In order for any company to remain competitive, there is a constant push to cut costs while keeping customers satisfied by providing quality,... Show moreIn order for any company to remain competitive, there is a constant push to cut costs while keeping customers satisfied by providing quality, robust products. While current methods for predicting the most cost effective manufacturing process have proven to offer a significant amount of utility for design engineers, the issue remains that for a cost estimation to be truly accurate, the component has to be completely or nearly completely designed, which could require a significant amount of upfront development time. The goal was to develop a design tool to predict the most cost effective process to manufacture a new component based solely on already available historical data and basic knowledge of the design requirements of the new part. This study focused on steel components that could be manufactured either as a fabrication or as a casting. Two real-world applications were studied from two separate industries, with each application being designed with each process. Common cost estimation techniques were used to develop models for predicting the cost for each component to offer insight for how the cost would be expected to vary with quantity. As a means of ensuring robustness and that each competing model was structurally equivalent, each model had to pass critical exceptional and fatigue load cases in FEA while also meeting predefined success criteria. Using the results from the structural analysis and cost estimation, a design tool was developed as a means of objectively predicting how a component with similar application requirements would most cost effectively be manufactured based on the desired quantity of parts that needed to be produced. By using historical information of similar components that have the possibility of being manufactured in more than one way, more effective and systematic decision making for how a new component should be manufactured was shown to be possible. A third, independent case study was also selected as a real world example from industry as a means of validating and assessing the sensitivity of the weighting used in the development of the design tool. This was used to further refine the tool for the use in analyzing future components. M.S. in Manufacturing Engineering, May 2017 Show less
