Process and Operation Planning: Revised Edition of The Principles of Process Planning: A Logical Approach
Springer Science & Business Media, 2003 - Business & Economics - 335 pages
Process planning determines how a product is to be manufactured and is therefore a key element in the manufacturing process. It plays a major part in determining the cost of components and affects all factory activities, company competitiveness, production planning, production efficiency and product quality. It is a crucial link between design and manufacturing. In spite of the importance of process planning in the manufacturing cycle, there is no formal methodology which can be used, or can help to train personnel for this job.
Process planning is based on knowledge of manufacturing processes. But the practice depends on the experience and the skill and intuition of the planner. There is methodology so far, for a thorough analysis and optimization of the process plan which nearly always results in higher than necessary production costs, delays, errors and non-standardization of processes. Process planning is regarded as an art and not a science. Research in the field of process planning has indicated that all experts have their own expertise and one expert's experience might be different from that of another. It is rare, therefore, for two planners to produce the same process. Each process will produce the part as specified, although different processes will result in different processing times and costs.
The question is, who is an expert? By definition an expert is one 'having or manifesting the knowledge, skill and experience needed for success in a particular field or endeavor', or 'one who has acquired special skill in or knowledge and mastery of something'.
The book tries to systematize the process planning procedure. It provides number of decision steps to be followed in sequence and also presents algorithms for some of the steps.
The book tries to systematize the process planning procedure. It provides number of decision steps to be followed in sequence and also presents algorithms for some of the steps.
https://books.google.co.in/books?id=tcHxCAAAQBAJ - Preview
Table of Contents
1 Introduction.-
2 Assembly Planning and Design.
3 Process Planning and Design.
4 Technical Drawings.
5 Selection of Primary Production Processes.
6 Forming by Metal Removal.
7 Positioning Workpiece and Clamping.
8 How to Determine the Type of Operation.
9 How to Select Cutting Speed.
10 How to Select a Machine for the JOB.
11 How to Select Tools for a Job.
12 Hole Making Procedure.
13 Milling Operations.
14 SPC — Statistical Process Control.
15 Process Planning and Production Management.
https://books.google.com.pa/books?id=sllbhwlgGuAC
Process and Operation Planning: Revised Edition of The Principles of Process Planning: A Logical Approach
Portada
G. Halevi
Springer Science & Business Media, 2003 - 335 pages
Important points noted from Chapter 6 first
Contents Detailed list by sections (Rearrangement and formatting to be done)
1. Introduction
1 Introduction
1.1 The place of process planning in the manufacturing cycle 1
1.2 Process planning and the economic management of a company 3
1.3 Process planning and production planning 7
References
2. Technology and Methods
2.1 Process planning and production management 8
2.2 Process planning and simultaneous engineering 9
2.3 Integration of process planning and design 12
3 Summary 14
5 Further Reading 15
Manufacturing Systems Design and Analysis
B. Wu
Springer Science & Business Media, 2012 M12 6 - 421 pages
Handbook of Manufacturing and Supply Systems Design: From Strategy Formulations to System Operation
Bin Wu
CRC Press, 2001 M12 20 - 304 pages
2. Assembly Planning and Design
1 Introduction
Definitions 17
2.Why Assembly Planning
21 Assembly planning benefits 18
22 Design dilemma 19
23 Assembly dilemma 23
3. What is Assembly Oriented Planning
3.1 Definition
3.2 Assembly techniques
3.2.2 Automatic assembly 26
3.2.3 Robotic assembly 27
3.2.4 Comparing of robots/human and automation 28
4 Design Constraints for Assembly
411 Reducing number of components
412 Parts variation
414 Placing the component into a product
42 Fastening
414 Placing the component into a product
42 Fastening
421 Joining with no separate fasteners required
423 Joining requiring more than One Separate Fastener
5 Component Design for Placement
51 Component which is nearly identical on both sides
53 Components design for placement
6 Summary
7 Review Questions
Further Reading 39
1 From Design to Process Planning 41
21 Forming from Liquid casting molding 42
221 Rolling
222 Forging
224 Powder metallurgy and plastic molding
23 Forming from Solid by Material Removal
24 Forming by joining parts
26 Forming by material increase incress
31 Forming from liquid
311 Wall thickness
313 Corner radii
315 Support ribs
316 Bosses
32 Forming from solid by deformation forging
331 Bending Radii
5 Review
6 Further Reading
1 Drawing
1.1Dimensioning Dimensioning from datum
1.2 Redundant dimensioning
1.3 Stackup of tolerances by arithmetic method
1.4 Geometric tolerances
1.5 Geometric tolerances interpretation
1.6 Surface roughness
1.6.1 Definition of surface finish methods
2.1 Tolerancing in production
2.1.2 Production tolerancing
2.2 Tolerances in forming operations
3 Short Review of Statistical Tolerancing
3.1 Process Capability
4 Conclusion
5 Review Questions
6 Further Reading
2 Selecting Primary Process Category
21 Mono
Figure 2 Example of open shape type
23 Complex This shape consists of open parts but lateral features are allowed Fig 3
24 Very complex
31 Selecting among Forming from Liquid process
311 Example
312 Subsequent processes
32 Selecting Forming from solid by deformation process
321 Example 1
323 Subsequent processes
34 Forming by joining parts
35 Forming by assembly
36 Forming by material increase
4 Review Questions
5 Further Reading
1 Forming by Metal Removal
2 Decisions and Constraints
3 Basic Types of Material Removal Processes
4 Material Removal as a Subsequent Process
5. Auxiliary Tables
6 Review Questions
Basic Types of Material Removal Processes
The planner has the classify the shape as per part drawing to:
a. Round symmetrical
b. Prismatic
Above the basic shape there will be special features like holes, threads, slots, and flats.
Processes used for Round symmetrical parts: Turning, Grinding,
Processes used for Prismatic parts: Milling, Grinding
Holes: Drilling, Boring Reaming
Threads: Tapping, Thread Milling
Selection machining technology also is dependent on surface finish.
Turning provides surface finish in the range of 0.8 microns to 25 microns Ra.
Grinding provides surface finish in the range of 0.1 microns to 1.6 microns Ra.
A basic process is selected first. In case of round symmetrical parts, turning is the basic process. If the basic process does not meet the surface roughness specification, an additional machining process is to be added, in addition to the first basic process. Then check the geometric tolerances (for parallelism, perpendicularity, concentricity and angularity). If the last machining process meets the required geometric tolerances the job can be completed. If it does not meet the specification, one machining process has to be added.
When more than one machining process is used, part drawings have to be prepared for each one. The working drawing or operation drawings are needed because the material to be left for the subsequent process has to be clearly indicated. Also the cutting parameters will be different for each operation.
Some guidelines in multiple operations;
1. In the first basic process you can specify the maximum capability value of the process as surface roughness.
2. In case of external dimension, increase the tolerance specified by 10 times to match the surface roughness specified above.
http://www.cnctrainingcentre.com/cnc-turn/cnc-turning-surface-finish/
https://www.kennametal.com/in/en/resources/engineering-calculators/turning-calculators/surface-finish.html
https://www.meadinfo.org/2009/06/surface-finish-roughness-ra.html
Surface roughness/finish obtained in various machining operations from a machine design book
https://books.google.co.in/books?id=hKlfEB8tkcAC&pg=PA121#v=onepage&q&f=false
Machine Design
Jindal U. C.
Pearson Education India, 2010 - Electronic books - 892 pages
Machine Design is a text on the design of machine elements for the engineering undergraduates of mechanical/production/industrial disciplines. The book provides a comprehensive survey of machine elements and their analytical design methods. Besides explaining the fundamentals of the tools and techniques necessary to facilitate design calculations, the text includes extensive data on various aspects of machine elements, manufacturing considerations and materials.
https://books.google.co.in/books?id=hKlfEB8tkcAC
1 The Technical Functions of a Fixture
2 Three Datum Positioning Concept
2.2 Error causes and preventing caused by the fixture
3 Calculation of Clamping Positions and Clamping Forces
3.1.1 Three jaw chuck
3.1.2 Three jaws chuck without support
3.1.3 Three jaws chuck with center support
3.1.5 Chuck with fourjaw chuck independent
3.1.6 Faceplate
3.2 Chucking type on milling and drilling fixtures
4 Development of an Algorithm Simulating Design of a Fixture
5. Conclusions - Economic Considerations in Fixture Design
Jigs and Fixtures are built as an accessory to part processing and their function is to hold the part firmly in the machine.
5.1 Group technology methods GT
5.2 Modular Fixturing
The fixture is made up of standard building blocks assembled in a suitable manner. The blocks are disassembled after use and they are used in different fixtures.
5.3 Set up time reduction
Setup time reduction is important. Rotary tables allow machining of the four sides of a cube in one setup. Quick clamping devices, special eccentric cams, slotted bolts and hydraulic or pneumatic clamping etc. are available to design fixtures that reduce setup time.
6 Review Questions
7 Further Reading
1 Boundary Limit Strategy
Technical constraints are set as boundary limits, and then, bearing in mind economic considerations, working point within these limits are determined.
1.1 Definition of technological constraints
Metal cutting theory indicates, minimum and maximum values for depth of cut, feed rate and cutting speed.
1.2 Part specification constaints
1.3 Definition of material constraints
1.4 Definition of machine constraints
1.5 Definition of tool constraints
1.6 User specified constraint
1.7 Boundary limits summary
A large number of boundary value symbols are given based on the above constraints
2 Analysis of Cutting Conditions vs Part Specifications
2.1 Effect of cutting speed on surface roughness
2.2.1 Turning processes
2.2.2 Milling processes
2.3 Effect of depth of cut on surface roughness
3 Operational and Dependent Boundary Limits
3.1 Depth of cut as a function of feed rate
3.2 Depth of cut as a function of a selected operation
4 The Algorithm for Selecting Cutting Operations
5 Examples of Using the Algorithm
5.1 Example 1
5.2 Example 2
5.3 Example 3
6 Review Questions
1 Introduction
Cutting speed and time taken to do the machining are related as formula for turning machine time = (L/nf) and n is determined by the cutting speed and diameter of the work.
2 Source for Selecting Cutting speed
2.1 Machining data handbooks
2.2 Machinability ratings
2.3 Technical books
2.4 Tool manufacturers
2.5 Machinability computerized systems
3. Cutting Speed Optimization
3.1 Taylor equation
The cost data and Taylor tool life equation are used to find optimal tool life.
3.2 How effective is cutting speed optimization?
In the end, cutting speed decision is economic subject to technological constraint.
3.2.1 Tool life definition
ISO standard 3865 defines the values of tool wear.
3.2.2 Lot size effect
The cutting speed can be modified slightly so that if it is possible the tool life is equal to the batch size.
3.2.3 Economic cutting speed for machining a part
If possible the number of parts after which a tool has to be changed is made the same for all operations.
4 Data for the Extended Taylor Equation
Table 1 in the chapter gives coefficients for various parameters of the extended Taylor equation for 37 groups of materials.
5 Review Questions
1 Parameters to Consider
Consider the size of the workpiece and its accuracy demands and estimate the required parameters, especially the power.
2 Optimization Strategy Two Phase Method
In the first phase, a theoretical process is generated by considering all technical constraints. For each individual operation, the parameters have been defined; depth of cut, feed rate and cutting speed.
In the second phase, the theoretical operations are transformed from available facilities point of view. Now the operation is specified to comply with the available machine specification.
2.1 Definition of the combinatorial problem
2.2 Mathematical definition of the process planning problem
2.3 Solving the problem by dynamic programming procedure
3 Machine Constraints
3.1 Power and force adjustment
Power is a linear function of cutting speed and cutting forces.
Cutting force is a function of feed and depth of cut.
We can calculate the power required to do the job in minimum time subject to technological constraints. If power of the available machine is less, we have to modify cutting parameters.
It is more profitable to reduce cutting speed.
The power adjustment guideline:
If the power has to be reduced by less than 50%.
1. Reduce the cutting speed to its lowest value.
2. Reduce the feed to lower limit.
3. Reduce the depth of cut, take more passes and adjust feed upward as possible.
3.2 Maximum depth of cut constraint
Each machine has d.o.c. constraint. A d.o.c above this value will result in chatter. So d.o.c has to be reduced below this value and more cuts are to be taken.
3.3 Maximum torque constraints
Torque is obtained by multiplication of cutting force by radius of part or tool. Hence adjustment has to be done appropriately.
3.4 Machine accuracy constraint
Old machines may be used for roughing operations and finish cuts are taken better machines to achieve the required accuracy.
3.5 Spindle bore constraint
If spindle bore is less than the part diameter, the type of holding the work piece will be different from chucking. The allowable bending forces are to be calculated and cutting conditions are to be modified.
3. 6 Time and cost conversion
The optimization criterion can be either maximum production or minimum cost.
4 Preliminary Machine Selection
4.1 First step in machine selection
Selection based on type of machine and its physical dimension.
For round symmetrical work a lathe machine is required. In the first step exclude machines which cannot do the job.
4.2 Second step
Exclude machines who do not have even the minimum power to run a cutting pass on the job.
4.3 Third step in machine selection
In the third step calculate the time require to machine the part of cost incurred in doing the job.
5 Matrix Solution
A matrix is developed with operations as rows and machines that can be used as columns. The time taken is put in each cell.
51 Single machine solution
If the total of operations times on a single machine is less than than the total of the minimum for each machine plus transfer time, single machine solution may be selected.
52 General matrix solution
General matrix solution is required when multiple machines are to be used to complete the job. The dynamic programming method is used for it.
5.2.1 Upward phase
5.2.2 Downward phase
6 Conclusion
7 Review Questions
This chapter is covered in a separate article.
1 Parameters to Consider
2 Selecting Insert Shape and Toolholder Type
2.1 Selection of insert shape
2.2 Selecting the insert grade
3. Standards for Indexable Inserts
3.1 The first digit
3.2 The second digit
3.3 The third digit
3.4 The fourth digit
3.5 The fifth digit
3.6 The sixth digit
3.7 The seventh digit
4. Standards for Toolholders
4.1 The first digit
4.2 The second digit
4.3 The third digit
4.4 The fourth digit
4.5 The fifth digit
4.6 The sixth seventh eighth and ninth digits
4.7 The tenth digit
5 Review Questions
6 Conclusion
https://nraoiekc.blogspot.com/2020/05/selection-of-tools-and-toolholders-for.html
------------------
Important points are yet to be posted.
12. Hole Making Procedure
1 Introduction 231
2 Basic Technology Concepts 231
21 Process planning optimization strategy 231
2.1.1 First level optimization single hole 232
2.1.2 Second level optimization several holes on one center line 235
3 Tools for Hole Making 237
31 Twist drill TDD from solid 237
32 Insert drill TDD from solid 240
33 Solid carbide drill TDD from solid 241
35 Reamers TDD improve hole 243
36 Boring MDD improve hole 244
37 End milling TDD from solid and disk milling TDD improve hole MDD improve hole 246
371 Computation of machining time 249
4 Data for Computation
41 Computation of a min 250
43 Location tolerance 254
44 Operation diameter final decision 255
5 Example 256
51 A single hole from a solid rough hole 257
52 A single hole from a solid rough hole with location tolerance 259
53 Several holes on one center line 261
6 Review Questions 265
7 Conclusions 268
1 Machining Time 269
11 Tool diameter 271
12 Milling direction face milling
2 Cutting Forces and Power 274
22 Power constraints 277
3. Milling Pockets and Semi-Pockets
31 Selecting tool diameter 278
determining the tool path
4 Review Questions
1 Introduction
1.2 Goals and benefits of SPC
2 Basic Statistical Concepts
21 Probability of distribution
3 Prerequisites for SPC Process Capability
4 Control Charts
41 Control chart parameters selection
5 Interpreting Control Chart Analysis
6 Cause and Effect Analysis Troubleshooting
7 Review Questions
8 Further Reading
2 Process Planning Optimization
21 Single operation optimization 311
22 Part optimization 312
221 Part optimization deviation 313
23 Product optimization scheduling 314
231 combination scheduling 317
24 Maximum profit process planning 318
241 Profit for a single item 320
These stages are described in the following sections 242 Constructing Relative Total Period Profit Table
244 Setting Selling Price and Maximum Profit Routing 322
245 Testing the Algorithm Results 323
246 Summary 324
3. Resource Planning
31 Introduction
311 Step 1 Request for quotation 325
313 Step 3 Solving the matrix 326
314 Resource planning 327
315 Summary 329
Index 331
Extra - To be removed
Assembly Planning and Design 1 Introduction Definitions
17
21 Assembly planning benefits
18
22 Design dilemma
19
23 Assembly dilemma
23
31 Definition 32 Assembly techniques
25
322 A utomatic assembly
26
323 Robotic assembly
27
324 Comparing of robotshuman and automation
28
4 Design Constraints for Assembly
29
411 Reducing number of components 412 Parts variation
30
414 Placing the component into a product
31
42 Fastening 421 Joining with no separate fasteners required
32
423 Joining requiring more than One Separate Fastener
33
5 Component Design for Placement 51 Component which is nearly identical on both sides
34
53 Components design for placement
35
6 Summary
36
7 Review Questions
37
Further Reading
39
Process Planning and Design 1 From Design to Process Planning
41
21 Forming from Liquid casting molding
42
221 Rolling 222 Forging
43
224 Powder metallurgy and plastic molding
44
23 Forming from Solid by Material Removal
48
24 Forming by joining parts
49
26 Forming by material increase incress
50
31 Forming from liquid 311 Wall thickness
51
313 Corner radii
52
315 Support ribs
53
316 Bosses
55
32 Forming from solid by deformation forging
56
331 Bending Radii
57
5 Review
59
6 Further Reading
60
Technical Drawings 1 Drawing Dimensioning Dimensioning from datum 12 Redundant dimensioning
63
13 Stackup of tolerances by arithmetic method
65
4 Geometric tolerances
67
Figure 7 Terminology and symbols for geometric tolerances 15 Geometric tolerances interpretation
69
16 Surface roughness
72
161 Definition of surface finish methods
73
21 Tolerancing in production
75
212 Production tolerancing
76
22 Tolerances in forming operations
78
3 Short Review of Statistical Tolerancing
79
31 Process Capability
81
4 Conclusion
82
5 Review Questions
83
6 Further Reading
84
Selection of Primary Production Processes 1 Introduction
87
2 Selecting Primary Process Category
88
21 Mono
89
Figure 2 Example of open shape type 23 Complex This shape consists of open parts but lateral features are allowed Fig 3
90
24 Very complex
91
31 Selecting among Forming from Liquid process
92
311 Example
94
312 Subsequent processes
95
32 Selecting Forming from solid by deformation process
96
321 Example 1
97
323 Subsequent processes
98
34 Forming by joining parts 35 Forming by assembly 36 Forming by material increase 4 Review Questions
102
5 Further Reading
104
Forming by Metal Removal 1 Forming by Metal Removal
105
2 Decisions and Constraints
107
3 Basic Types of Material Removal Processes
110
4 Material Removal as a Subsequent Process
115
6 Review Questions
117
Positioning Workpiece and Clamping 1 The Technical Functions of a Fxture
123
2 Three Datum Positioning Concept
124
22 Error causes and preventing caused by the fixture
128
3 Calculation of Clamping Positions and Clamping Forces
131
311 Three jaw chuck Fig 11
132
312 Three jaws chuck without support
134
313 Three jaws chuck with center support
135
315 Chuck with fourjaw chuck independent 316 Faceplate 32 Chucking type on milling and drilling fixtures
136
4 Development of an Algorithm Simulating Design of a Fixture
137
51 Group technology methods GT
142
53 Set up time reduction
143
6 Review Questions
144
7 Further Reading
145
How to Determine the Type of Operation 1 Boundary Limit Strategy
147
Definition of technological constraints
148
13 Definition of material constraints 14 Definition of machine constraints
149
15 Definition of tool constraints
150
7 Boundary limits summary
151
21 Effect of cutting speed on surface roughness
152
221 Turning processes
153
222 Milling processes
156
23 Effect of depth of cut on surface roughness
158
31 Depth of cut as a function of feed rate
159
First Edition
Principles of Process Planning: A logical approach
G. Halevi, R. Weill
Springer Science & Business Media, 31-Dec-1994 - Technology & Engineering - 399 pages
Process planning determines how a product is to be manufactured and is therefore a key element in the manufacturing process. It plays a major part in determining the cost of components and affects all factory activities, company competitiveness, production planning, production efficiency and product quality. It is a crucial link between design and manufacturing. There are several levels of process planning activities. Early in product engineering and development, process planning is responsible for determining the general method of production. The selected general method of production affects the design constraints. In the last stages of design, the designer has to consider ease of manufacturing in order for it to be economic. The part design data is transferred from engineering to manufacturing and process planners develop the detailed work package for manufacturing a part. Dimensions and tolerances are determined for each stage of processing of the workpiece. Process planning determines the sequence of operations and utilization of machine tools. Cutting tools, fixtures, gauges and other accessory tooling are also specified. Feeds, speeds and other parameters of the metal cutting and forming processes are determined.
https://books.google.co.in/books/about/Principles_of_Process_Planning.html?id=AK6Y57fKv38C
Other Books
Updated on 21.9.2022, 25 December 2020, 17 July 2020
11 May 2020
423 Joining requiring more than One Separate Fastener
5 Component Design for Placement
51 Component which is nearly identical on both sides
53 Components design for placement
6 Summary
7 Review Questions
Further Reading 39
3. Process Planning and Design
1 From Design to Process Planning 41
21 Forming from Liquid casting molding 42
221 Rolling
222 Forging
224 Powder metallurgy and plastic molding
23 Forming from Solid by Material Removal
24 Forming by joining parts
26 Forming by material increase incress
31 Forming from liquid
311 Wall thickness
313 Corner radii
315 Support ribs
316 Bosses
32 Forming from solid by deformation forging
331 Bending Radii
5 Review
6 Further Reading
4. Technical Drawings
1 Drawing
1.1Dimensioning Dimensioning from datum
1.2 Redundant dimensioning
1.3 Stackup of tolerances by arithmetic method
1.4 Geometric tolerances
1.5 Geometric tolerances interpretation
1.6 Surface roughness
1.6.1 Definition of surface finish methods
2.1 Tolerancing in production
2.1.2 Production tolerancing
2.2 Tolerances in forming operations
3 Short Review of Statistical Tolerancing
3.1 Process Capability
4 Conclusion
5 Review Questions
6 Further Reading
5. Selection of Primary Production Processes
1 Introduction2 Selecting Primary Process Category
21 Mono
Figure 2 Example of open shape type
23 Complex This shape consists of open parts but lateral features are allowed Fig 3
24 Very complex
31 Selecting among Forming from Liquid process
311 Example
312 Subsequent processes
32 Selecting Forming from solid by deformation process
321 Example 1
323 Subsequent processes
34 Forming by joining parts
35 Forming by assembly
36 Forming by material increase
4 Review Questions
5 Further Reading
Important Points in the Chapters
-----------------------------------------6. Forming by Metal Removal
1 Forming by Metal Removal
2 Decisions and Constraints
3 Basic Types of Material Removal Processes
4 Material Removal as a Subsequent Process
5. Auxiliary Tables
6 Review Questions
Basic Types of Material Removal Processes
The planner has the classify the shape as per part drawing to:
a. Round symmetrical
b. Prismatic
Above the basic shape there will be special features like holes, threads, slots, and flats.
Processes used for Round symmetrical parts: Turning, Grinding,
Processes used for Prismatic parts: Milling, Grinding
Holes: Drilling, Boring Reaming
Threads: Tapping, Thread Milling
Selection machining technology also is dependent on surface finish.
Turning provides surface finish in the range of 0.8 microns to 25 microns Ra.
Grinding provides surface finish in the range of 0.1 microns to 1.6 microns Ra.
A basic process is selected first. In case of round symmetrical parts, turning is the basic process. If the basic process does not meet the surface roughness specification, an additional machining process is to be added, in addition to the first basic process. Then check the geometric tolerances (for parallelism, perpendicularity, concentricity and angularity). If the last machining process meets the required geometric tolerances the job can be completed. If it does not meet the specification, one machining process has to be added.
When more than one machining process is used, part drawings have to be prepared for each one. The working drawing or operation drawings are needed because the material to be left for the subsequent process has to be clearly indicated. Also the cutting parameters will be different for each operation.
Some guidelines in multiple operations;
1. In the first basic process you can specify the maximum capability value of the process as surface roughness.
2. In case of external dimension, increase the tolerance specified by 10 times to match the surface roughness specified above.
http://www.cnctrainingcentre.com/cnc-turn/cnc-turning-surface-finish/
https://www.kennametal.com/in/en/resources/engineering-calculators/turning-calculators/surface-finish.html
https://www.meadinfo.org/2009/06/surface-finish-roughness-ra.html
Surface roughness/finish obtained in various machining operations from a machine design book
https://books.google.co.in/books?id=hKlfEB8tkcAC&pg=PA121#v=onepage&q&f=false
Machine Design
Jindal U. C.
Pearson Education India, 2010 - Electronic books - 892 pages
Machine Design is a text on the design of machine elements for the engineering undergraduates of mechanical/production/industrial disciplines. The book provides a comprehensive survey of machine elements and their analytical design methods. Besides explaining the fundamentals of the tools and techniques necessary to facilitate design calculations, the text includes extensive data on various aspects of machine elements, manufacturing considerations and materials.
https://books.google.co.in/books?id=hKlfEB8tkcAC
7. Positioning Workpiece and Clamping
1 The Technical Functions of a Fixture
2 Three Datum Positioning Concept
2.2 Error causes and preventing caused by the fixture
3 Calculation of Clamping Positions and Clamping Forces
3.1.1 Three jaw chuck
3.1.2 Three jaws chuck without support
3.1.3 Three jaws chuck with center support
3.1.5 Chuck with fourjaw chuck independent
3.1.6 Faceplate
3.2 Chucking type on milling and drilling fixtures
4 Development of an Algorithm Simulating Design of a Fixture
5. Conclusions - Economic Considerations in Fixture Design
Jigs and Fixtures are built as an accessory to part processing and their function is to hold the part firmly in the machine.
5.1 Group technology methods GT
5.2 Modular Fixturing
The fixture is made up of standard building blocks assembled in a suitable manner. The blocks are disassembled after use and they are used in different fixtures.
5.3 Set up time reduction
Setup time reduction is important. Rotary tables allow machining of the four sides of a cube in one setup. Quick clamping devices, special eccentric cams, slotted bolts and hydraulic or pneumatic clamping etc. are available to design fixtures that reduce setup time.
6 Review Questions
7 Further Reading
8. How to Determine the Type of Operation
1 Boundary Limit Strategy
Technical constraints are set as boundary limits, and then, bearing in mind economic considerations, working point within these limits are determined.
1.1 Definition of technological constraints
Metal cutting theory indicates, minimum and maximum values for depth of cut, feed rate and cutting speed.
1.2 Part specification constaints
1.3 Definition of material constraints
1.4 Definition of machine constraints
1.5 Definition of tool constraints
1.6 User specified constraint
1.7 Boundary limits summary
A large number of boundary value symbols are given based on the above constraints
2 Analysis of Cutting Conditions vs Part Specifications
2.1 Effect of cutting speed on surface roughness
2.2.1 Turning processes
2.2.2 Milling processes
2.3 Effect of depth of cut on surface roughness
3 Operational and Dependent Boundary Limits
3.1 Depth of cut as a function of feed rate
3.2 Depth of cut as a function of a selected operation
4 The Algorithm for Selecting Cutting Operations
5 Examples of Using the Algorithm
5.1 Example 1
5.2 Example 2
5.3 Example 3
6 Review Questions
9. How to Select Cutting Speed
1 Introduction
Cutting speed and time taken to do the machining are related as formula for turning machine time = (L/nf) and n is determined by the cutting speed and diameter of the work.
2 Source for Selecting Cutting speed
2.1 Machining data handbooks
2.2 Machinability ratings
2.3 Technical books
2.4 Tool manufacturers
2.5 Machinability computerized systems
3. Cutting Speed Optimization
3.1 Taylor equation
The cost data and Taylor tool life equation are used to find optimal tool life.
3.2 How effective is cutting speed optimization?
In the end, cutting speed decision is economic subject to technological constraint.
3.2.1 Tool life definition
ISO standard 3865 defines the values of tool wear.
3.2.2 Lot size effect
The cutting speed can be modified slightly so that if it is possible the tool life is equal to the batch size.
3.2.3 Economic cutting speed for machining a part
If possible the number of parts after which a tool has to be changed is made the same for all operations.
4 Data for the Extended Taylor Equation
Table 1 in the chapter gives coefficients for various parameters of the extended Taylor equation for 37 groups of materials.
5 Review Questions
10. How to Select a Machine for the Job
1 Parameters to Consider
Consider the size of the workpiece and its accuracy demands and estimate the required parameters, especially the power.
2 Optimization Strategy Two Phase Method
In the first phase, a theoretical process is generated by considering all technical constraints. For each individual operation, the parameters have been defined; depth of cut, feed rate and cutting speed.
In the second phase, the theoretical operations are transformed from available facilities point of view. Now the operation is specified to comply with the available machine specification.
2.1 Definition of the combinatorial problem
2.2 Mathematical definition of the process planning problem
2.3 Solving the problem by dynamic programming procedure
3 Machine Constraints
3.1 Power and force adjustment
Power is a linear function of cutting speed and cutting forces.
Cutting force is a function of feed and depth of cut.
We can calculate the power required to do the job in minimum time subject to technological constraints. If power of the available machine is less, we have to modify cutting parameters.
It is more profitable to reduce cutting speed.
The power adjustment guideline:
If the power has to be reduced by less than 50%.
1. Reduce the cutting speed to its lowest value.
2. Reduce the feed to lower limit.
3. Reduce the depth of cut, take more passes and adjust feed upward as possible.
3.2 Maximum depth of cut constraint
Each machine has d.o.c. constraint. A d.o.c above this value will result in chatter. So d.o.c has to be reduced below this value and more cuts are to be taken.
3.3 Maximum torque constraints
Torque is obtained by multiplication of cutting force by radius of part or tool. Hence adjustment has to be done appropriately.
3.4 Machine accuracy constraint
Old machines may be used for roughing operations and finish cuts are taken better machines to achieve the required accuracy.
3.5 Spindle bore constraint
If spindle bore is less than the part diameter, the type of holding the work piece will be different from chucking. The allowable bending forces are to be calculated and cutting conditions are to be modified.
3. 6 Time and cost conversion
The optimization criterion can be either maximum production or minimum cost.
4 Preliminary Machine Selection
4.1 First step in machine selection
Selection based on type of machine and its physical dimension.
For round symmetrical work a lathe machine is required. In the first step exclude machines which cannot do the job.
4.2 Second step
Exclude machines who do not have even the minimum power to run a cutting pass on the job.
4.3 Third step in machine selection
In the third step calculate the time require to machine the part of cost incurred in doing the job.
5 Matrix Solution
A matrix is developed with operations as rows and machines that can be used as columns. The time taken is put in each cell.
51 Single machine solution
If the total of operations times on a single machine is less than than the total of the minimum for each machine plus transfer time, single machine solution may be selected.
52 General matrix solution
General matrix solution is required when multiple machines are to be used to complete the job. The dynamic programming method is used for it.
5.2.1 Upward phase
5.2.2 Downward phase
6 Conclusion
7 Review Questions
11. How to Select Tools for a Job
This chapter is covered in a separate article.
1 Parameters to Consider
2 Selecting Insert Shape and Toolholder Type
2.1 Selection of insert shape
2.2 Selecting the insert grade
3. Standards for Indexable Inserts
3.1 The first digit
3.2 The second digit
3.3 The third digit
3.4 The fourth digit
3.5 The fifth digit
3.6 The sixth digit
3.7 The seventh digit
4. Standards for Toolholders
4.1 The first digit
4.2 The second digit
4.3 The third digit
4.4 The fourth digit
4.5 The fifth digit
4.6 The sixth seventh eighth and ninth digits
4.7 The tenth digit
5 Review Questions
6 Conclusion
https://nraoiekc.blogspot.com/2020/05/selection-of-tools-and-toolholders-for.html
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Important points are yet to be posted.
12. Hole Making Procedure
1 Introduction 231
2 Basic Technology Concepts 231
21 Process planning optimization strategy 231
2.1.1 First level optimization single hole 232
2.1.2 Second level optimization several holes on one center line 235
3 Tools for Hole Making 237
31 Twist drill TDD from solid 237
32 Insert drill TDD from solid 240
33 Solid carbide drill TDD from solid 241
35 Reamers TDD improve hole 243
36 Boring MDD improve hole 244
37 End milling TDD from solid and disk milling TDD improve hole MDD improve hole 246
371 Computation of machining time 249
4 Data for Computation
41 Computation of a min 250
43 Location tolerance 254
44 Operation diameter final decision 255
5 Example 256
51 A single hole from a solid rough hole 257
52 A single hole from a solid rough hole with location tolerance 259
53 Several holes on one center line 261
6 Review Questions 265
7 Conclusions 268
13. Milling Operations
1 Machining Time 269
11 Tool diameter 271
12 Milling direction face milling
2 Cutting Forces and Power 274
22 Power constraints 277
3. Milling Pockets and Semi-Pockets
31 Selecting tool diameter 278
determining the tool path
4 Review Questions
14. SPC Statistical Process Control
1 Introduction
1.2 Goals and benefits of SPC
2 Basic Statistical Concepts
21 Probability of distribution
3 Prerequisites for SPC Process Capability
4 Control Charts
41 Control chart parameters selection
5 Interpreting Control Chart Analysis
6 Cause and Effect Analysis Troubleshooting
7 Review Questions
8 Further Reading
15. Process Planning and Production Management
1 Introduction2 Process Planning Optimization
21 Single operation optimization 311
22 Part optimization 312
221 Part optimization deviation 313
23 Product optimization scheduling 314
231 combination scheduling 317
24 Maximum profit process planning 318
241 Profit for a single item 320
These stages are described in the following sections 242 Constructing Relative Total Period Profit Table
244 Setting Selling Price and Maximum Profit Routing 322
245 Testing the Algorithm Results 323
246 Summary 324
3. Resource Planning
31 Introduction
311 Step 1 Request for quotation 325
313 Step 3 Solving the matrix 326
314 Resource planning 327
315 Summary 329
Index 331
Extra - To be removed
Assembly Planning and Design 1 Introduction Definitions
17
21 Assembly planning benefits
18
22 Design dilemma
19
23 Assembly dilemma
23
31 Definition 32 Assembly techniques
25
322 A utomatic assembly
26
323 Robotic assembly
27
324 Comparing of robotshuman and automation
28
4 Design Constraints for Assembly
29
411 Reducing number of components 412 Parts variation
30
414 Placing the component into a product
31
42 Fastening 421 Joining with no separate fasteners required
32
423 Joining requiring more than One Separate Fastener
33
5 Component Design for Placement 51 Component which is nearly identical on both sides
34
53 Components design for placement
35
6 Summary
36
7 Review Questions
37
Further Reading
39
Process Planning and Design 1 From Design to Process Planning
41
21 Forming from Liquid casting molding
42
221 Rolling 222 Forging
43
224 Powder metallurgy and plastic molding
44
23 Forming from Solid by Material Removal
48
24 Forming by joining parts
49
26 Forming by material increase incress
50
31 Forming from liquid 311 Wall thickness
51
313 Corner radii
52
315 Support ribs
53
316 Bosses
55
32 Forming from solid by deformation forging
56
331 Bending Radii
57
5 Review
59
6 Further Reading
60
Technical Drawings 1 Drawing Dimensioning Dimensioning from datum 12 Redundant dimensioning
63
13 Stackup of tolerances by arithmetic method
65
4 Geometric tolerances
67
Figure 7 Terminology and symbols for geometric tolerances 15 Geometric tolerances interpretation
69
16 Surface roughness
72
161 Definition of surface finish methods
73
21 Tolerancing in production
75
212 Production tolerancing
76
22 Tolerances in forming operations
78
3 Short Review of Statistical Tolerancing
79
31 Process Capability
81
4 Conclusion
82
5 Review Questions
83
6 Further Reading
84
Selection of Primary Production Processes 1 Introduction
87
2 Selecting Primary Process Category
88
21 Mono
89
Figure 2 Example of open shape type 23 Complex This shape consists of open parts but lateral features are allowed Fig 3
90
24 Very complex
91
31 Selecting among Forming from Liquid process
92
311 Example
94
312 Subsequent processes
95
32 Selecting Forming from solid by deformation process
96
321 Example 1
97
323 Subsequent processes
98
34 Forming by joining parts 35 Forming by assembly 36 Forming by material increase 4 Review Questions
102
5 Further Reading
104
Forming by Metal Removal 1 Forming by Metal Removal
105
2 Decisions and Constraints
107
3 Basic Types of Material Removal Processes
110
4 Material Removal as a Subsequent Process
115
6 Review Questions
117
Positioning Workpiece and Clamping 1 The Technical Functions of a Fxture
123
2 Three Datum Positioning Concept
124
22 Error causes and preventing caused by the fixture
128
3 Calculation of Clamping Positions and Clamping Forces
131
311 Three jaw chuck Fig 11
132
312 Three jaws chuck without support
134
313 Three jaws chuck with center support
135
315 Chuck with fourjaw chuck independent 316 Faceplate 32 Chucking type on milling and drilling fixtures
136
4 Development of an Algorithm Simulating Design of a Fixture
137
51 Group technology methods GT
142
53 Set up time reduction
143
6 Review Questions
144
7 Further Reading
145
How to Determine the Type of Operation 1 Boundary Limit Strategy
147
Definition of technological constraints
148
13 Definition of material constraints 14 Definition of machine constraints
149
15 Definition of tool constraints
150
7 Boundary limits summary
151
21 Effect of cutting speed on surface roughness
152
221 Turning processes
153
222 Milling processes
156
23 Effect of depth of cut on surface roughness
158
31 Depth of cut as a function of feed rate
159
First Edition
Principles of Process Planning: A logical approach
G. Halevi, R. Weill
Springer Science & Business Media, 31-Dec-1994 - Technology & Engineering - 399 pages
Process planning determines how a product is to be manufactured and is therefore a key element in the manufacturing process. It plays a major part in determining the cost of components and affects all factory activities, company competitiveness, production planning, production efficiency and product quality. It is a crucial link between design and manufacturing. There are several levels of process planning activities. Early in product engineering and development, process planning is responsible for determining the general method of production. The selected general method of production affects the design constraints. In the last stages of design, the designer has to consider ease of manufacturing in order for it to be economic. The part design data is transferred from engineering to manufacturing and process planners develop the detailed work package for manufacturing a part. Dimensions and tolerances are determined for each stage of processing of the workpiece. Process planning determines the sequence of operations and utilization of machine tools. Cutting tools, fixtures, gauges and other accessory tooling are also specified. Feeds, speeds and other parameters of the metal cutting and forming processes are determined.
https://books.google.co.in/books/about/Principles_of_Process_Planning.html?id=AK6Y57fKv38C
Other Books
Setup Planning for Machining
Manjuri Hazarika, Uday Shanker Dixit
Springer, 27-Nov-2014 - Technology & Engineering - 137 pages
Professionals as well as researchers can benefit from this comprehensive introduction into the topic of setup planning, which reflects the latest state of research and gives hands-on examples. Starting with a brief but thorough introduction, this book explains the significance of setup planning in process planning and includes a reflection on its external constraints. Step-by-step the different phases of setup planning are outlined and traditional as well as modern approaches, such as fuzzy logic based setup planning, on the solution of setup planning problems are presented. Three detailed examples of applications provide a clear and accessible insight into the up-to-date techniques and various approaches in setup planning.
Knowledge-Based Process Planning for Construction and Manufacturing
Carlos Zozaya-Gorostiza
Elsevier, 02-Dec-2012 - Business & Economics - 320 pages
Knowledge-Based Process Planning for Construction and Manufacturing describes a knowledge-based system architecture that is used to develop process planning systems called PLANEX.
This book explains that PLANEX is a domain-independent, knowledge-based process planning system architecture. Starting from a description of the physical artifact to be constructed or manufactured, PLANEX generates the set of activities used to create the artifact. These activities, with their required resources, are linked into a process planning network which can be used in project scheduling or management. This text also reviews the concepts, requirements, and resulting architecture of PLANEX, including detailed descriptions of applications of the system in construction and manufacturing.
This publication is recommended to engineers, architects, and specialists interested in construction and manufacturing process planning.
Process Planning Optimization in Reconfigurable Manufacturing Systems
Farayi Musharavati
Universal-Publishers, 2010 - Technology & Engineering - 200 pages
To date, reconfigurable manufacturing systems (RMSs) are among the most effective manufacturing styles that can offer manufacturers an alternative way of facing up to the challenges of continual changes in production requirements within the global, competitive and dynamic manufacturing environments. However, availability of optimal process plans that are suitable for reconfigurable manufacturing is one of the key enablers - yet to be fully unlocked - for realizing the full benefits of true RMSs. To unlock the process planning key and advance the state of art of reconfigurable manufacturing in the manufacturing industry, a number of questions need to be answered: (i) what decision making models and (ii) what computational techniques, can be applied to provide optimal manufacturing process planning solutions that are suitable for logical reconfiguration in manufacturing systems? To answer these questions, you must understand how to model reconfigurable manufacturing activities in an optimization perspective. You must also understand how to develop and select appropriate optimization techniques for solving process planning problems in manufacturing systems. To this end, Process Planning Optimization in Reconfigurable Manufacturing Systems covers: the design and operation of RMSs, optimal process planning modelling for reconfigurable manufacturing and the design and implementation of heuristic algorithm design techniques. The author explores how to: model optimization problems, select suitable optimization techniques, develop optimization algorithms, comparatively analyze the performance of candidate metaheuristics and how to investigate the effects of optimal process planning solutions on operating levels in manufacturing systems. This book delineates five alternative heuristic algorithm design techniques ─ based on simulated annealing, genetic algorithms and the boltzmann machine ─ that are tasked to solve manufacturing process planning optimization problems in RMSs. After reading this book, you will understand: how a reconfigurable manufacturing system works, the different types of manufacturing optimization problems associated with reconfigurable manufacturing, as well as the conventional and intelligent techniques that are suitable for solving process planning optimization problems. You will also be able to develop and implement effective optimization procedures and algorithms for a wide spectrum of optimization problems in design and reconfigurable manufacturing.
Modelling and Management of Engineering Processes
Peter Heisig, P. John Clarkson, Sandor Vajna
Springer Science & Business Media, 01-Jun-2010 - Technology & Engineering - 213 pages
Modelling for Business Improvement contains the proceedings of the First International Conference on Process Modelling and Process Management (MMEP 2010) held in Cambridge, England, in March 2010. It contains contributions from an international group of leading researchers in the fields of process modelling and process management.
This conference will showcase recent trends in the modelling and management of engineering processes, explore potential synergies between different modelling approaches, gather and discuss future challenges for the management of engineering processes and discuss future research areas and topics.
Modelling for Business Improvement is divided into three main parts:
1. Theoretical foundation of modelling and management of engineering processes, and achievements in theory.
2. Experiences from management practice using various modelling methods and tools, and their future challenges.
3. New perspectives on modelling methods, techniques and tools.
Based on the latest achievements in this and related fields, the editors aim to landmark the research map for modelling and management of engineering processes for 2020.
Construction Process Planning and Management: An Owner's Guide to Successful Projects
Sidney M Levy
Butterworth-Heinemann, 24-Sept-2009 - Technology & Engineering - 392 pages
By their very nature, construction projects can create seemingly endless opportunities for conflict. Written by a best selling author with over 40 years of experiences in the construction and general contracting business, Construction Process Planning and Management provides you with the necessary tools to save time and money on your construction project. In this book, Sid Levy provides valuable advice for avoiding or working through the common problems that are a result of the long-term nature of construction projects, failure to select a ?project delivery system? appropriate to the project, incomplete drawing and specifications, unrealistic scheduling, poor communication and coordination among participants, and inadequate contract administration. From project genesis, through design development to contractor and contract selection, on to construction oversight, punch list and successful project close-out, this book will point out those pitfalls to avoid and offer practical advice at every step along the way.
Administer the general construction process including solicitation of contractor's qualifications (pre-qualify bidders), comparative analysis of bid packages, recommendation for contract award, contract document negotiation and documentation of job change orders
Provide Project Planning and on-site management and coordination of all construction projects
Ensure compliance of building construction rules and regulations and collaborate with chief engineers to monitor quality of construction
Conduct technical/plan review of construction documents and submit written responses identifying required corrections or changes
Design, implement and oversee Company standards for construction policies, practices and processes
Integrated Product and Process Design and Development: The Product Realization Process, Second Edition
Edward B. Magrab, Satyandra K. Gupta, F. Patrick McCluskey, Peter Sandborn
CRC Press, 28-Jul-2009 - Science - 304 pages
Since the publication of the first edition of Integrated Product and Process Design and Development: The Product Realization Process more than a decade ago, the product realization process has undergone a number of significant changes. Reflecting these advances, this second edition presents a thorough treatment of the modern tools used.
Updated on 21.9.2022, 25 December 2020, 17 July 2020
11 May 2020
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