SCENARIO
TEAM KART
IIT KHARAGPUR
OBJECTIVE
To propose a suitable
MANUFACTURING PROCESS
MATERIAL
to reduce the cost of K-2s uprights without
significant design
changes for an
annual volume of 25,000 vehicles.
SPECIFICATION OF UPRIGHTS
FRONT UPRIGHT
REAR UPRIGHTS
Cost of process
Material selection
Lead time of process
Reliability of the product
POSSIBLE PROCESSES
AFTER CONSIDERING MANY PROCESSES WE ARRIVED
AT THE FIVE MOST APPROPRIATE FOR THE
MANUFACTURING OF OUR UPRIGHTS. THEY WERE:
1.SAND CASTING
2. CNC MACHINING
3. WIRE EDM
4.FORGING
5.DIE CASTING
INITIAL
CAPITAL
INVESTMENT
SURFACE
FINISH
STRENGTH
LEAD
TIME
Scale of
production
Sand
casting
low
low
Low
high
small
CNC
machining
high
high
high
low
large
Wire EDM
high
high
high
high
small
Die casting
high
medium
medium
low
large
forging
high
high
high
low
large
no defects
Change in
homogeneity
no change
Longevity of dies.
lower
higher
strength
medium
high
Complexity of dies
Can be complex
Cannot be very
complex
Operating cost
lower
higher
DIE CASTING
PROCESS
After deciding upon the die-casting process
there are several decisions to be made
1.Choice of upright material and die casting
equipment
2.Choice of number of dies and die material
3.Die Design (Orientation and Cores)
4.Post casting processes
th
(ksi)
resistance
2XXX
27 to 62
poor
Yes
3XXX
16 to 41
good
No
4XXX
25 to 55
medium
5XXX
18 to 51
good
No
6XXX
18 to 58
good
Yes
7XXX
32 to 88
poor
Yes
High
melting
point metals like aluminium use
SERIES
(6061)
casting method.
NUMBER OF DIES
Cycle time for die casting is typically very short, ranging from
a few seconds to a minute.
Taking the upper limit of cycle time, the total time required to
manufacture 25,000 units of one upright is a mere 416 hours
and 40 minutes.
Since time is no constraint, we only need one set of dies per
upright.
DIE DESIGN
Design features
Two runners
Multiple water
channels for uniform
cooling
Thin zigzag air vents
(2mm wide and 0.2
mm high)
(only allows air to
pass)
Draft allowance in
cover is more than in
ejector
Ejector pad with 5
MACHINING
13.105 cm3
CUTTING
4.8 cm
DRILLING AND
TAPING
8 holes
RATE
PER CAR
TOTAL
2.78 kg
69500 kg
5.80 kg
145000 kg
8.58 kg
214500 kg
0.858 kg
21450
9.438 kg
235,950 kg
10%
$ 0.2921 per kg
$ 4 per kg
13.105 cm3
$ 2.757
$ 68,921
$ 37.752
$ 943,800
52.42 cm3
1310500 cm3
Cost of machining
$ 2.0968
$ 52420
holes
8 per upright
32
800000
Cost of Drilling
$ 11.2
$ 280000
cost of tapping
$ 11.2
$ 280000
Length to be cut
19.2 cm
480 m
Cost of cutting
$0.10 per cm
$ 1.92
$ 48000
Cost of dies
Total cost
$ 17.5314 per
$ 80,000
$ 70.1256
$ 1753141
CONCLUSION
Manufacturing process-
die casting
Material to be used
$ 8,347,750
$ 1,753,141
$83.47
$ 17.5314
Reduction in cost
$8,347,750 - $ 1,753,141 = $
6,594,609
THANK YOU