Value Engineering Applied to Micro Components

Value Engineering Applied to Micro Components



Value engineering (VE) is an organized/systematic approach directed at analyzing the function of systems, equipment, facilities, services, and supplies for the purpose of achieving their essential functions at the lowest life-cycle cost consistent with required performance, reliability, quality, and safety.1 The implementation of the VE process on a problem typically increases performance, reliability, quality, safety, durability, effectiveness, or other desirable characteristics.Get more news about Micro Precision Cold Extrusion Part Exporter,you can vist our website!

As a manufacturing technique, cold heading (along with roll forming) offers multiple opportunities to meet the criteria of value engineering applied to a variety of micro applications. Let’s start by understanding what it is.

Cold heading is a technique of component manufacturing achieved by the application of force with a punch to a metal blank, typically a wire, staged in a die. This method of forming is achieved by force alone, forgoing the application of additional heat or cutting and shearing. Here are some of the benefits of the process.

Strength. The cold heading process compresses material rather than removing it. So instead of weakening the part as screw machining does, cold forming actually strengthens it. This can be a major consideration in components that require high durability or added integrity.

Cost. The per-piece cost of cold-headed parts is often an order of magnitude less than that of parts made by screw machining. This is due largely by virtue of the significantly higher throughput capabilities of cold-heading machinery, at 90–300 ppm versus 5–30 ppm (typical) for screw machining. This results in a much lower application of overhead to each part than for other processes. Cold forming machines run 24/7 with little supervision, repeatably producing high-quality parts over millions of impressions.

Another factor that contributes to cost savings is the virtual elimination of scrap and its associated cost for recycling material as well as lubricating oil. Cold forming is a net or near-net shape process that eliminates or severely limits scrap, reduces energy, labor, and recycling costs.
In the first VE example applied to micro-miniature components, a large component manufacturer was seeking to redesign a pressure regulator pin with the objectives of reducing cost and improving performance. The new design presented several challenges for manufacturability. First, the design of the valve seat limited the weight of the part, so to reduce weight, the material between the rubber seal and the spring had to be as thin as possible. Second, the rubber seal molded into the valve seat required compliance with a strict flatness specification of ±0.002 in. to ensure the rubber overmold retention ring provided precise and repeatable seating.