Reference no: EM132858535

Assessment - Quality control - ASCEND body panel manufacture

Assessment introduction

The structure of a material, and hence it‘s mechanical properties, is often sensitive to the temperature and pressure it is exposed to during manufacturing (as well as the times and rates that the temperatures and pressures are applied ). In addition, defects such as the surface finish and geometrical accuracy of a component are also sensitive to these variables. In any manufacturing process there are a number of factors related to the input material, equipment and/or tooling that can be controlled or varied, and understanding how these impact the final quality and properties of that component is vital to ensure that product requirements are met.

This assessment task focuses how the effects of design decisions and process steps can affect the the assembly of the ASCEND body panels. This type of problem is common when moving from the prototyping stage to the production staqe of manufacturing a component. Design and process decisions need to be assessed for all stages of the manufacture of a component, and this is happening currently for the ASCEND car and you may propose a solution that will be used for future designs and manufacturing steps for the car body panels.

Assessment background
You need to deliver a body panel for the ASCEND car. A colleague has selected a process and designed a panel for that process and had it made. Unfortunately they didn't document the decisions much and used an offensive snap filter in a Zoom meeting and have been let go at short notice. The design and prototype has gone well, but did they just get lucky? Or is it a robust design and the manufacturing method is ready to scale up and apply to all other panels.

The 3D printed parts are to be made using the MultiJet Fusion method, as it can create solid nylon parts wilh isotropic properties GoProto has been selected for this, who provide lots of information about the process here. Support ribs are water jet cut in the Deakin School of Engineering as per a .dxf cutting file.

Assessment specification

Students will be eepected to investigate and understand how manufacturing process decisions can affect the whole production line. The student should gain a basic understanding of how the process involved work, what variables can be controlled in the processes, and how each of these variables relate to final quality of the component (surface finish and dimensional accuracy). It is expected that students may need to do some literature/ independent research to fill in any gaps in their understanding to enable them to complete the report.

Students are welcome to discuss ideas and learnings amongst each other, however, the assignment must be written indivisually including the preparation of figures for the report. Students are welcome to share RAW resources (such as journal papers or relevant websites) that assist in preparing the report or justifying explanations.

Assessment requirements

Each student will submit their OWN report that should be approximately 2000 words and include :

i. A clear, accurate and brief explanation of how the manufacturing process works, including ;
a Process/Production Flow Chart (PFC) or Diagram (PFD) that clearly identifies the steps, inputs and equipment involved. This may also be in a table format.
b. Identification of what failures miqht occur at each process step, and if the failure is to be controlled in the design or while processing/assembling.
Identification of variables that may lead to the identified failure and that can be directly controlled by the operator to prevent defects.
c. Identification of each variable that can be directly measurecf by the operator of the equipment to defects.

2. From your answers above, go into more detail about how the variables that impact the two quality issues below in the manufacturing process, explaining how and why pressure/force, temperature and time aPect them, or if are they more affected by design and or equipment limitations (you will likely need to consult online or literature sources to be able to explain the mechanisms that cause these accurately);
•. Surface finish
. Dimensional accuracy.
•. Clearly identify and explain the reason behind the key processing limits relevant to the design and manufacturing processes selected that are based on:
. Limits of the material being processed
. Limits of the equipemnt being used

Attachment:- Doc.rar