Manufacturing Process Planning E-Book

José V. Abellán-Nebot

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 622

Veröffentlichungsjahr: 2025

Beschreibung

Comprehensive introduction to manufacturing process planning in the context of the latest techniques being used in industry

Manufacturing Process Planning is a comprehensive guide to the intricacies of the manufacturing planning process that leads readers through each stage of planning while providing practical examples that illustrate the manufacturing activities taking place at every juncture. Beginning with the fundamentals, the book bridges the gap between technical documents and product specifications, and how the information they contain can be effectively applied on the shop floor.

The book focuses around four key areas: selection of manufacturing processes, process planning in sand casting, process planning in machining, and process planning in inspection. Each chapter highlights best practices for activities such as casting, mold design, machining sequence identification, geometrical validation, CNC programming, the preparation of inspection reports, and more. Special attention is paid to manufacturing cost estimation and pricing, ensuring that the production process is not only feasible but also cost-effective.

To enhance the learning experience, the book comes complete with an active learning project brief and tutorial sessions covering casting simulation, pattern design, and CNC simulation using freely available software.

Manufacturing Process Planning includes information on:

• Fundamentals of casting, including heating the metal, pouring the molten metal, solidification and cooling, determining casting quality, and performing cleaning operations
• Definition and selection of workholding systems, covering principles of workholding, types of workholding systems, and general purpose of workholding devices for turning and milling
• Machine and cutting tool selection, and process parameter selection, covering specific guidelines in turning, milling, and drilling
• Documents for process planning, including process flow charts, routing sheets, and operation and tooling lists

Providing a hands-on approach to mastering the principles of manufacturing process planning, Manufacturing Process Planning is an ideal resource for undergraduate and graduate academic courses that incorporate a lab component, as well as production planning supervisors and managers looking to hone their knowledge base.

Leseprobe

Table of Contents

Cover

Table of Contents

Title Page

Copyright Page

Foreword

Preface

About the Companion Website

Part I: Fundamentals of Process Planning

1 Introduction to Process Planning

1.1 Introduction

1.2 Process Planning Within Product Development Cycle

1.3 Process‐Planning Levels of Detail and Activities

1.4 Technical Data Required for Process Planning

1.5 Process‐Planning Methods

Questions and Exercises

References

2 Product Data and Manufacturability

2.1 Introduction

2.2 Product Data

2.3 Manufacturability

Questions and Exercises

References

3 Selection of Manufacturing Processes

3.1 Introduction

3.2 Materials in Manufacturing

3.3 Manufacturing Processes

3.4 Manufacturing Process Selection

3.5 Use of Software for Process Selection

Questions and Exercises

References

4 Process‐Planning Documentation

4.1 Introduction

4.2 Process Flow Charts

4.3 Assembly Charts and Operation Process Charts

4.4 Routing Sheets

4.5 Operations Lists

4.6 Tooling List

4.7 CNC Programs

4.8 Work Instructions Sheet

4.9 Inspection Sheets and Reports

Questions and Exercises

References

Part II: Process Planning in Casting

5 Fundamentals of Casting

5.1 Introduction

5.2 Sand Casting

5.3 Heating the Metal

5.4 Pouring the Molten Metal

5.5 Solidification and Cooling

5.6 Casting Quality

5.7 Cleaning Operations

Questions and Exercises

References

6 Process Planning in Sand Casting

6.1 Introduction

6.2 Mold‐Making Guidelines

6.3 Pattern Fabrication Guidelines

6.4 Core and Core Box Fabrication

6.5 Casting Simulation

6.6 Melting and Casting

6.7 Knockout, Fettling, and Finishing

6.8 Inspection

6.9 Operations List in Sand Casting

Questions and Exercises

References

Part III: Process Planning in Machining

7 Definition and Selection of Workholding Systems

7.1 Introduction

7.2 Principles of Workholding

7.3 Types of Workholding Systems

7.4 Permanent and Modular Fixtures

7.5 General Purpose of Workholding Devices for Turning

7.6 General Purpose of Workholding Devices for Milling

7.7 Workholding Drawing Representation

Questions and Exercises

References

8 Geometry Analysis and Machining Operations Sequence

8.1 Introduction

8.2 Definition of Terms

8.3 Geometry Analysis

8.4 Machining Volumes

8.5 Definition and Sequence of Machining Operations

8.6 Definition of Locating Surfaces and Workholding

8.7 Practical Example

Questions and Exercises

References

9 Machine Tool/Cutting Tool Selection

9.1 Introduction

9.2 Machine Tool Selection

9.3 Cutting Tool Selection

9.4 Example Data: Shop‐Floor Tool Tables

Questions and Exercises

References

10 Process Parameter Selection

10.1 Introduction

10.2 Methodology

10.3 Specific Guidelines for Turning

10.4 Specific Guidelines in Milling

10.5 Specific Guidelines in Drilling

10.6 Use of Cutting Fluids

10.7 Practical Example

Questions and Exercises

References

11 Geometric Validation

11.1 Introduction

11.2 Definition of Terms

11.3 Steps for Tolerance Charting

Questions and Exercises

References

12 CNC Programming

12.1 Introduction

12.2 CNC Machine Tools

12.3 Programming CNC Machine Tools

12.4 Basic Concepts of CNC Programming. G‐Code

12.5 CNC Canned Cycles

12.6 Machining Methods/Cutting Strategies

Questions and Exercises

References

Part IV: Process Planning in Inspection and Costing

13 Inspection Process Planning

13.1 Introduction

13.2 Inspection Plans for Product and Process Validation

13.3 Inspection Plans in Production

13.4 Features to be Inspected

13.5 Selection of Measurement Instruments for Inspection

13.6 Example Data: Measurement Instrument Specifications

Questions and Exercises

References

14 Product Cost Estimation

14.1 Introduction

14.2 Elements of Costs

14.3 Make‐or‐Buy Decision

14.4 Pricing

14.5 Sand‐Casting Cost Estimation (

C

tsc

)

14.6 Machining Cost Estimation (

C

tmach

)

14.7 3D Printing Cost Estimation (

C

3Dpr

)

14.8 Computer‐Aided Cost Estimators

14.9 Web‐Based Tools for Cost Estimation

14.10 Product Costing Sheets

14.11 Data of Interest: Wage Statistics for Primary Metal Manufacturing Industries

Questions and Exercises

References

Appendix 1: ISO Dimensional Tolerances

Appendix 2: Cutting Data

A2.1 Recommended Cutting Data

A2.2 Specific Cutting Force

A2.3 Cross‐Reference Materials Table and ISO codes

Appendix 3: AQL Tables

Index

End User License Agreement

List of Tables

Chapter 2

Table 2.1 Classification and symbols of geometric tolerancing.

Table 2.2 General dimensional tolerances (length).

Table 2.3 General dimensional tolerances (angles).

Table 2.4 General geometric tolerances. Straightness and flatness.

Table 2.5 General geometric tolerances. Perpendicularity.

Table 2.6 General geometric tolerances. Circular run‐out.

Table 2.7 General geometric tolerances. Symmetry.

Table 2.8 General dimensional tolerances for castings.

Table 2.9 General geometrical tolerances for castings. Roundness, parallelis...

Table 2.10 General geometrical tolerances for castings. Flatness.

Table 2.11 DCTG values for different casting processes.

Table 2.12 GCTG values for different casting processes.

Table 2.13 Surface roughness classes according to ISO 1302 and examples of ...

Table 2.14 Relationships between dimensional tolerances and minimal surface...

Table 2.15 Minimum wall thickness for aluminum alloys in some casting proce...

Chapter 3

Table 3.1 Common classification of metals.

Table 3.2 Common classification of ceramics and polymers.

Table 3.3 Common classification of composites.

Table 3.4 Classification, description, and use of different casting process...

Table 3.5 Characteristics of casting processes.

Table 3.6 Casting process. Economic considerations.

Table 3.7 Characteristics of bulk‐forming processes.

Table 3.8 Bulk‐forming process selection table. Economic considerations....

Table 3.9 Characteristics of traditional/conventional machining processes....

Table 3.10 Minimum machining allowance for different machining processes....

Table 3.11 Characteristics of nontraditional machining processes.

Table 3.12 General classification of surface processes.

Table 3.13 Selected treatments and their effects.

Table 3.14 Report for drawing interpretation.

Table 3.15 Compatibility between materials and manufacturing processes. Cas...

Table 3.16 Compatibility between materials and manufacturing processes. Bul...

Table 3.17 Geometry and process compatibility.

Table 3.18 Report for geometry compatibility of manufacturing processes.

Table 3.19 Report for technical feasibility of manufacturing processes.

Table 3.20 Report for the economic feasibility of manufacturing processes....

Table 3.21 Density and costs of different metal alloys. Data gathered from ...

Table 3.22 Common material removal rates in conventional machining.

Table 3.23 Report for final process selection.

Table 3.24 Report for drawing interpretation. Case study.

Table 3.25 Report for geometry compatibility of manufacturing processes. Ca...

Table 3.26 Report for technical feasibility of manufacturing processes. Cas...

Table 3.27 Report for economic feasibility of manufacturing processes. Case...

Table 3.28 Report for final process selection (primary processing costs). C...

Table 3.29 Report for final process selection (secondary and total cost per...

Chapter 5

Table 5.1 Different thermophysical properties for some metals and metal all...

Table 5.2 Viscosity and density values of different elements and alloys in ...

Table 5.3 Volumetric contraction for different casting metals. Liquid contr...

Chapter 6

Table 6.1 Gating ratios and densities for different alloys.

Table 6.2 Pouring rates in kg/s for castings.

Table 6.3 Volume, area, and modulus for different riser geometries.

Table 6.4 Modulus of different sections in the part to be cast.

Table 6.5 Ranges of minimum diameters of cored holes in the casting.

Table 6.6 Minimum thickness for different casting processes and materials....

Table 6.7 Typical patternmaker's shrinkage for important casting metals....

Table 6.8 General machining allowance for different metals.

Table 6.9 Common draft values for different casting processes. The values m...

Table 6.10 Ratios of buoyant force to core weight.

Table 6.11 Recommended core prints for horizontal and vertical cores.

Table 6.12 Time for different temperature losses in uncovered ladles from 5...

Table 6.13 Recommended pouring temperature for different materials and part...

Chapter 7

Table 7.1 Friction coefficients for dry and lubricating contact between dif...

Table 7.2 Approximate clamping forces of different stud sizes in clamp stra...

Table 7.3 The three broad alternatives for workholding: permanent fixtures,...

Table 7.4 Symbols for positioning and clamping according to each technology...

Table 7.5 Symbols for the type of surface.

Table 7.6 Symbols for the function of the technological elements. Normal an...

Table 7.7 Symbols related to the type of contact.

Table 7.8 Example of some physical elements in fixtures and their associate...

Table 7.9 Concentric and radial location. Symbols and examples of physical ...

Table 7.10 Examples of different workholding systems and their correspondin...

Chapter 8

Table 8.1 Common machining features and corresponding machining operations....

Table 8.2 Overview of dimensional and geometrical capabilities of machining...

Table 8.3 Estimated values of factors contributing to inaccuracy in machini...

Table 8.4 Analysis of surface specifications.

Table 8.5 Machining operations and TADs for identified machining volumes

Chapter 9

Table 9.1 Application group and subgroups of hard cutting tool materials, a...

Table 9.2 Typical feed rates according to cutting tool nose radius for turn...

Table 9.3 Double negative, double positive, and positive/negative geometry....

Table 9.4 Depth of cut for reaming operations.

Table 9.5 Machining sequence for the example in Chapter 8.

Table 9.6 Example of cutting tools available for a CNC lathe (external tool...

Table 9.7 Example of cutting tools available for a CNC lathe (internal tools...

Table 9.8 Example of tool table for a CNC machining center (indexable tools)...

Table 9.9 Example of tool table for a CNC machining center (solid tools).

Table 9.10 Tools available for Exercise 3.

Chapter 10

Table 10.1 Table to correct cutting speed for different tool‐life values....

Table 10.2 Table to correct cutting speed for variations of material hardne...

Table 10.3 Feed rate according to nose radius and surface roughness require...

Table 10.4 Cutting forces in machining.

Table 10.5 Cutting power requirement in machining.

Table 10.6 Deflections in turning with different workholding systems.

Table 10.7 Correction factor of feed rate for profile milling according to ...

Table 10.8 Machining sequence and cutting tools of the example in Chapters ...

Table 10.9 Operations and tools for Exercise 9.

Chapter 12

Table 12.1 General CNC G‐codes.

Table 12.2 Example of G81 turning canned cycle and resulting trajectory fro...

Table 12.3 Example of G87 pocket canned cycle and resulting trajectory from...

Chapter 13

Table 13.1 Table of instruments.

Table 13.2 Example of list of instruments for inspection.

Table 13.3 List of instruments for inspection. Exercise 10.

Chapter 14

Table 14.1 Tool life and relative costs.

Table 14.2 Common pattern cost from a Chinese manufacturer.

Table 14.3 Properties and costs of commonly used sand‐casting alloys.

a

Table 14.4 Densities and approximate costs in $/kg for various metals under...

Table 14.5 Setup time for different machine tools and setup time for each a...

Table 14.6 Loading and unloading time (in seconds) versus workpiece weight....

Table 14.7 Time to tool's engage/disengage and tool change time (nonproduct...

Table 14.8 Number of edges for different insert shapes. Reversible and nonr...

Table 14.9 Cost of common cutting inserts, tools, and tool holders.

a

Table 14.10 Material cost for different materials and technologies in 3D pr...

Table 14.11 Salary wage for different occupations in primary metal manufact...

Appendix 1

Table A1.1 Values of standard tolerances grades.

Table A1.2 Fundamental deviation values A to M for internal features (in μm)...

Table A1.3 Fundamental deviation values N to ZC for internal features...

Table A1.4 Fundamental deviation values for external features a to j ...

Table A1.5 Fundamental deviation values for external features k to zc...

Appendix 2

Table A2.1 External and internal turning (straight turning, face turning, an...

Table A2.2 External and internal turning (grooving, parting, and threading)....

Table A2.3 Number of infeeds (nap), infeed per pass, and total depth of thre...

Table A2.4 Milling operations with large engagement and coated carbide inser...

Table A2.5 Milling operations with small engagement and coated carbide inser...

Table A2.6 Large engagement milling operations with HSS end mill tools (coat...

Table A2.7 General milling operations with uncoated carbide end mill tools....

Table A2.8 General milling operations with coated carbide end mill tools.

Table A2.9 Center drills HSS. Cutting speeds and curve for feed rate.

Table A2.10 Feed curves for HSS center drills.

Table A2.11 HSS spot drills. Cutting speed and feed curves.

Table A2.12 Feed curves for HSS spot drills.

Table A2.13 HSS twist drills (uncoated and coated drills). Cutting speed and...

Table A2.14 Feed curves for HSS twist drills (uncoated and coated drills).

Table A2.15 Carbide twist drills (uncoated and coated drills). Cutting speed...

Table A2.16 Feed curves for carbide twist drills (uncoated and coated drills...

Table A2.17 Reamers (uncoated HSS‐E and uncoated solid carbide tools). Cutti...

Table A2.18 Feed curves for reamers.

Table A2.19 Tap drilling. Cutting speed and feed rate calculation.

Table A2.20 Specific cutting force for different materials. Elaborated from ...

Table A2.21 (Continuation) Specific cutting force for different materials. E...

Table A2.22 Cross‐reference materials table. Elaborated from different data ...

Table A2.23 (Continuation) Cross‐reference materials table. Elaborated from ...

Appendix 3

Table A3.1 AQL Tables: sample size code letter for single sampling and norm...

Table A3.2 AQL Tables: AQL values according to size code letter, sample siz...

List of Illustrations

Chapter 1

Figure 1.1 Traditional process planning deployment where machining operation...

Figure 1.2 Sequential engineering versus concurrent engineering.

Figure 1.3 Impact of product design on product cost and production cost in c...

Figure 1.4 Explanation of the form codes (digits 1–5) in the Opitz coding sy...

Figure 1.5 Explanation of the supplementary codes in the Opitz coding system...

Figure 1.6 Example of application of the Opitz coding system.

Figure 1.7 Preparatory stage of CAPP variant approach.

Figure 1.8 Production stage of CAPP variant approach.

Figure 1.9 CAPP generative approach.

Chapter 2

Figure 2.1 Engineering drawing of a mechanical part.

Figure 2.2 Example of a product structure.

Figure 2.3 Product structure for product 1 and summarized bill of materials ...

Figure 2.4 Example of an engineering BOMs (eBOMs).

Figure 2.5 Example of manufacturing BOM (mBOM) for a bicycle product.

Figure 2.6 Example of a 3D model with product manufacturing information (PMI...

Figure 2.7 Dimensions for a cylindrical part. Units in mm.

Figure 2.8 Four possible shapes that fit the previous dimensioned part. Unit...

Figure 2.9 Geometric tolerancing of a cylindrical part. Units in mm.

Figure 2.10 (a) Datum feature and feature control frame. Units in mm; (b) da...

Figure 2.11 Datum reference frame (DRF) and tolerance zone according to the ...

Figure 2.12 Part with traditional tolerancing. Units in mm.

Figure 2.13 Ambiguity in traditional tolerancing: (a) plane position; (b) ho...

Figure 2.14 Unambiguous geometry definition using geometric product specific...

Figure 2.15 Orientation defects not limited to the traditional tolerancing a...

Figure 2.16 Part with GPS tolerancing approach. Units in mm.

Figure 2.17 Traditional tolerancing example. References are not specified fo...

Figure 2.18 Different interpretations related to references for inspecting t...

Figure 2.19 Example 1 – part design with general tolerances.

Figure 2.20 Example 2 – part design with general tolerances.

Figure 2.21 Interpretation of part design drawing – example 1.

Figure 2.22 Interpretation of part design drawing – example 2.

Figure 2.23 Casting drawing with general tolerances.

Figure 2.24 Symbols related to surface roughness.

Figure 2.25 Example of surface roughness indication in a drawing.

Figure 2.26 Design for manufacturing and assembly (DFMA) tools included in c...

Chapter 3

Figure 3.1 A common sequence of manufacturing processes to produce a part.

Figure 3.2 Casting processes classification according to part dimensions and...

Figure 3.3 Machining processes classification with dimensional quality (IT) ...

Figure 3.4 Surface finishes for some common manufacturing processes.

Figure 3.5 Geometry classification.

Figure 3.6 Examples of break‐even analysis for different manufacturing proce...

Figure 3.7 Casing for the case of study and part and production characterist...

Figure 3.8 Relative cost index with respect to batch size given default cost...

Figure 3.9 Part 1 – Support. N10 (ISO 1302); General tolerance ISO 2768 – cH...

Figure 3.10 Part 2 – Hook. N10 (ISO 1302); General tolerance ISO 2768 – cH. ...

Chapter 4

Figure 4.1 Example of flow process chart.

Figure 4.2 Example of assembly chart for a bench vice.

Figure 4.3 Example of operation process chart for a bench vice.

Figure 4.4 A casing part. Technical drawing.

Figure 4.5 Routing sheet for the example given (casing part).

Figure 4.6 Operations list for the example given.

Figure 4.7 Tooling list for the example given.

Figure 4.8 Example of CNC program under a simulation software.

Figure 4.9 Example of a work instructions sheet.

Figure 4.10 Inspection report example. Units in mm.

Figure 4.11 Assembly for Exercise 1.

Figure 4.12 Assembly for Exercise 2.

Chapter 5

Figure 5.1 Top five casting producers in 2019. Total casting tons produced a...

Figure 5.2 Aluminum die casting parts for an electrical vehicle.

Figure 5.3 Outline of production steps in a typical sand‐casting process.

Figure 5.4 Features of sand‐casting molds. Cross‐section of typical sand‐cas...

Figure 5.5 Filling process of a mold cavity in sand casting.

Figure 5.6 Example of ceramic filter and placement in a sand‐casting mold.

Figure 5.7 Cylindrical casting shrinkage during solidification and cooling: ...

Figure 5.8 (Left top) External chill and (left bottom) internal chill to pro...

Figure 5.9 Sand mold for Exercise 7. Material: gray cast iron.

Chapter 6

Figure 6.1 Parts of a generic sand‐casting mold.

Figure 6.2 Sprue well and pouring basin design.

Figure 6.3 Balanced gating system.

Figure 6.4 Parameters for the effective sprue height (

H

) calculation.

Figure 6.5 Aluminum part (a) and (b) complete casting result.

Figure 6.6 Top risers, side risers, blind and open risers.

Figure 6.7 Correct and incorrect riser's locations and channel dimensions.

Figure 6.8 Neck riser recommendations.

Figure 6.9 CAD part to be cast.

Figure 6.10 Risers included in the design to improve part quality.

Figure 6.11 Simulation of the casting process without (a) and with (b) riser...

Figure 6.12 Tool fabrication process for sand casting.

Figure 6.13 Simplified version for casting (a) and actual component after ma...

Figure 6.14 Two contraction situations.

Y

‐Dimension cannot shrink (constrain...

Figure 6.15 Example of taper allowance.

Figure 6.16 Split patterns and resulting casting part.

Figure 6.17 (a) Core prints to support core; (b) chaplets added to support t...

Figure 6.18 Parameters

h

and

c

related to the opening force of the cope.

Figure 6.19 Cylindrical part to be cast. Dimensions in mm.

Figure 6.20 Metallostatic force in a cylindrical cavity and equivalent flat ...

Figure 6.21 Cross‐section of the cope pattern with core prints. Dimensions i...

Figure 6.22 Different analysis, equations, and variables typically handled b...

Figure 6.23 Analysis of a valve in casting simulation software (Altair Inspi...

Figure 6.24 Typical operations list in sand casting.

Figure 6.25 Part Exercise 2. Dimensions in mm.

Figure 6.26 Part Exercise 3. Dimensions in mm.

Figure 6.27 Part Exercise 5. Cavity dimensions in mm.

Figure 6.28 Part Exercise 6. Dimensions in mm.

Chapter 7

Figure 7.1 (a) Drill jig.(b) Permanent workholder used for machining a p...

Figure 7.2 The 12 movements of a part in the three‐space.

Figure 7.3 The three forms of location: plane, concentric, and radial.

Figure 7.4 Spherical fixed locator (a) and adjustable supports to locate/sup...

Figure 7.5 The 3‐2‐1 locating scheme and movements constrained by locators i...

Figure 7.6 Two locating pins mounted on a plate lock 11‐out‐of‐12 possible m...

Figure 7.7 Cutting forces in a milling operation should be directed into the...

Figure 7.8 Correct and incorrect locating schemes for machining. Locators sh...

Figure 7.9 Examples of redundant locators that produce a non‐repeatable loca...

Figure 7.10 Example of foolproofing workholding design to ensure that compon...

Figure 7.11 Example of comparing different fixture layouts by evaluating the...

Figure 7.12 Clamps should always be positioned so the clamping force is dire...

Figure 7.13 Using gooseneck clamps is one way to reduce the height of the cl...

Figure 7.14 Use of supports to avoid workpiece deformation.

Figure 7.15 (a) Directing the clamping forces against an unsupported area wi...

Figure 7.16 Simple example of clamping force calculation. Friction forces du...

Figure 7.17 A more general clamping‐force calculation, using a two‐dimension...

Figure 7.18 General classification of workholding systems.

Figure 7.19 Break‐even analysis for the example presented.

Figure 7.20 Basic structural elements for modular/permanent fixtures.

Figure 7.21 Example of self‐aligning rest pads to support sloped surfaces....

Figure 7.22 Different types of rest pads and locating pins.

Figure 7.23 (a) Clamping forces for toggle, down‐hold clamps, and centering ...

Figure 7.24 Different types of supporting elements and application example....

Figure 7.25 Example of fixtures and components according to vendor's nomencl...

Figure 7.26 Examples of modular fixtures.

Figure 7.27 Examples of modular fixtures.

Figure 7.28 (a) Three‐jaw chuck and (b) four‐jaw independent chuck.

Figure 7.29 (a) Magnetic chuck and (b) face plate.

Figure 7.30 Collet and collet chuck for lathes.

Figure 7.31 Mandrel for internal clamping in turning operations.

Figure 7.32 Holding a workpiece between centers.

Figure 7.33 Common steady rest (a) and follower rest (b) for shop‐floor turn...

Figure 7.34 Automated steady rest.

Figure 7.35 Plain vice and different types of jaw for vices.

Figure 7.36 (a) Bench vice with swivel base and (b) universal vice for milli...

Figure 7.37 Different clamps and step blocks for workholding.

Figure 7.38 Set of components for clamping a workpiece on machine tool table...

Figure 7.39 Different types of clamps for mounting on a machine tool table....

Figure 7.40 (a) Angle plate and (b) Vee‐blocks with a cylindrical part and t...

Figure 7.41 (a) Rotary table and (b) tilt milling table.

Figure 7.42 (a) Example of permanent magnetic clamping plate; (b) use of mag...

Figure 7.43 Basic symbol used to define positioning and clamping according t...

Figure 7.44 Exercise 6. Complete the name of the components.

Figure 7.45 Exercise 7. Complete the name of the components.

Figure 7.46 Exercise 8. Complete the name of the components.

Chapter 8

Figure 8.1 Process planning methodology for machining operations.

Figure 8.2 Definition of job, subjob, and operation.

Figure 8.3 Tool approach directions (TADs) for some machined features in a r...

Figure 8.4 Example of machining features and machining volumes in milling op...

Figure 8.5 Example of machining features and machining volumes in turning op...

Figure 8.6 Examples of milling and turning operations.

Figure 8.7 Different types of interactions: (a) and (b) fixture

–

featur...

Figure 8.8 Examples of recommended precedence constraints: (a) hole before s...

Figure 8.9 Example of a drawing of a mechanical part.

Figure 8.10 Machining sequence diagram template.

Figure 8.11 Practical example. Part drawing.

Figure 8.12 Numbering of surfaces. The datum letter used in the drawing is s...

Figure 8.13 Machining volumes and surfaces generated.

Figure 8.14 Machining sequence diagram of the case study.

Figure 8.15 Liaisons between currently analyzed subjob and previous subjobs/...

Figure 8.16 Tolerance stackup if surface R9 is used as datum surface. Design...

Figure 8.17 Graphical representation of the location and clamping method in ...

Figure 8.18 Diagram updated with the setup datum in subjob 1, job 1.

Figure 8.19 Tolerance stackups for different alternatives of locating datum ...

Figure 8.20 Updated diagram including the datum surface for subjob 2, job 1....

Figure 8.21 Graphical representation of the location and clamping scheme in ...

Figure 8.22 Updated diagram, including the datum surfaces for subjob 1, job ...

Figure 8.23 Graphical representation of subjob 1, job 2.

Figure 8.24 Updated diagram, including the datum surfaces for subjob 2, job ...

Figure 8.25 Graphical representation of subjob 2, job 2.

Figure 8.26 Exercise 3 to carry out the machining process planning. Units in...

Figure 8.27 Exercise 4 to carry out the machining process planning. Units in...

Figure 8.28 Exercise 5 to carry out the machining process planning. Units in...

Figure 8.29 Exercise 6 to carry out the machining process planning. Units in...

Chapter 9

Figure 9.1 Example of break‐even point between two CNC machines with differe...

Figure 9.2 Overview of cutting tool materials, properties, and applications....

Figure 9.3 External and internal turning operations.

Figure 9.4 Turning holders. Example of ISO nomenclature.

Figure 9.5 Clamping method of cutting inserts.

Figure 9.6 Insert shape according to insert geometry code.

Figure 9.7 Recommended cutting insert geometry for external and internal tur...

Figure 9.8 Influence of insert geometry with respect to toughness, vibration...

Figure 9.9 Holder style.

Figure 9.10 Relationship between entering angle and end cutting‐edge angle, ...

Figure 9.11 Initial contact of the insert with the workpiece according to th...

Figure 9.12 Insert clearance angle.

Figure 9.13 Hand of tool. Left‐handed, right‐handed, and neutral‐handed tool...

Figure 9.14 Height of shank and width of shank.

Figure 9.15 Length of holder, LF, and length of insert cutting edge, L.

Figure 9.16 Designation for internal tool holder bars. Parameters 1–3 are sp...

Figure 9.17 Cutting inserts nomenclature according to ISO 1832.

Figure 9.18 ISO 1832. Nomenclature of cutting inserts I.

Figure 9.19 ISO 1832. Nomenclature of cutting inserts II.

Figure 9.20 ISO 1832. Nomenclature of cutting inserts III.

Figure 9.21 The geometry of conventional inserts versus wiper inserts.

Figure 9.22 Common milling operations.

Figure 9.23 Common cutting tools for different milling operations.

Figure 9.24 Entering angle and its relationship with normal cutting force di...

Figure 9.25 Different types of cutter density in face cutters.

Figure 9.26 Nomenclature used by Seco Tools AB for milling tool holders.

Figure 9.27 ISO 1832. Nomenclature of cutting inserts in milling (I).

Figure 9.28 ISO 1832. Nomenclature of cutting inserts in milling (II).

Figure 9.29 ISO 1832. Nomenclature of cutting inserts in milling (III).

Figure 9.30 ISO 1832. Nomenclature of cutting inserts in milling (IV).

Figure 9.31 General overview of drilling tools and their application accordi...

Figure 9.32 Main geometrical characteristics of a twist drill.

Figure 9.33 Counterboring and countersinking operations.

Figure 9.34 Boring and reamer tools.

Figure 9.35 Methods for threading.

Figure 9.36 Sequence for threading a counterbored hole: drilling, counterbor...

Figure 9.37 External and internal thread turning.

Figure 9.38 External and internal thread milling.

Figure 9.39 Part drawing of example in Chapter 8.

Figure 9.40 3D part to be machined. Exercise 7.

Figure 9.41 Engineering drawing for Exercise 8. Units in mm.

Chapter 10

Figure 10.1 Production cost and parts per hour as a function of cutting spee...

Figure 10.2 Frontal milling and surface roughness

Figure 10.3 Peripheral milling and surface roughness.

Figure 10.4 Chip‐breaking diagram for an insert designed for roughing operat...

Figure 10.5 Chip breakers, as part of the insert geometry, are designed to w...

Figure 10.6 Effective cutting‐edge length.

Figure 10.7 Chip formation issues. (a) Problematic long chips due to low dep...

Figure 10.8 Cutting tool deflection in milling and turning.

Figure 10.9 Drawing to illustrate the milling operation for cutting forces a...

Figure 10.10 Example of three‐jaw chuck specifications.

Figure 10.11 Correction factor for side milling.

Figure 10.12 Theoretical roughness (

R

z

) in profile milling with ball end mil...

Figure 10.13 Gripping force for shrinking and hydraulic chucks. Elaborated f...

Figure 10.14 Part drawing of example in Chapters 8 and 9.

Figure 10.15 Face turning operation analyzed. Main parameters for cutting fo...

Figure 10.16 Drilling operation analyzed. Main parameters for cutting force ...

Figure 10.17 Part to be machined. Exercise 10.

Chapter 11

Figure 11.1 (a) Design and preform dimensions for a given part. (b) Subjobs,...

Figure 11.2 Basic features of a tolerance chart.

Figure 11.3 Tolerance chart symbols.

Figure 11.4 Additional features to build the tolerance chart. Rooted tree an...

Figure 11.5 Rooted tree for the previous example.

Figure 11.6 Tolerance chart for the example. Steps 1 and 2. Units in mm.

Figure 11.7 Stock removal set table for the example. Units in mm.

Figure 11.8 Path between 0200 and 0300 surfaces and resulting stackup. Units...

Figure 11.9 Resulting tolerance chart for the example. Units in mm.

Figure 11.10 Path between 0101 and 0300 surfaces and resulting stackup consi...

Figure 11.11 Resulting tolerance chart for the previous example adding fixtu...

Figure 11.12 Part drawing and rooted tree for Exercise 1. Units in mm.

Figure 11.13 Design dimensions and machining sequence for Exercise 2. Units ...

Figure 11.14 Design dimensions and machining sequence for Exercise 3. Units ...

Chapter 12

Figure 12.1 Definition of axes

X

,

Y

, and

Z

in a CNC lathe and a vertical mac...

Figure 12.2 Machine tool coordinate system (MCS), fixture coordinate system ...

Figure 12.3 Tool coordinate system (a) before and (b) after tool height comp...

Figure 12.4 Example of manual programming and 3D simulation by the software ...

Figure 12.5 Example of computer‐aided manufacturing (CAM) with SolidWorks CA...

Figure 12.6 Example of postprocessing in CAM.

Figure 12.7 Example of conversational programming. (a) FAGOR 8055‐T panel an...

Figure 12.8 Example of changing a reference system in a CNC program and work...

Figure 12.9 Example of linear movements in a lathe. Units in mm.

Figure 12.10 Meaning of codes G02 and G03 according to the use of G17, G18, ...

Figure 12.11 Example of circular movements and the use of G02 and G03. Units...

Figure 12.12 (a) Positions of the cutting tools in a lathe turret; (b) X, Z ...

Figure 12.13 Machining error due to tool nose radius in contour turning oper...

Figure 12.14 Compensation functions in a lathe. G41 and G42.

Figure 12.15 Compensation of cutting tool radius on (a) G41 or (b) G42.

Figure 12.16 Special caution should be paid when the radius compensation is ...

Figure 12.17 Example of cutting tool radius compensation in milling. Note th...

Figure 12.18 Spindle rotation and commands M03 and M04 for different spindle...

Figure 12.19 Turning canned cycle with straight sections.

Figure 12.20 Rectangular pocket canned cycle.

Figure 12.21 (a) Radial passes should be approximately ¾ the cutter diameter...

Figure 12.22 Keep cutter constantly engaged.

Figure 12.23 (a) Climb milling (down milling); (b) conventional milling (up ...

Figure 12.24 Profile milling for mold cavities. Example of roughing and semi...

Figure 12.25 The final cut (5) shall be done in one vertical cut starting fr...

Figure 12.26 Specific strategies should be applied when drilling nonflat sur...

Figure 12.27 After each drilling cycle, retract the drill from the hole to e...

Figure 12.28 Steps for drilling a hole with different diameter sections.

Figure 12.29 Number of passes and depth of cut in external threading operati...

Figure 12.30 Steps for threading with machine taps.

Figure 12.31 Machined part for Exercise 1. Units in mm.

Figure 12.32 Machined part for Exercise 2. Units in mm.

Figure 12.33 Machined part for Exercise 3. Units in mm.

Figure 12.34 Machined part for Exercise 5. Units in mm.

Figure 12.35 Machined part for Exercise 6. Units in mm.

Chapter 13

Figure 13.1 Phases of APQP and some activities at the PPAP phase.

Figure 13.2 First article inspection (FAI). Example. Balloons. Units in mm....

Figure 13.3 Example of first article inspection (FAI) report. Units in mm.

Figure 13.4 Example of four types of processes according to their stability ...

Figure 13.5 Example of process stability analysis under a control chart.

Figure 13.6 Break‐even quality of the example.

Figure 13.7 A typical OC curve for a specific sampling plan.

Figure 13.8 The steeper the OC curve, the more discriminating the sampling p...

Figure 13.9 An OC curve with the AQL, LTPD, producer's risk

α

, and cons...

Figure 13.10 AQL is shown on a drawing in the form of a note. Units in mm.

Figure 13.11 Input data for sampling plan.

Figure 13.12 Results of the single and double sampling plan.

Figure 13.13 Representation of the conformity zone and uncertainty zone in t...

Figure 13.14 Dimension to be inspected. Exercise 10.

Chapter 14

Figure 14.1 Typical contribution of cost elements to the final selling price...

Figure 14.2 Definition of the selling price based on different cost terms an...

Figure 14.3 Overview of buy‐and‐make decision according to economic factors ...

Figure 14.4 Flow chart for “make‐or‐buy” decision process at operational lev...

Figure 14.5 Number of patches of the casting part and the core for pattern a...

Figure 14.6 Regrinding operation.

Figure 14.7 Example of cost estimation using SolidWorks Costing.

Figure 14.8 Online cost estimator website for plastic injection molding, die...

Figure 14.9 Template for estimating the cost components of a product.

Figure 14.10 Template for estimating the final profit of a product according...

Figure 14.11 Casting part for Exercise 6. Units in mm.

Figure 14.12 Casting part for Exercise 7. Units in mm.

Note:

Hole depth is 2...

Figure 14.13 Casting part for Exercise 8. Part (a) and printing time, grams,...

Guide

Cover Page

Table of Contents

Title Page

Copyright Page

Foreword

Preface

About the Companion Website

Begin Reading

Appendix 1: ISO Dimensional Tolerances

Appendix 2: Cutting Data

Appendix 3: AQL Tables

Index

WILEY END USER LICENSE AGREEMENT

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Manufacturing Process Planning

A Practical Approach for Mechanical Engineering

José V. Abellán-Nebot

Department of Industrial Systems Engineering and Design,Universitat Jaume I, Castellón, Spain

Carlos Vila Pastor

Department of Mechanical Engineering and Materials,Universitat Politècnica de València, Valencia, Spain

Héctor R. Siller

University of North Texas, Denton (Texas), USA

Copyright © 2025 by John Wiley & Sons, Inc. All rights reserved, including rights for text and data mining and training of artificial technologies or similar technologies.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey.Published simultaneously in Canada.

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Cover Design: WileyCover Image: © Nordroden/Shutterstock

Foreword

This book is intended to be a reference textbook for teaching manufacturing process planning at undergraduate and graduate courses in the fields of design, manufacturing, and mechanical engineering. Process planning refers to all the activities that should be carried out in a manufacturing company to produce a product given the 3D model or technical drawing from the design office. The book sequentially illustrates all the necessary steps and provides practical examples at each stage of the process.

The book is organized as follows: the first chapters cover the fundamentals of process planning, the information that comes from the technical drawings, and the documents that process planners should create to communicate the required operations at the shop‐floor level. Then, specific process planning tasks are explained and illustrated with practical examples. Some of these tasks are Selection of Manufacturing Processes, Process Planning in Sand Casting, Process Planning in Machining and Process Planning in Inspection. These four topics are detailed in different chapters and cover important activities performed in manufacturing companies. Fundamentals of casting, mold design, machining sequence identification, tool and parameter selection, geometric validation, CNC programming, and inspection reports are some of the key aspects that are reviewed throughout the book. Finally, manufacturing cost estimation and pricing are presented as the final activities performed by process planners to ensure a feasible and cost‐effective production.

The book also includes, as supplementary files, five practical computer sessions relating to manufacturing process selection, casting simulation, pattern design, and CNC simulation. In addition, a project proposal is included for instructors that may be interested in teaching the course using a project‐based approach. The project allows students to practice almost all of the concepts covered with in the book, using minimal workshop equipment found in most university facilities.

The authors of the book are recognized lecturers from the Universitat Jaume I (Spain), Universitat Politècnica de València (Spain), and the University of North Texas (United States), with more than 20 years of experience in teaching and research in the field of manufacturing.

The Spanish Society of Manufacturing Engineering (MES‐SIF, Sociedad Ingeniería de Fabricación) acknowledges the fine work presented and recommends the book as a reference textbook for courses related to manufacturing process planning, especially for those who wish to study in detail sand casting and machining process planning. The activities presented in the proposed manufacturing process planning project and the computer sessions provide a good practical view of process planning and orient the instruction to a more active learning approach where learning by doing is a keystone.

Lorenzo Sevilla Hurtado

Chairman of the Spanish Society of Manufacturing EngineeringApril 2024

Preface

We started to work on Manufacturing Process Planning in the 1990s in the field of concurrent and collaborative engineering. The thesis from Carlos Vila Pastor and Héctor R. Siller (Implementation Strategies of New Technologies in the Field of Concurrent Engineering 2001 and Collaborative Process Planning Model Applied to High Performance Machining of Hardened Steels Parts 2009) investigated process planning at different levels, paying special attention to machining process planning. In 2004, Abellan‐Nebot joined the research team to work on aspects more related to intelligent machining systems and computer‐aided manufacturing. Our research team has been always working on design and manufacturing practices, teaching topics such as integrated manufacturing, design for manufacturing, geometric product specifications, computer‐aided manufacturing, manufacturing process planning and manufacturing process and materials selection at the Universitat Jaume I (Castellón, Spain), Universitat Politècnica de València (Valencia, Spain), Instituto Tecnológico y de Estudios Superiores de Monterrey (Monterrey, Mexico), and The University of North Texas (Texas, United States).

This book is mainly based on the material and notes prepared since the end of the 1990s for the course Manufacturing Process Planning, a graduate course for industrial engineering at the Universitat Jaume I and the Universitat Politècnica de València, which was later updated for a fourth‐year course in mechanical engineering. Part of the material was first prepared by Professor Fernando Romero‐Subirón, Pedro Rosado‐Castellano, PhD, and Gracia M. Bruscas‐Bellido, PhD, who also contributed to reviewing and providing useful feedback to improve the current manuscript. All this previous material was completed during the last eight years of teaching Manufacturing Process Planning by José V. Abellán‐Nebot, PhD. During that period, active learning activities were prepared to motivate and engage the students in activities related to manufacturing process planning. A manufacturing process planning project was successfully applied and new material was prepared to cover CNC activities, inspection planning, computer sessions, and project activities. The positive performance and feedback from students were the spark that motivated us to prepare and share this book. With this book, the authors want to share the material on manufacturing process planning together with computer sessions and project activities with other engineers, students, and instructors around the world.

The result of the book is a self‐contained manual that presents all the steps required in manufacturing process planning, starting with the identification of key aspects from a technical drawing, moving through manufacturing process selection, detailed process planning for casting, machining, and inspection, and finally, costing and pricing the product.

For the instructors, the book is organized to let them apply a project‐based learning approach. Given a technical drawing and minimum laboratory equipment, the manufacturing process plan can be done by applying the contents learned in each chapter. For this purpose, the book provides as supplementary documentation with five computer sessions and one project description to let the instructors apply active learning practices in class.

The book is primarily intended to be useful to designers, mechanical and production engineers, and engineering students in general interested in learning the basics of process planning from a practical point of view.

The authors and publisher do not assume any responsibility with respect to the use of the information contained in this book.

April 2024

José V. Abellán‐Nebot, Carlos Vila Pastor, and Héctor R. Siller

About the Companion Website

This book is accompanied by a companion website.

www.wiley.com/go/Manufacturing_Process_Planning_1e 

This website includes:

Computer sessions 1‐52)

Process Planning Project

Part IFundamentals of Process Planning

1Introduction to Process Planning

1.1 Introduction

Manufacturing process planning involves figuring out the best way to make a product or component, from choosing the right materials and methods to determining the most efficient sequence of steps. The main goal of manufacturing process planning is to optimize the production process, making it cost‐effective while ensuring high‐quality results. In small manufacturing companies, process planning is still conducted by manual methods that rely on experienced process planners who apply their knowledge in design and manufacturing to produce efficient and cost‐effective process plans. More advanced manufacturing companies may utilize computer‐aided process‐planning (CAPP) systems to help in process‐planning activities, saving money, and making more efficient process plans.

In this chapter, an overview of the manufacturing process‐planning activities is presented, and the importance of these activities and the communication between design and manufacturing departments is highlighted to ensure competitive products in shorter lead times. The chapter briefly describes CAPP methods, whereas the manual methods are just schematically presented since this method is covered in detail throughout this book.

1.2 Process Planning Within Product Development Cycle

Process planning is the deliberate selection of the techniques needed to make a product affordable and competitive. Procedures, machine tools, and other equipment must be devised, chosen, and determined to transform raw materials into finished and assembled goods.

Process planning may be also considered as a bridge between product design and manufacturing, as illustrated in Figure 1.1. The initial steps of process planning coincide with the product design phase, involving decisions such as material selection and manufacturing methods such as casting, forging, or die casting. The formal endpoint for product design is marked by the release of all product data, usually in the form of three‐dimensional (3D) models and engineering drawings, which specify the precise product details. At this juncture, process planning takes charge, outlining the comprehensive manufacturing plan for each component of the product.

Figure 1.1 Traditional process planning deployment where machining operations are involved.

Process planning derives its input from 3D models or engineering drawings that detail what needs to be produced and in what quantity. These drawings are carefully scrutinized to determine the project's overall scope. For complex assembled products, considerable effort may be invested in breaking down the product into its constituent parts and subassemblies. Initial decisions regarding subassembly groupings, such as whether to manufacture certain parts or purchase them, as well as determining the general tooling requirements, may also be made. Subsequently, a detailed routing plan is developed for each part, requiring technical expertise in processes, machinery, and production economics. In essence, process planning translates the engineering drawing of a component into a group of manufacturing process steps, leading to the creation of a route sheet, which outlines the sequence of operations necessary for the component. The term “route sheet” is used because it also specifies the machines through which the part must pass to complete the sequence of operations (Kesavan 2009).

In the context of product design and manufacturing on a global scale, three key functions are involved: marketing and sales, design, and manufacturing. These functions traditionally follow a sequential process. Marketing assesses the contemporary market trends and requirements, creating new product concepts based on its findings. It also formulates specifications for the further enhancement of existing products, guided by market assessments. The design function utilizes these product concepts and specifications from marketing, providing a comprehensive overview of all parts and subassemblies required for the final product. This includes detailed 3D models, drawings, assembly plans, and bills of materials. The product requirements determined during the design phase are then assigned to the process‐planning team. This information serves as the basis for creating detailed work instructions needed for production, defining, in case the part should be manufactured in‐house, the manufacturing processes, the machine/equipment needed, tooling requirements, etc. These instructions are transferred to the manufacturing facility for production, as depicted in Figure 1.1.

Consequently, even though the design and manufacturing departments operate independently, the process‐planning activity serves as a connection between them, following a sequential approach. This sequential approach, traditionally utilized in product design and manufacturing, assumes a lengthy lifespan for the product with a consistent demand over an extended period. However, in current competitive global markets, this assumption often does not hold true. As a result, manufacturing organizations have explored ways to reduce the time required for product design and manufacturing, commonly known as time to market. Some organizations have prioritized organizational changes with the intention of forcing all the stakeholders to be involved in the whole product development cycle and fostering cross‐functional collaboration to expedite the design and manufacturing processes of their products. This method, based on the collaboration of cross‐functional teams, is commonly known as concurrent engineering. However, it can be found with other terms such as simultaneous engineering or integrated product development.

Unlike a sequential approach, commonly referred to as “over‐the‐wall engineering” since no bidirectional communication exists to ensure product performance and manufacturability, concurrent engineering can be seen as a cooperative approach where members from all stages are in continuous communication to improve product design and facilitate the subsequent stages of production (Figure 1.2). Some activities that may be found under a concurrent engineering approach are listed in the following:

Collaborate in the definition of product design specifications.

Choose the best design and manufacturing techniques to employ.

Propose modifications of geometrical specifications or relaxation of tolerances.

Evaluate the design's manufacturability and modify it accordingly.

Evaluate the assembly of the design to detect potential assembly issues and improvements.

Figure 1.2 Sequential engineering versus concurrent engineering.

Besides reducing time to market, the main benefits of applying concurrent engineering are reducing cost and increasing product quality and productivity. However, managing concurrent engineering is challenging, and it requires the commitment of all stakeholders, and very often some of them are reticent to multidisciplinary collaboration.

Regarding product and production costs, it is important to note that approximately 70% of the total cost of a product is determined during the design phase (Ullman 1992). However, some studies reduce this impact to 47% on average (Ulrich and Pearson 1993). This cost allocation is primarily influenced by material selection and the associated manufacturing methods. The remaining 30% is attributed to decisions made regarding the manufacturing process, such as the utilization of production equipment and tooling. Additionally, it is widely recognized that any modifications made to the product during later stages have a greater impact on production costs compared to earlier stages, and the time required to implement such changes is longer. Figure 1.3 shows the impact of product design on product cost and production cost in common manufacturing companies.

Due to these reasons, concurrent engineering should be considered a widespread practice within manufacturing companies to minimize lead times and decrease the overall costs associated with the final product.

1.3 Process‐Planning Levels of Detail and Activities

As stated earlier, process planning seeks to completely define the manufacturing processes, tools, process parameters, inspection methods, etc., required to manufacture a product according to the 3D models and technical drawings from the design office. Process planning can be conducted at different levels of detail defining four different types of process planning (ElMaraghy and Nassehi 2014): generic planning, macroplanning, detailed planning, and microplanning.

Figure 1.3 Impact of product design on product cost and production cost in common manufacturing companies.

Source: Adapted from Munro and Associates (1989).

Generic planning refers to rough process planning where only manufacturing process selection is conducted according to material, production volume, process capabilities, and cost. Macroplanning details the equipment selection related to manufacturing, assembly, and inspection, and defines the routing sheets, a document that shows the route of each part with the stations and equipment involved at each step. Detailed planning refers to specific information at each station about the sequence of operations, tooling, fixtures, etc. Finally, microplanning describes process and operation parameters, NC programs, inspection procedures (conformity zones, sampling strategy, etc.), working instructions, calculation of overall times and costs, etc., which ends with the documentation of operation sheets. Although a first analysis for a new product development starts with generic planning, a final microplanning will be required before production.

Many different process‐planning activities are required depending on the level of detail needed. For a complete process planning before production, the following activities are commonly conducted:

1.3.1 Interpretation of Product Design Data and Manufacturability

The initial stage in developing a process plan for any component involves referring to the product design data, mainly in the form of 3D models and engineering drawings. Interpreting the product data involves analyzing the part's geometry, dimensions, and correlated dimensional and geometric tolerances, as well as surface finish conditions and material specifications. Production information about lead time and production volume is also gathered.

A key analysis to be conducted at this step is a manufacturability analysis. Process planners should evaluate and propose design modifications that may reduce manufacturing costs and time. Practices related to design for manufacturing (DFM) and design for assembly (DFA) are applied for this purpose, and modification or relaxation of geometrical specifications and tolerances are also studied and shared with the design team.

1.3.2 Bill of Materials Analysis and Make‐or‐Buy Decision

Given the final 3D models and technical drawings, all components of the product are analyzed to decide which parts are going to be purchased from the market and which ones are going to be manufactured in‐house. Typically, if the part can be produced in‐house, a cost comparison between making versus buying is done. Assumptions are often required regarding factors such as expected capacity, demand patterns, waste, inventory levels, and fluctuations in material availability and affordability. After the make‐or‐purchase decisions are made, the bill of materials for the product is defined, including the make‐or‐buy nature.

1.3.3 Manufacturing Process Evaluation and Selection

After analyzing the technical drawings and deciding which parts are being manufactured in‐house, process planners can start to evaluate which manufacturing processes are more appropriate for producing the parts.

At this stage, the part material highly determines the manufacturing process selection. Thus, the process planner may engage in meaningful discussions with design engineers to reconsider the material selection. For example, some alloys are well‐suitable for casting or machining processes but are less adequate for forming processes. Note that these discussions are typically conducted at the design stage when cross‐functional teams work together.

Manufacturing process selection requires identifying both primary processes (e.g., casting, forging, rolling, extrusion, drawing, and bending) and secondary processes (e.g., machining, surface finishing, and joining/assembly processes) that are required for reaching part specifications under the constraints of production volume and production rate identified. For example, every manufacturing process and equipment possesses inherent capabilities when it comes to achieving a certain surface quality. Therefore, any process or machinery that cannot meet the specified surface quality requirements would either be eliminated beforehand in the selection process, or additional finishing operations would need to be incorporated.