Reduction of Reworks and Rejections in Manufacturing of a Thin Walled Aerospace Component
P Mahesh Babu1 and
K Sreenivas2
1.M. Tech Student, Department of Mechanical Engineering, Krishna Chaitanya Institute of Technology & Sciences, Markapur – 523 316,
Prakasam District, A.P., India.
2.Professor, Department of Mechanical Engineering, Krishna Chaitanya Institute of Technology & Sciences, Markapur – 523 316, Prakasam
District, A.P., India.
Abstract—Nowadays rejection is a serious problem arising in every manufacturing industry. Due to this
reason the manufacturing industry is advancing into losses. There are many factors responsible
for rejection and reworks, such as human errors, machine errors, process planning. Machining
of thin-walled components has increasingly become a difficulty for manufacturers. Advanced
digital analyses have been developed by many researchers to model, predict and reduce errors
induced by machining processes. Moreover, today’s machining shop floors, characterized by a
large variety of products in small batch sizes, require flexible simulation tools that can be quickly
reconfigured. CAD/CAM systems play a vital role in design optimization and process optimization
of any component and helpful in reducing the rejections and reworks. Keeping in view the
above important aspect this project has been taken up for reducing the rejections to a minimum.
The aim of the project is to reduce rejection rate rework rate. The thin wall component taken for
this project is a missile shield. The missile shield protects the missile by covering the entire
body. The missile shield design and process planning are studied in detail. This project also
deals with development of manufacturing process plan of missile component (missile shield)
using CAM software (NX 7.5) which is exclusively CAM software used to generate part program
by feeding the geometry of the component and defining the proper tool path and thus transferring
the generated part program to the required CNC machine with the help of DNC lines. In this
project efforts are made to produce different process plans in CAM software by changing the
work holding systems, tool paths, cutting tools etc. Finally, recommending an optimum process
plan for manufacturing of the component.
Index Terms—NX-CAD, NX-CAM, Mandrel design, Manufacturing process plan, WHY-WHY
analysis, MORI SEIKI 4-axis turning machine
Cite: P Mahesh Babu and K Sreenivas, "Reduction of Reworks and Rejections in Manufacturing of a Thin Walled Aerospace Component," International Journal of Mechanical Engineering and Robotics Research, Vol.3, No.4, pp. 604-611, October 2014.