MECH 3582 A01: MANUFACTURING PLANNING AND QUALITY CONTROL

C.A.P.P. – PROCESS PLANNING

REPORT IV - (DUE FEBRUARY 9, 2011)
JASEN FULLANTE (#6842437) JUSTIN ALBO (#6842375) ARJUN KAUSHAL (#7668240)

DOCUMENT PREPARED FOR: PROFESSOR Q.PENG

DEPARTMENT OF MECHANICAL ENGINEERING
UNIVERSITY OF MANITOBA
 X4’

Z1’
Z2’
Z3’

Z3’’

X6’ X7’

X5’

2 1
Since the part is cylindrical we use pin and hole locating method. One end can be held in a three jaw chuck as it
centers automatically. The other end can be held with a pin specially when machining the longer end

We first machine the end 1 holding it from face till X4. The detailed process is discussed in third part of the

assignment. Once end 1 is finished the Part is flipped to machine the other end i.e.

Thus in the whole machining process the part is only flipped once. While machining the end we can hold it
by Z1 till T. The reason for so is discussed in the later part of the assignment.

For most surfaces the tolerance is default i.e. IT 10. However for face Z1 and the linear
dimension X1 to X4 the tolerance grade is IT 5 since the tolerance is + 0.2. This has been
deduced from the following table.

The shapes of the tools used can be decided

from the table shown.
2)Process plans:

As we decided we would start manufacturing the part from so the process plan for this would be as follows.

Also the datum planes would be

and X7 as these are the

edges already available to us.

Process Plan
Set up Sequence ID: 1
Datum plane ID: X7(linear
dimensions) Z ( radial
dimensions)

Clamping Face ID:

Machine: Lathe
 Cut of feed speed
Face Depth Xstart Xend Zstart Zend
(mm/rev (m/min) Tool
(mm) )
X4’
Semi rough
X7 4mm 0.4 95 X7 Z1’ D
turning (226mm)
200mm

X4
Diamond turning X4’ 2mm .05 135 X4’ Z1’ D
(230mm)
200mm

X5 Z1’ Z1
Diamond turning Z1’ 2mm .05 135 X4 D
(132mm) 144mm 140mm

X5 X7 Z1’ Z2’
Semi rough
X7 2mm .4 95 D
Turning (132mm) (0mm) 144mm 120mm

Rough turning for X5’ X5 Z2’ Z2

X5’ 5mm .4 105 R
Functional groove (122mm) (132mm) 120mm 100mm

X5’ X6 Z2’ Z2
Semi Rough
X5’ 2mm .4 95 D
turning (122mm) (82mm) 120mm 100mm

X6 X7 Z2’ Z3’
Semi rough
X6 2mm .4 95 D
turning (82mm) (0mm) 120mm 80mm

Semi rough
X6 X6’ Z3’ Z3
turning for X6 5mm .4 95 R
(82mm) (72mm) 80mm 60mm
Functional groove

X6’ X7 Z3’ Z3
Semi rough
X6’ 2mm .4 95 D
turning (72mm) (0mm) 80mm 60mm
 Semi rough 2mm .4 95 X7 X7’ Z3 Z3’’ S
turning X7 (0mm) (10mm)
For chamfering

Process plan

Set up Sequence ID: 2 T

Datum plane ID: X1(linear
dimensions) Z ( radial X1”
dimensions)
Clamping Face ID: Z1 till T
Machine: Lathe
Z1

Z1”
Z6”
 D’ D

Cut of feed speed

Face Depth Xstart Xend Zstart Zend
(mm/rev) (m/min) Tool
(mm)
Semi Z1’’
Rough 3mm .4 95 X1 X3 D
turning 140mm
200mm
Semi Z1’’ Z4
Rough 2mm .4 95 X1 X2’ D
turning Z1’’ 140mm 120mm
Just
Drilling X1 40mm According to the drill bit X1 D 0 enough for Drill bit
specifications boring tool
to enter

to be large enough so that the boring tool can enter it. We drill to a depth of D instead of X2. This gives us a clearance of 4mm for creating
 Cut of feed speed
Face Depth Xstart Xend Zstart Zend
(mm/rev) (m/min) Tool
(mm)
Diamond X1 D From
X1 36mm 0.2 130 Z5 V
Boring (0mm) (36mm) drilled hole

Counter X1 D’
X1 16mm 0.2 130 Z5 Z6 V
boring (0mm) (16mm)

Internal D X2 Reaming
Reaming 4mm According
0.4 to the Z5 Z5
of X2 reaming bit (36mm) (40mm) bit
specifications
 Internal of D’ X1 Reaming
Reaming 4mm According to the Z6 Z6
X1’ reaming bit Bit
(16mm) (0mm)
specifications
Semi
rough X2’ X2
turning
X2’ 2mm 0.4 95 Z1” Z4 S
(30mm) (40mm)
for
chamfering
Semi
rough X1 X1”
turning
X1 2mm 0.4 95 Z4 Z6” S
(0mm) (10mm)
for
chamfering

Rough According to the new

X3 10mm X3 X3’ -10 New tool
Chamfering tool specifications
200mm 190mm
Rough According to the new
X4 10mm X4 X4’ -10 New tool
Chamfering tool specifications
200mm 190mm

which can create a convex radial surface. We may have to use a new tool shape somewhat like what is given in the image below. The spec
 New tool
Proposed

R 10.00

3) Reason for selecting the above Parameters

Now since the material is given as Heat resistant steel we choose MI for the material specification from

Material classifications according to ISO 513

Since the default tolerance grade is IT 10 we have an option of choosing either of the two processes here:

Apart from face Z1 and length X1-X4 where the tolerance is of grade IT 5

Explaining the sequence for

The clamping face for this sequence would be

. The datum for linear dimensions is selected

as X7 as this end is going to be exposed while
machining. For radial dimensions datum would be
Z i.e. the central axis. It can be held in a three jaw

chuck at face from X1 to X4. We have to

create a tolerance of IT 5 grade at X4 so we can
use the semi rough cutting from X7 till let’s say
4mm before X4 i.e. X4’. From X4’ till X4 we turn
and remove material using diamond turning and
thus achieving the required tolerance grade. Similarly we can use a rough cut from 200 till 144 mm diameter
(Z1’). The last 4 mm from face X4 till X5 can be done by diamond turning to achieve the required tolerance
grade IT 5. So now the diameter is Z1 i.e. 140. After that the face from X5 till X7 can be turned and cut using the
rough turning till 120 mm is achieved. Then the functional grove of r 10 can be created on face X5 generating a
new surface X5’. The rest of cutting from X5’ to X6 can be done by again using rough or semi rough cutting. The
final diameter will now be Z2. Using the same
process the diameter will be brought to 80 mm
for X6 to X7. Again a functional grove of r 10 can
be created on face X6 generating a new surface
X6’. The remaining length of X6’ to X7 would be
turned and cut using the same rough or semi
rough turning. The final diameter would now be
Z3 i.e. 60 mm. At the end we would make the
chamfers at X7 using S tool by holding it inclined
at 45o. Thus the part is complete from one side.

Explaining the sequence for 2

The part is now flipped to machine 2 . The part

can now be held from Z1 till T. This is to allow some
clearance to machine the concave fillet at X4. Now
we begin by reducing to Z1” from X1 till X3. This is done by semi rough cutting. Similarly from X1 till X2’ the diameter
is reduced from Z1” till Z4. Now the process of creating the hole starts. For boring the holes we need to first drill a small
hole for boring tool to enter. We drill it only till D since some clearance has to be left for generating a perfect flat through
reaming since Boring can only finish the side walls not the base (shown in figure)
Thus first we enlarge the drilled hole to a diameter of Z5. Then we counter bore till D’( again for the same reason for
generating a flat. At the end We ream the flat surfaces to the required or better tolerance grade.
At the end we create the fillets at X3 and X4. The reason for suing a new tool has already been introduced earlier.