Optimization of the product and manufacturing process of an aluminum pulley for industrial air conditioning applications

Abstract

The optimization process encompasses several aspects related to the design within a manufacturing process. For this reason, it is extremely important that when optimizing a specific product, all the stages to which that product is subjected are taken into account. Only in this way will it be possible to achieve the final objective effectively and without unforeseen issues, minimizing potential failures in the manufacturing processes. The present work aims to describe the improvements that were made in the planning of the production process for an aluminum pulley used in the industrial ventilation and air conditioning sector, produced by the company Fundição Mademil, located in Nova Veneza in the Caravaggio Industrial District. Using the 3D modeling software SolidWorks®, it was possible to alter the design characteristics of the obsolete product and design a new model capable of withstanding the same working conditions, aiming for a lower process cost. The real gain for the company was not in the added value of the optimized product, as the manufacturing time and the item's weight remained very close to those of the obsolete product. The main justification for the optimization's approval was the time savings in the manufacturing stages. Therefore, the changes made to the manufacturing processes and the main differences between the products will be presented.