Process Optimization of Spike Support Using Cam Software

Abstract

                In manufacturing, the goal is to produce components that meet the design specifications. The design specification ensures the functionality aspect. Next step to follow is to assemble these

Spike support  is used in a fourth generation man-portable fire-andforget anti-tankguidedmissile with tandem charged heat warhead, developed and designed by the Israeli company  and in service with a number of nations. As it is a missile component it should be light in weight at the same time strength should be more. Aluminum material is used for spike support due to its best material properties. Due to this thin wall thickness there is more chance of rejections and Reworks.

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, material errors etc.CAD/CAM/CAE 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 and maintain the rejection rate below 6 %which was previously 9% and reduce and maintain the rework rate below 10 %which was previously 15%.

                Initially the optimum cutting speed of the tool has been evaluated by doing the harmonic analysis in the CAE system using ANSYS software. Once the cutting speeds are determined, manufacturing process plan will be developed in CAM system using NX-CAM software. Process optimization was also carried out by using the Mandrel for job holding to reduce damage to the component while machining operation is running.