Rapid tooling route selection for metal casting using QFD–ANP methodology

Abstract

An integrated methodology using quality function deployment (QFD) and analytic network process (ANP) is proposed to determine and prioritize the engineering requirements of a cast part, based on the customer needs, for selecting and evaluating an appropriate rapid prototyping (RP)-based route for tooling fabrication. The QFD incorporates a planning matrix to translate the customer needs into measurable engineering requirements using a robust evaluation method based on ANP. Experimental data generated by carrying out benchmarking studies of widely used RP processes were used to facilitate assignment of relative weights in ANP. The methodology is demonstrated and validated with an industrial example of a separator body casting. It has proved to be a robust evaluation and decision-making tool for selecting appropriate tooling route for a given casting based on customer requirements.

Keywords:

• Casting
• Rapid prototyping
• Process selection
• Quality deployment function
• Analytic network process

Acknowledgements

The authors gratefully acknowledge the support and assistance provided by Shri U. Chandrasekhar, Rapid Prototyping Lab, Gas Turbine Research Establishment (GTRE), Bangalore, India in carrying out the case studies. This study was jointly supported by Department of Science and Technology, New Delhi, India and Indian Institute of Technology, Bombay. Special thanks are due to M. M. Akarte, R. G. Chougule, Nagahanumaiah and K. Subburaj, Indian Institute of Technology, Bombay, for their valuable suggestions and help during the research work.