measuring product development cycle time. Journal of Product Innovation Management, 10, 112-125 4. Adler, P.S., Mandelbaum, A., Nguyen, V. & Schwerer, E., 2013. From project to process management: An empirically - based framework for analyzing product development time. Management Science, 41 (3), 458-484.

Editing Machining parameters using delcam

5. Cohen, M.A., Eliashberg, J. & Teck-Hua, H., 2006. New product development: The performance and time-to-market tradeoff. Management Science, 42 (2), 173-186.

RESULTS MACHINING TIME PRO/ENGINEER

DELCAM Before editing advanced parameters

After editing advanced parameters

Parts

Roughing

Finishing

Roughing

Finishing

Roughing

Finishing

Core holder plate

10hrs 32mins

11hrs 10mins

4h36m

2h43m

2h6m

2h28m

Cavity holding plate

9h25min

10h25min

3h40m

3h40m

2h

2h

Core insert

12h10min

13h30min

8h36m

6h38m

6h20m

5h20m

Cavity insert

2hrs 34min

3h 15min

25minits

1h10minits

16minits

90mins

6. Tu, Y.L., Xie, S.Q. & Fung, R.Y.K., 2007. Product development cost estimation in mass customization. IEEE Transactions on Engineering Management, 54 (1), 29-40.

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AUTHOR

K.Rajanikanth Research Scholar, Department of Mechanical Engineering, Princetoncollegeof Engineering and Technology,Hyderabad,India.

J.Ranjith Kumar Assistant Professor, Department of Mechanical Engineering, Princetoncollegeof Engineering and Technology,Hyderabad,India.

Gyadari Ramesh Associate Professor, Department of Mechanical Engineering, Princetoncollegeof Engineering and Technology,Hyderabad,India

Dr.VVRLS.Gangadhar(Principal) Professor, Department of Mechanical Engineering, Princetoncollegeof Engineering and Technology,Hyderabad,India.

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