Near net shape technology: An innovative opportunity for the automotive industry

• Published in: Robotics and computer-integrated manufacturing 2008-12, Vol.24 (6), p.722-727
• Main Authors: Cominotti, R., Gentili, E.
• Format: Article
• Language: English
• Subjects: Flow; Forming; Near; Net; Process; Shape
• ISSN: 0736-5845; 1879-2537
• DOI: 10.1016/j.rcim.2008.03.009

Near net shape is an innovative concept in industrial manufacturing. The main focus of this technology is to produce parts, as near as possible close to their final shape and contour, implementing non-chipping techniques. In this way the manufacturing gives the possibility of a finished product with minimal cutting. Near net shape technology also generates the opportunity to reduce the productive steps for a given process chain. Both the above-mentioned characteristics have the same main goal: achieving cost reduction. This fundamental target incorporates several other advantages, such as: reduction of process variability, quality improvement in the finished product and the possibility to focus the design of mechanical devices on functional features, eliminating technical constraints imposed by the process. Based on these factors and in cooperation with the IWU Fraunhofer Institut of Chemnitz, the authors conducted a research regarding the manufacturing of an innovative automotive gear shaft, produced by applying near net shape processes. The goal of this study is to evaluate whether it is more convenient to produce the part implementing a traditional production chain or an innovative one, based on near net shape techniques. The first step was to locate the available technologies in order to produce the selected part. There are two alternatives: a traditional cutting manufacture, performed with a numerical control turning machine and a near-net-shape technique, characterized only by deformation processes. The next step was to detect the main differential costs between the two opportunities. Comparing technical data and information available in literature, the authors detected the main differential voices of cost: raw material, amortization, manpower and direct setup. In order to make the study more reliable, the authors assumed an actual industrial environment, featured by an annual demand of 400,000 pieces and a product lifetime cycle of 10yr. The evaluation led to the conclusion that the innovative manufacturing chain is more convenient.