PPRSRsgGGAGEGAHAHGrgEEreeE-Unit-I & 2.ppt

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1. ME8793-PROCESS PLANNING AND COST ESTIMATION Mr.P.Prabhakaran Associate Professor Department of Mechanical Engineering

2. 2 Curriculum & Syllabus

3. 3 Curriculum & Syllabus

4. 4 Books & Lecture notes https:// www.youtube.com/watch?v=Om24w_EcWlE (IIT Guwahati) https:// nptel.ac.in/content/storage2/courses/105103023/pdf/mod5.pdf https://easyengineering.net/me6005-process-planning-and-cost-estimation / Process planning and Cost Estimation – Dr.V.Jayakumar , Lakshmi Publications

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6. A system in which raw materials are processed from one form into another , known as a product, gaining a higher or added value in the process and thus creating wealth in the form of a profit 6 Introduction-Manufacturing system

7. Inputs & Outputs 7

8. Manufacturing engineer is responsible for ensuring that the product is manufactured to the correct specification , at the lowest possible cost and completed on time 8 PROCESS PLANNING

9. Process planning  is a preparatory step before manufacturing Determines the sequence of operations or   processes  needed to produce a part or an assembly. This step is more important in job shops, where one-of-a-kind products are made. 9 PROCESS PLANNING

10. 10 PROCESS PLANNING - Definition

11. 11 PROCESS PLANNING

12. 12 PROCESS PLANNING-Design Manufacture Cycle

13. 13 PROCESS PLANNING-Design/Manufacture Interface

14. 14 PROCESS PLANNING-Activities

15. 15 PROCESS PLANNING-Activities

16. 16 Methods of Process Planning (Approaches to Process Planning)

17. 17 Traditional Approach

18. 18 Traditional Approach (Route sheet)

19. 19 Traditional Approach (Route sheet)

20. 20 Workbook Approach

21. 21 Computer Aided Process Planning (CAPP)

22. 22 Computer Aided Process Planning (CAPP)

23. 23 Computer Aided Process Planning (CAPP)

24. 24 Computer Aided Process Planning (CAPP)

25. P 25 Approaches of CAPP

26. 26 Retrieval CAPP Procedure

27. 27 CAPP Systems

28. Process is method of shaping, joining or finishing Selection of right manufacturing process is paramount important Selection is depends upon materials, size, shape, accuracy and no. of parts needed 28 PROCESS SELECTION

29. 29 Typical route sheet

30. 30 Typical route sheet

31. 31 Classification of Manufacturing methods

32. Material form Component size and weight Economic considerations Dimensional and geometrical accuracy Surface finish needs Batch size Production rate 32 Factors in Process selection

33. 33 Material and Process selection factors

34. Drawing interpretation Identification of critical process factors Comparison of potential manufacturing processes Selection of suitable process 34 Process selection methods (Steps in Process selection)

35. 35 Process selection method

36. 36 Process selection matrix

37. Material type Component size and weight Size of the machine Power of the machine Availability of tools Production rate 37 PRODUCTION EQUIPMENT AND TOOLING SELECTION

38. 38 Factors in equipment selection

39. 39 Steps in Machine selection

40. 40 Steps in Tooling selection

41. 41 CUTTING SPEED SELECTION

42. UNIT II PROCESS PLANNING ACTIVITIES Process parameters calculation for various production processes Selection jigs and fixtures election of quality assurance methods Set of documents for process planning-Economics of process planning- case studies 42 Unit-II

43. The three importañt process parameters to be calculated for each operation during process planning are: Cutting speed, Feed rate, and Depth of cut. Process Parameters Calculation

44. The feed rate of a machining operation is defined as the speed at which the cutting tool penetrates the workpiece . This is usually stated in mm/rev or mm/min 44 FEED RATE

45. 45 Selection of feed rate

46. 46 Selection of feed rate

47. 47 Selection of feed rate

48. The difference between the original surface and that being produced by the cutting tool. 48 DEPTH OF CUT

49. 49 Selection of depth of cut

50. A general definition is that the depth of cut can be defined as the difference between the original surface and that being produced by the cutting tool. 50 DEPTH OF CUT

51. 51 WORK HOLDING DEVICES

52. For many machining and assembly operations, general-purpose work holding devices may not be sufficient. Special work holding requirements are generally satisfied by designing and building special-purpose work holding devices known as jigs and fixtures. Components can be produced quicker; Greater repeatability of manufacture which subsequently reduces assembly time; Accuracy can be easily obtained and maintained; Unskilled or semi-skilled labour may be used on a machine, resulting in reduced manufacturing costs. 52 JIGS AND FIXTURES

53. 53 Jigs

54. 54 Fixtures

55. 55 Jigs vs Fixtures

56. Jig: A device that holds the work and locates the path of the tool. Fixture: A device fixed to the worktable of a machine and locates the work in an exact position relative to the cutting tool. 56 Definitions Superior Jig Flexible Fixturing Systems

57. Reduce cost of production. Increase the production. To assure high accuracy of parts Provide for interchangeability Enable heavy and complex parts to machine Reduced quality control expenses. Increased versatility of machine tool. Less skilled labour . Saving labour . Partially automates the machine tools Use improve the safety, accidents low 57 Uses of Jig and fixture

58. Sufficiently rigid bodies (plate, box or frame structure Locating elements. Clamping elements. Tool guiding elements. Elements for positioning or fastening the jig or fixture. 58 Elements of Jig and fixture

59. 59 Selection of Quality Assurance System

60. 60 Statistical Quality Control (SQC)-Tools

61. 61 Statistical Quality Control (SQC)-Tools

62. 62 Statistical Quality Control (SQC)-Tools

63. 63 Statistical Quality Control (SQC)-Tools

64. 64 Detection and Prevention Method

65. 65 Selection of Quality Assurance System

66. 66

67. 67 Problems

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