PROCESS PLANNING for metal cutting 1.ppt

process planning

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WHAT IS PROCESS PLANNING?
It is a function of scientifically and
systematically determining the best possible
method laying down an efficient sequence of
operations, selecting proper tools and
equipments, so that the end product can be
manufactured efficiently and economically,
conforming to the specifications laid in the
product design.

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PRODUCT CYCLE IN MANUFACTURING
PROCESS
ENGINEERING
TOOLING
DESIGN
MANUFACTURE
AND TRYOUT
MANUFACTURE
METHODS AND
WORKS
STANDARDISATION
PRODUCT
ENGINEERING
PRODUCT
REDESIGN
PURCHASING
TOOL, FIXTURE &
GAUGE DESIGNS
PRODUCTION
TOOLING
PRODUCTION
MACHINE TOOL
STANDARD TIME
OPERATION DRAWINGS
EQUIPMENT
SPECIFICATION
REDESIGN SUGGESTIONS
MODEL
TEMPLATES
PART MANF REQ
TOOLING
SPEC

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STEPS IN PROCESS PLANNING
1.CUSTOMER REQUIREMENT
2.DRAWING STUDY
3.MACHINE SELECTION
4.TIME ESTIMATION
5.TOOLS SELECTION
6.FIXTURE CONCEPTS
7.COSTING SHEET
8.CUSTOMER EXPECTATION

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PROCESS PLANNING MAINLY DEPENDS ON CUSTOMER
REQUIREMENTS, ANNUAL VOLUMES, QUALITY
REQUIREMENTS, ECONOMICAL FEASIBILITY.
DRAWINGS ARE ANOTHER METHOD OF UNDERSTANDING
CUSTOMER REQUIREMENTS AND THESE ARE THE MAIN
COMMUNICATION LANGUAGE FOR ENGINEERS. TIME OF
PRODUCTION DETERMINES THE CUSTOMER SATISFACTION,
COST, DELIVERY, SO TIME ESTIMATION OF
MANUFACTURING IS AN IMPORTANT JOB OF PROCESS
ENGINEER.
PROPER SELECTION OF MACHINES FOR ACCURATE
MACHINING AND TIME UTILISATION IS A MUST
REQUIREMENT.
PROPER TOOLS SELECTION FOR UNINTERRUPTED
MACHINING IS A MUST.
PROCESS OVERVIEW

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DIMENSION MEASUREMENTS AND QUALITY
CONFIRMATION NEEDS GUAGES.
INVESTMENT NEEDED TO MANUFACTURE A
PART IS THE BASIC REQUIREMENT AND THIS IS
DONE BY COST ESTIMATION.
A PROCESS ENGINEER MUST LOOK FOR
CONTINUOUS IMPROVEMENTS BASED ON
CUSTOMER REQUIREMENTS AND FEEDBACKS.

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PROCESS FLOW DIAGRAM

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INFORMATIONS FROM THE CUSTOMER
TO MAKE PROCESS PLANNING, MINIMUM
INFORMATION REQUIRED FROM THE CUSTOMER ARE
DRAWING, RELATED STANDARDS AND ANNUAL
REQUIREMENT
EXAMPLE:
DRAWING Hard copy / soft copy
RELATED STANDARDS TSG3200G, TSH5102G-C7
ANNUAL REQUIREMENTS 75000 pcs
ADDITIONAL
REQUIREMENT
To be checked for compressive
strength

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WHY ANNUAL VOLUME NEEDED?
TO DECIDE THE TIME FOR PART PRODUCTION .
IN OUR COMPANY WE USE TWO TERMS FOR TIME
TACT TIME
THEOREOTICAL CALCULATION TO DECIDE TIME NEEDED TO
PRODUCE A PART.
ANNUAL TIME FOR PRODUCTION
TACT TIME = -----------------------------------------------------
------= -----SECS.
ANNUAL REQUIREMENT IN NOS
EX: TACT TIME OF SSL = ( 445*2*360*0.85*0.98*60) /
(168000)
TACT TIME = 80 SECS.
CYCLE TIME
IT IS THE ACTUAL TIME USED IN SHOPFLOOR TO PRODUCE
THE PART. IF THE CYCLE TIME AND TACT TIME WILL MATCH
THEN THE PRODUCTION EFFICIENCY WILL BECOME 100%.

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Drawingstudy
A drawing is the principal document which contains
the manufacturing specifications for a part or
component, as determine by the product engineer.
The main information contained in these drawings are:
Type of material required.
Geometric shape and dimension of the part.
Tolerances, i.e., prescribed permissible deviations
from basic dimension.
Geometrical accuracy desired.
Required surface finish on surfaces to be machined.

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Method of machining to be employed to achieve
required surface finish.
Surfaces or areas to be heat treated and the type of
heat treatment to be given.
Location and types of surface coatings to be given, if
needed.
Specific inspection requirements and methods, if
needed such as ultrasonic testing, hydraulic testing,
leak testing etc.
Bill of material.(incase of assembly drawings)

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RAW MATERIAL PROCESSES
CASTING FORGING
EXTRUSION
INJECTION MOULDING
ROLLING
SHEET METAL PRESS
DRAWING
POWDER
METALLURGY

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Selection of machine tool
A process planner has to decide machine tool to perform the
operations conforming to manufacturing specifications. Some
of the factors to decide machine tool are categorized as:
Availability of the machine tool.
How much output is required over a period of time
Capacity of the machine tool to give required output.
Work piece material, its shape and size.
Required accuracy and surface finish on the work piece.
Power required by the machine to do particular operation
is sufficient or not?
Ease and convenience in operating the machine tool.
Operational performance, as to whether it is economical or
not.

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The machine tool capacity that guarantees the required
output within the stipulated time is, therefore, a vital factor
influencing The selection of the machine tool. Example
General purpose machine tools:
These will suit best for production of small quantities,
because of their large versatile in handling variety of
operations.
Special purpose machine tools:
These machine tools are very much helpful in large scale
Production, because their employment leads to substantial
saving of Production cost and time.

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SELECTION OF MACHINE TOOL
A process planner has to decide machine tool to perform
The operations conforming to manufacturing
specifications. Some of the types are as below
TYPES OF MACHINE TOOLS
CNC TURNING
CENTRE
DRILLING
VMC
GRINDING
HMC
MILLING
SPM
BROACHING
MACHINE TOOLS

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DIFFERENT MACHINE SPECIFICATIONS
CNC TURNING CENTRE:
I.CAPACITY: RANGE
1.SWING OVER BED ¢ 500 ~ 700 mm
2.SWING OVER CARRIAGE ¢ 300 ~ 500mm
3. DISTANCE BETWEEN CENTRES UPTO 1000mm
4. MAXIMUM TURNING DIA 500 ~ 800mm
5. MAXIMUM TURNING LENGTH UPTO 1000 mm
II. MAIN SPINDLE
1.SPINDLE NOSE A2 –6
2.BORE THROUGH SPINDLE UPTO 100 mm
3.BAR CAPACITY UPTO 80~100 mm
4.CHUCK SIZE UPTO 300 mm
III. SPINDLE DRIVE
1.SPIDLE MOTOR RATED POWER 11/15 KW (CONT/30 min RATING)
2.SPEED RANGE 50 ~ 4000 RPM
IV. AXLE SLIDES
1.Z AXIS STROKE 600~1000 mm
2.X AXIS STROKE 200~500 mm
V. TAIL STOCK VI. TURRET
VII. WEIGHT VIII. DIMENSIONS

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VERTICAL MACHINING CENTRES:
I.SPINDLE : RANGE
1. POWER 5 ~10 KW
2. SPEED 40~10000 RPM
3. TOOL HOLDER TAPER BT40, BT50
II.TRAVERSE :
1.X AXIS 500~1000 mm
2.Y AXIS 400~600 mm
3.Z AXIS 400~600 mm
II.AXIS DRIVE
1.FEED RATES 1~10000mm/min
2.RAPID TRAVERSE 10~20m/min
III.TABLE
1.CLAMPING AREA 400X710 etc IN mmXmm
2.NO/WIDTH/CD OF T SLOT 3/18/125 OR 5/18/100 NO/mm/mm
3.SAFE LOAD 300 ~ 1000 KG
4.DIST FROM SPINDLE TOP TO FACE 100 ~ 500 mm
IV.ACCURACY
1.POSITIONING ±0.006 mm
2.REPEATABILITY ±0.004 mm
V.INSTALLATION DATA
1.MACHINE WEIGHT 3000~10000KG
2.POWER SUPPLY 415V,50Hz,3PHASE

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HORIZONTAL MACHINING CENTRES:
I.SPINDLE : RANGE
1. POWER 5 ~10 KW
2. SPEED 40~10000 RPM
3. TOOL HOLDER TAPER BT40, BT50
II.TRAVERSE :
1.TABLE (X AXIS) 500~1000 mm
2.SPINDLE(Y AXIS) 400~600 mm
3.SPINDLE(Z AXIS) 400~600 mm
II.AXIS DRIVE
1.FEED RATES 1~10000mm/min
2.RAPID TRAVERSE 10~20m/min
III.INDEX TABLE
1.PALLET TABLE SIZE 320X320 mmXmm etc
2.LOAD CAPACITY 250~400 KG
3.MAX JOB SWING 500 KG
4.INDEX POSITIONS 1
O
X 360
IV.ATOMATIC TOOL CHANGER
1.NO OF TOOLS 20 ~ 32 NOS
2.MAX TOOL DIA 80~100 mm
3.MAX TOOL LENGTH 250~300 mm
4.TOOL CHANGE TIME 4 secs

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DIFFERENT TOOL MATERIALS
TOOL MATERIALS
HIGH SPEED
STEEL
CARBON TOOL STEEL
CARBIDES
COATED
CARBIDES
CERAMICS
DIAMOND
CUBIC BORON
NITRIDE

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N
O
PROCESS PREPARAT
ORY
PROCESS
TOLER
ANCES
IN mm
SURFACE
FINISH IN
MICRONS
PROD VOL
PER HOUR
TOOLIN
G COST
1TURNING ±0.020 1.5 60 MEDIUM
2 BORING DRILLING±0.025 1.5 60 LOW
3INTERNAL
THREADING
BORING ±0.075 3.0 100 MEDIUM
4EXTERNAL
THREADING
TURNING±0.075 3.0 100 MEDIUM
5DRILLING +0.125/-
0.050
3.0 60 LOW
6REAMING DRILLING
BORING
±0.015 1.5 125 LOW
7MILLING ±0.02 2.0 40 MEDIUM
8GRINDING TURNING
MILLING
±0.005 0.4 75 MEDIUM
9BROACHING DRILLING±0.010 1.5 150 HIGH
COMPARATIVE EVALUATION OF THE MACHINING PROCESSES

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FIXTURE CONCEPTS
ANY FREE BODY HAS 12 DEGREES OF FREEDOM OF
MOTION. WHENEVER THE MACHINING IS PLANNED IT IS
NECESSARY TO PLAN THE ARRESTING OF ALL THESE 12
DEGREES OF FREEDOM TO ENSURE MECHANICAL
STABILITY OF THE COMPONENT ON THE FIXTURE.
X AXIS
Y AXIS
Z AXIS
12 DEGREES
OF FREEDOM
OF A CUBE

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CUSTOMER EXPECTATION
CUSTOMER NEEDS ARE VERY IMPORTANT. SO FOLLOWING
PARAMETERS GOVERNS AS PARTS ARE CONCERNED
QUALITY
COST
QUANTITY
BASED ON THIS PROCESS ENGINEERS WORK ON CONTINUOUS
IMPROVEMENTS IN MANUFACTURING FACILITIES AND
OTHER REQUIREMENTS.

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DRAWING STUDY
OF SSL

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TIME ESTIMATION SHEETOpn
No
Opn DetailsTool
No
Tool
Details
Cutting
Speed
V
Spind
le
spee
Feed/
tooth
Sz
Feed
/ rev
Sr
Feed/
minute
Sm mm
Cut
length
Cl
Cut
time
Ct
Tool
change
time
Air
cut
time
Pallet
Index
time
100
Turning, Bar
cutting &
Chamfering
- - - - - - - - - - - -
Centering &
Chamfering of
¢5mm. T01
¢2.5/¢6.3
C'Drill
12.5716000.100.10160 0.100.03
Drilling of ¢6.8
hole.
T02
¢6.8 long
drill
14.536800.060.0640.8 0.10
¢10 C'sink
T03
¢10 C' sink
drill 47.1315000.200.20300 0.10
¢5 Drilling
T04
¢5 carbide
drill 40.0625500.080.08191.25 0.10
¢4.8 long
Drilling T05
¢4.8 long
drill 49.7733000.100.10330 0.10
¢5 Reaming T06¢5 reamer9.986350.080.0850.8 0.10
¢6.8 Drilling
T07
¢6.8 Solid
carbide drill
80.0437460.070.07262.22 0.10
410
C'less
grinding Soft
stage
600OD Grinding
Material :
Hardness :
Total Time
310
TIME ESTIMATION SHEET
Component Name :
Part no :
Drawing No :
Machine :
No of setups :

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OPERATION DRAWING

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MEASURING GUAGESSl.No Unit/Price in Rs.
1
2
3
4
5
6
7
0
0
LIST OF GUAGES
Component Name : Shaft shift lever
Part no :
Drawing No :
Guage Details
Plate guage for ¢6.8 drill
Flush pin guage for 45±1
Special guage for 42±0.3
Total for 1 Set
Total for 2 Set
Special guage for 51±0.2
Go Nogo guage for ¢5 drill
Special guage for 21.8±0.3
Special guage to check symmetry

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4M condition
(Man machine Materials Method)
Process where the quality of the part can
not be assured with out destructive
methods /Process control
These process should be controlled
indirectly by 4m conditions set based on
the trials.
Example of these process : Induction
Hardening, Washing etc.

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THANK YOU