Question 5 As the IKEA manufacturing engineer, your production team has been instructed to prepare for the production of stainless-steel wine bucket as shown in Figure 05. There are several options of manufacturing processes that could be used for the wine bucket production. Therefore, a brainstorming session was held to decide on the most appropriate manufacturing process for the bucket production. From the brainstorming session, five suggestions have been highlighted: Option A: Sand casting Option B: Deep drawing Option C: CNC machining Option D: Impression-die forging Option : High pressure die-casting a. Evaluate all five suggestions in term of the factors that affect the selection of manufacturing processes (25 marks) b. Recommend the most appropriate process that is suitable for both high and low production volumes of the wine bucket and justify your recommendation. Justify your recommendation and suggest TWO (2) advantages of the recommended process. (5 marks) Figure Q5 (No more than 800 words) [Total = 30 marks]

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Sand casting makes use of sand molds to form complex metal parts that can be made of any desired material composition.

Because the sand mold must be destroyed in order to remove the part, called the casting or the product which is to be made by achieving machining process.The metal from which the product is to be made is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern.

The sand mold separates along a parting line and the solidified casting can be machined to get the desired product.

Deep drawing process is a forming process which involves combination of tensile and compressive stresses.

A flat sheet metal blank is transformed into a hollow body with a smaller cross-section punch and die assembly.

CNC machining is a manufacturing process which uses computerized controls to operate machine and cutting tools to shape stock material into custom parts and designs product structures.

The fundamental principles of the CNC machining process remain largely the same throughout all of various types of machining processes.

In Die forging operation, two dies are brought together and the workpiece undergoes plastic deformation until its enlarged sides touch the side walls of the die.

A small amount of material begins to flows outside the die which is termed as flash of the material.Later the flash cools rapidly and helps build up pressure inside the bulk of the workpiece that aids material flow into unfilled impressions.

The material inside the die takes the shape of the pattern formed in the die along with the cavity so as to get the desired product shape with dimension accuracy.

Die casting can be referred as the combination of casting and die forging operation.

In this method proper die pattern is used and molten metal is poured into the die and under desired condition and pressure and temperature the product is produced.

The two most recommended processes for the desired product are:

Impressive die forging and it is one of the most widely used manufacturing process with high production capacity and least manufacturing cost involved.

CNC can be consider to be one of the best options since the human intervention in this methos is least and so the chances of errors are also least.

The time required for manufacturing per piece of product is minimum. Hence it is widely used manufacturing process for bulk manufacturing.


Machining operation is required are die forging since the surfaces obtained in this methos is not smooth and does not maintain desired high dimensional accuracy.

CNC operation involves machining which requires huge maintainence and cost.

So CNC machining is one of the costly process and requires proper maintenance .