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.