Professional Documents
Culture Documents
Procedure of Process
Planning
To achieve the main economic
manufacture of the product, process
planning is done as follows:
The finished product is broken into
components of the product which forms a
basis for purchase of raw materials.
Prepare a bill of materials for all components
of the product which forms a basis for
purchase of raw materials.
Decide which parts are to be manufactured in
the plant and which parts are to be purchased
from the market depending upon the facilities
available in the plan.
1. Requirements and
conditions of the process
Before any problem can be solved, its
requirements and conditions must be
defined. In process planning, these things
include
The specifications of the finished product.
The size, shape and other properties of
the raw material.
The quantity or number of pieces of the
product to be made and date of delivery
2. Improvements of the
Specifications
All specifications must be clear and
explicit.
Faulty specifications include:
Overlapping dimensions
Omitted tolerances
Indefinite notations for surface finish quality
5. Selection of Equipment
Selection of equipment is closely related to
the selection of process of manufacture.
They usually represent long term capital
commitment.
The following factors are considered while
selecting the right equipment: Size and shape of the workpiece
The work material
The accuracy and surface quality required.
The quality of parts and the sizes of lots
required
Personal preferences.
Simulation
Two or more elements of an operation or
two or more operations are performed at
the same time.
For example, drilling a series of holes
simultaneously using a multiple spindle
drill head.
Integration
Several individual elements of an operation
or group of operations are combined in
succession but not simultaneously, the
performance is said to be integrated.
For example, hole must be drilled before it is
tapped.
Advantages of Combining
operations are: Improved accuracy
Reduced labor cost
Less tooling required
Less handling required
Fewer set ups
Less scrap
Fewer inspection points required
Disadvantages of combining
operations: Maintaining tool accuracy
Possible higher tool cost
More costly set ups
CAPP
Family Formation
Part family classification and
coding is based on
manufacturing features of the
part
Components requiring similar
processes are grouped into the
same family
All parts in a part family must
be related
Start
New/Ol
d
Component representation
module
1)Code Generation
2)Part geometry creation
(Design and manufacturing
attributes)
Semi-Generative Process
planning
The semi- generative approach is defined as a
combination of the generative and the variant,
where a pre-process plan is developed and
modified before the plan itself is used in a real
production environment.
This is similar to the generative approach, expect
that the final process plan and intermittent
stages of the generative process plan is
modified, or supplemented by a process planner
Modifying and process planner intervention is
small compared to the variant approach.
Manufacturing
Processes
Manufacturing process
Manufacturing processes are the steps
through which raw materials are
transformed into a product.
The manufacturing processes can be
broadly classified into three categories viz.
Shaping
Joining
Finishing
Shaping Process
The shaping processes are
referred to those that use a
certain raw material and shape
it to a final part.
Typical examples include,
Casting
Forming
Machining
Casting
In this process, metal is first heated in a
furnace until it melts and then the molten
metal is poured into a mold so that the
liquid metal takes the shape of the mold
cavity, which is the final shape of the part.
Once the liquid metal in the mold cavity
solidifies, the mold is broken or opened to
take the final part out of the mold cavity.
The metal casting process involves three
sequential steps: liquefying of metallic material by properly
heating it in a suitable furnace,
pouring of hot molten metal into a previously
made colder mould cavity,
extraction of the solidified cast from the mould
cavity
Forming
This involves use of mechanical forces
like compression, tension, shear or
combined forces to produce plastic
deformation to produce the required
shapes
It is broadly classified into two types: Hot Working Involves deformation above
recrystalization temperature
Cold Working Involves deformation below
recrystalization temperature
Examples include, forging, extrusion,
Machining
Machining is a manufacturing
process that involves removal of
the material from the workpiece by
means of appropriate machine
tools to obtain the required shape.
It is carried out on an already cast
or formed workpiece.
Examples include, turning, drilling,
milling and shaping.
Joining
It is concerned with the physical joining
of two pre-shaped parts to form a fully
functional product.
It is broadly classified into two types: Permanent joint
Non-permanent joint
Permanent joint
As the name suggests, this type of joint cannot
be removed or modified. Eg. Arc welding,
riveting, etc.
Non Permanent joint
These joints are not permanent and can be
removed or replaced at any time. Eg. Screw
and nut, turnbuckles, etc.
Finishing
These processes are concerned with
post-processing activities like polishing,
electro-plating, heat treatment, printing,
enameling, etc
They are done to improve the surface or
physical properties(hardness, corrosion
resistance, etc) of the finished product.
Selection of primary
manufacturing process
(rough
rules)
The following design factors have a
bearing on the choice of a
manufacturing process:
Quality
Complexity of form
Nature of material
Size of part
Section thickness
Dimensional accuracy
Cost of raw material, possibility of defects
and scrap rate
Subsequent processes
Forming
Forming
Forming
Forming
Forming
Forming
Forming
Forming
Forming
Forming
Selecting primary
manufacturing process
(
Refined
rules)
The quantity of parts is divided into low and
Code
Code
Code
Code
Code
Code
Mono
Very Complex
Open
Quantity
Quantity
Complex
Quantity
Quantity
<180> 1000
<150> 2000
<50>
1500
<100> 1000
Sand casting
Permanent casting
Die casting
Investment casting
Sand
Permanent
Die
Investment
Material
All
Almost all
Light
materials
Certain alloys
Size or
Weight
Any size
Upto 25 kg
Upto 10 kg
Upto 40 kg
Section
thickness
3 5 mm
minimum
2.5 mm
minimum
0.6 mm
minimum
0.75 mm
minimum
Accuracy
+ - 1.5 mm
+ - 0.4 mm
+ - 0.05 mm + - 0.12 mm
Surface
finish (um)
6.25 25
2.5 6.25
1 2.5
0.25 - 2
Tool costs
Low
Medium
High
High
Rolling
Extrusion
Swaging
forging
spinning
deep drawing
Bending (brake press)
Press work (power press, with progressive
Selecting of machining
process, tools and cutting
parameters
This is closely linked with the geometry of the
Blank
2. CNC turning of a
casting