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Chapter 40 
Product Design and Process Selection in a 
Competitive Environment 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
References to 
Textbook Topics 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Relative Cost of Repair at Stages of Product 
Development and Sale 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Average Life 
Expectancy for 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 
Various 
Products
Commercially Available Shapes of Materials 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cost per Unit Volume for Wrought Metals and 
Polymers Relative to Cost of Carbon Steel 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Approximate Ranges of Scrap Produced in Various 
Manufacturing Processes 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Example: Material Changes in Transport Aircraft 
Figure 40.1 Advanced materials in 
the Lockheed C-5A transport aircraft. 
(Note: FRP is fiber-reinforced 
plastic.) 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Capabilities for Minimum Part Dimensions 
Figure 40.2 Manufacturing process capabilities for minimum part dimensions. 
Source: After J. A. Schey. 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Dimensional 
Tolerances and 
Surface Finish 
Figure 40.3 A plot of achievable tolerance versus surface roughness for assorted 
manufacturing operations. The dashed lines indicate cost factors where an increase in 
precision corresponding to the separations of two neighboring lines gives an increase in 
cost for a given process (for a factor of two). Source: M. F. Ashby, Materials Selection 
in Design. Butterworth-Heineman, 1999. 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Dependence of Manufacturing Cost on 
Dimensional Tolerances 
Figure 40.4 Dependence of manufacturing cost on dimensional tolerances. 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Production Time as a Function of Surface Finish 
Figure 40.5 Relative production time as a function of surface finish 
produced by various manufacturing processes. (See also Fig. 26.34.) 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
General Characteristics of Manufacturing 
Processes for Various Metals and Alloys 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods of Making a Part 
Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy, 
(b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Two Methods of Making Dish-Shaped Sheet-Metal Part 
Figure 40.7 Two methods of making a dish-shaped sheet-metal part: 
(a) pressworking using a male and female die, (b) explosive forming 
using one die only. 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Relative Costs for 
Machinery and Equipment 
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. 
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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Ch40 design selection

  • 1. Chapter 40 Product Design and Process Selection in a Competitive Environment Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 2. References to Textbook Topics Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 3. Relative Cost of Repair at Stages of Product Development and Sale Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 4. Average Life Expectancy for Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Various Products
  • 5. Commercially Available Shapes of Materials Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 6. Cost per Unit Volume for Wrought Metals and Polymers Relative to Cost of Carbon Steel Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 7. Approximate Ranges of Scrap Produced in Various Manufacturing Processes Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 8. Example: Material Changes in Transport Aircraft Figure 40.1 Advanced materials in the Lockheed C-5A transport aircraft. (Note: FRP is fiber-reinforced plastic.) Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 9. Manufacturing Capabilities for Minimum Part Dimensions Figure 40.2 Manufacturing process capabilities for minimum part dimensions. Source: After J. A. Schey. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 10. Dimensional Tolerances and Surface Finish Figure 40.3 A plot of achievable tolerance versus surface roughness for assorted manufacturing operations. The dashed lines indicate cost factors where an increase in precision corresponding to the separations of two neighboring lines gives an increase in cost for a given process (for a factor of two). Source: M. F. Ashby, Materials Selection in Design. Butterworth-Heineman, 1999. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 11. Dependence of Manufacturing Cost on Dimensional Tolerances Figure 40.4 Dependence of manufacturing cost on dimensional tolerances. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 12. Production Time as a Function of Surface Finish Figure 40.5 Relative production time as a function of surface finish produced by various manufacturing processes. (See also Fig. 26.34.) Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 13. General Characteristics of Manufacturing Processes for Various Metals and Alloys Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 14. Methods of Making a Part Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 15. Two Methods of Making Dish-Shaped Sheet-Metal Part Figure 40.7 Two methods of making a dish-shaped sheet-metal part: (a) pressworking using a male and female die, (b) explosive forming using one die only. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
  • 16. Relative Costs for Machinery and Equipment Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.