Process selection methodology for near net shape manufacturing

This paper presents a new selection methodology that for the first time supports the identification of Near Net Shape (NNS) processes. The methodology, known as "Product, Geometry, Manufacturing and Materials Matching" (ProGeMa3), is composed of four steps, which aim to minimize raw material usage and machining by adopting a NNS approach. A key component of the methodology is the Process Selection Matrix (ProSMa) that associates a component's shape and production volume with its material requirements to reduce the number of candidate NNS processes. A final selection is then made from this shortlist by using fuzzy logic and considering other constraints and functional requirements. The ProGeMa3 selection process is illustrated by its application to an industrial component that resulted in changes to the processes used for its commercial manufacture. The ProGeMa3 and ProSMa presented in this paper aspires to be current and comprehensive for solid metallic components produced by casting, forging and additive technologies. However, ProSMa is also accessible as an open source resource available for other researcher to extend and adapt.