Published Paper Details:

In manufacturing, the goal is to produce components that meet the design specifications. The design specification ensures the functionality aspect. Spike support is used in a fourth-generation man-portable fire-and-forget anti-tank guided missile with tandem-charged heat warhead, developed and designed by the ISRAELI company and in service with some 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 that has been arising in every manufacturing industry. Due to this reason, the manufacturing sector 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 crucial role in design optimization and process optimization of any component and it is helpful in reducing the reworks and rejections. By considering the above important aspect, this project is taken up for reducing the rejections to the least values. The aim of the project is to reduce and maintain the rejection rate below six percent which was previously 9 percent and reduces and keep the rework rate below 10 percent which was previously 15%. Initially, the optimum cutting speed of the tool is 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 the NX-CAM software. Process optimization was also carried out by using the mandrel for a job holding to reduce damage to the component while machining operation is running.