ADDITIVE MANUFACTURING FOR INNOVATIVE DESIGN AND PRODUCTION Case Study: Strategy and Operations

Transcription

1 ADDITIVE MANUFACTURING FOR INNOVATIVE DESIGN AND PRODUCTION Case Study: Strategy and Operations NOTES: - Be sure to save your copy of this case study, as you will use some of the answers gathered in this week to make comparative assessments in the week after. - This case study is a composite document. Will read the prompt, write your answers, and review the rubric (to help guide your submissions) all in this same document. Then, save a copy and upload to submit. - You may want to write your answers in a different color than the main text so your reviewer can identify them easily. Dark blue (like this) is a good option. - Click the number on the right-hand side of the Table of Contents to navigate to that page.

2 TASK #1 AM POTENTIAL FOR AEROSPACE For each of the following categories of parts, describe how metal AM capability within AAC s production portfolio could aid in their production. In 150 words or more per category, discuss: - Among SLM/EBM, Binder Jetting, and DED, which AM processes would suitable to AAC s interests, and why? - What improvement could using AM bring over conventional manufacturing processes, and is this in part performance, part cost, supply chain dymanics, a combination of the above, or other elements not listed here? - What additional challenges exist for a robust implementation of AM in each application category? Categories: - Jigs, fixtures, and assembly aids - Production tooling - Flyaway parts Use examples you find on your own, or those you have learned about over the past 6 weeks, to validate your reasoning. Type your answer here.

3 B: Referring to your understanding of aerospace applications of AM in Week 3, answer: Source: Boeing In at least 150 words, identify a single part of a landing gear (shown below) that might be suitable for conversion to AM? What would be the primary functional requirements of the parts you ve selected, and how do these requirements suggest the use of certain AM processes over others? Describe how the criteria you identified relate to cost, production time, and performance as applicable. Type your answer here

4 TASK 4: Another alternative process News of AAC investigating AM for production has been leaked, and AAC s recently been approached by Swedish Alloys, a manufacturer of a novel high-resolution DED-based process compatible with titanium, inconel, and other performance alloys for aerospace applications. They want AAC to consider using their equipment to produce the brackets. However, they re struggling to know for certain how competitive their process is by-cost against the other processes you ve considered. Of course, as the new AAC expert on cost modeling for AM, it s your job to make a reasonable determination. Using the MIT AM Cost Model, calculate the approximate cost of this new DED process. Machine specifications are provided below, and only the costs that differ from SLM are provided (i.e. all other parameters can be assumed the same): Parameter Value Unit Support Material Fraction* 0 % Machine Cost $2,000,000 USD ($) Material Cost (Ti6Al4V, wire) $200 USD ($) per kg Build Area 3716 cm^2 Build Height 183 cm Build Rate 500 cm^3/hr Recycling fraction 100 % Additional operating cost 75 USD ($) per hr Consumable cost* $350 USD ($) per build Support removal time* 0 Constant (c) *Note that DED does not use supports, and that typically the build plate is a solid billet made from the same material as the final part and therefore is treated as part of the final part geometry (thus each build requires a single build plate be utilized). This however restricts the geometry, and here necessitates a 5- axis machine configuration. Post-processing is considered separately below. Moreover, due to the geometry limitation, the design must be re-optimized for DED, and therefore the final mass (if the part is produced from Titanium) is kg. Using this, answer the following: Q: What is the cost of producing the bracket at quantity 1? Round your answer up to the nearest whole Q: What is the cost of producing the bracket at quantity 120? Round your answer to the nearest whole Q: What is the cost of producing the bracket at quantity 900? Round your answer to the nearest whole

5 In at least 100 words, describe how the constituent costs of the final part cost differ using this new DED process versus an SLM process? What does this indicate about the sensitivity i.e., do you expect that part cost is similarly sensitive to the same elements you identified for SLM in the previous week, or would you anticipate that changes in other variables would have higher weights associated with them? Type your answer below Now, consider the implications of post-processing. Assume that you can standardize the cost of postprocessing on a per-part basis. Use the table below: Process: Cost per Part: Band-saw Part Removal $20.00 Wire EDM Part Removal $40.00 Surface Finishing (abrasive) $20.00 Surface Finishing (chemical) $40.00 CNC machining $ Thread and Hole Tapping $50.00 Heat Treatment (standard, post-build) $25.00 Hot Isostatic Pressing $35.00 Dimensional Inspection (e.g. CMM) $25.00 Computed Tomography Scanning $ Tensile testing (including samples) $ In 100 words, use this table to suggest which post-processing steps are required for each part if they were produced using this new DED process. For each step, describe why you included it here, and provide a post-processing cost estimate per-part. Type your answer here