SEAS - HIGHER NATIONAL DIPLOMA

First semester HARMONIZED C.A.

2023/2024 Academic year

Department: Technology Option : MEM Level : 200

Course code/ Title: Manufacturing Analysis 1 Credit value: 4
Duration: 3 hours Date: __08_/11/2023 Venue: Examination Hall
Course Instructor(s) Engr. TUECHE FOSSI GABRIEL

QUESTION FILE

AUTHORISED DOCUMENTS
Handbook for standard tables (Memento du dessinateur) that carry no marks made by the candidate

CALCULATORS
Only the Non-programmable silent type pocket scientific calculators are allowed

NB. Before you start to treat any part of the paper, check to be sure that you have been given all the
related sheets (1/21 to 21/21

PRESENTATION OF THE PAPER

This paper has two parts:

 Elaboration of the manufacturing sequence;
 Study of phases.

The paper is equally made up of three files:

 Question file (Subject-matter): 1/21 to 2/21
 Technical file: 3/21 to10/21
 Answer file: 11/11 to 21/21

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SUBJECT
This study aims at manufacturing the Bushing, which Detail drawing and
Manufacturing drawing are represented on sheets 4/21 and 5/21 respectively.

MANUFACTURING HYPOTHESIS
 Production rate: 200 pieces per month for five (05) years without any
modification of shape or dimensions.
 Rough piece
 Production: Sand casting, D1 cored;
 Material: EN-GJL200

WORK REQUIRED
Working on sheets 12/21 to 21/21, establish the Draft Manufacturing
Sequence presenting, in a chronological order, the phases and surfaces to be
machined.

1- What is the role of the process office? / 2 marks

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2- Determine the IT of all the size tolerance dimension on the drawing. 7 marks

Nominal Maximum Minimum

Upper Lower
Size dimensio dimensio dimensio IT
limit limit
n n n
48f7

Ø28H7

Ø12H7

68h9

16±0.4

23.5±0.4

Ø56H8

3- Find the type of fit of the following Ø12H7p6. / 2 marks

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4- Interpret the following symbol: EN-GJL200 / 2 marks
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5- Briefly explain all the seven (7) geometric tolerances find on the drawing. / 7
marks

a-………………………………………………………………………………………………
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b-………………………………………………………………………………………………
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c-………………………………………………………………………………………………
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d-………………………………………………………………………………………………
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e-………………………………………………………………………………………………
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f-………………………………………………………………………………………………
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g-………………………………………………………………………………………………
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6- What is the nature of B2 , X1, D1, C2 and F2 surfaces. / 2.5 marks

Surface Nature

7- Using the Symbols for Normals Location (second part of the norms) table,
establish the isostatic positioning and location for the machining of D1, C2, and F2
surfaces. Use the drawing on page 7 (Manufacturing Drawing) / 5 marks
8- On the below dimension link graph page, do the classification of each size
dimension and geometric dimension according to the OX; OY and OZ direction /
3 marks

Presentation : / 0.5 marks

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 The end
TECHNICAL FILE

This file has 08 sheets numbered from 3/21 to 10/21

3/21 Presentation sheet of the file

4/21 Detail drawing

5/21 Manufacturing drawing

6/21 - Equipment/Tools available

- Table of the theoretical values of minimum value
- Table of interval of tolerance
7/21 -Table defining the number of minimum operations expected
-Rotational speed chart
8/21 Symbolisation of normal locations

9/21 Table of roughness values

10/2 International tolerance grades related to machining processes

1 Cutting speeds and feeds

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 6

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 DETAIL DRAWING

23.5

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 F5

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 EQUIPMENTS/TOOLS AVAILABLE

Machines tools Cutting tools

Tapping
Ref Designation Production accessories T1 Taps from M3 to M24
M1 Centre lathe - Three-jaw chuck Milling
M2 Capstan lathe - Four-jaw chuck T2 Side and face cutter
- Face plate
M3 Automatic lathe T3 Slab milling cutter
- Steadies
M4 Numerically controlled lathe - Carrier plate and lathe carrier T4 End mill
M5 Vertical milling machine - Expanding mandrels T5 Slot drill
M6 Horizontal milling machine - Vee blocks T6 Face milling cutter
- Angle plate
M7 Universal milling machine Turning
- Plain dividing head
M8 Pillar drilling machine - Universal dividing head T7 Knife tool
M9 Sensitive drilling machine - Rotary table T8 Broring tool
M10 Radial arm drilling machine - Plain vice T9 Bent facing tool
- Rotary vice
M11 Column drilling machine T10 Straight-nosed roughing tool
- Universal vice
M12 Plane grinding machine - Milling machine arbor T11 Threading tool
M13 Cylindrical grinding machine T12 Facing tool
M14 Planing machine Drilling
M15 Power band saw T13 Drills from Ø1 to Ø50
M16 Reciprocating power saw T14 Center drills
Control Instruments
Ref Designations Remarks Ref Designations Remarks
C1 Vernier caliper (1/50) C11 Taper plug gauge
C2 Vernier caliper (1/20) C12 Ring gauge
C3 Vernier caliper (1/10) C13 Snap gauge
C4 Micrometer calliper, 0-25, 1/100 C14 Thread plug gauge
C5 Steel rule C15 Thread ring gauge
C6 Micrometer depth gauge C16 Thread snap gauge
C7 Chamfer micrometer C17 Dial indicator with magnetic base
C8 Vernier depth gauge C18 Telescoping gauge
C9 Vernier protractor C19 Gauge blocks
C10 Double end cylindrical plug gauge C20 Roughness average test

TABLE OF THE THEORETICAL TABLE OF INTERVAL OF TOLERANCE

VALUES OF MINIMUM VALUE
1/2
Operations Mini Maxi Machining Rough finishing Finishing
Scalping on rough cut 1,5 to 4 Milling 0,5 0,2 0,05
Rough cut after scalping 0,5 Turning (on Ø) 0,5 0,2 0,1
Direct rough cut 1 Boring with tool (Ø) 0,4 0,15 0,06
Semi-finishing with tool 0,2 Form boring (Ø) 0,2 0,1 0,1
Finishing with tool 0,1 Drilling 0,2 0,1 0,1
Precision grinding 0,05 Planning 0,5 0,2 0,1
Super-finishing 0 0,05 Broaching 0,1 0,03 0,1
Grinding 0,2 0,05 0,1
Electro-discharge 0,2 0,05 0,02
machining

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 TABLE DEFINING THE NUMBER OF MINIMUM OPERATIONS EXPECTED
NUMBER OF OPERATIONS
TYPE OF FUNCTIONAL
PRECISION LEVEL 1 2 3 4
REQUIREMENTS
F R+F R + F/2 + F R+F/2+F+SF
IT > 0,4 X
INTERVAL OF 0,15 < IT ≤ 0,4  X
TOLERANCE (IT) 0,05 < IT ≤ 0,15  X
IT ≤ 0,05 X X
Q ≥ 12 X
Q = 9 – 10 - 11  X
IT/QUALITY (Q)
Q=7-8  X
Q≤6  X
Ra > 6,3 X
ROUGNESS (Ra) 3,2 ≤ Ra ≤ 6,3 X
Ra < 3,2 X X

CODING OF ELEMENTARY SURFACES R: Roughing F/2: 1/2 finishing F: Finishing SF: Super finishing
NUMBER OF ELEMENTARY OPERATIONS 1: F 2: R + F 3: R + F/2 + F 4: R + F/2 + F + SF
: Unnecessary application : Less frequent application X : Average application

ROTATION SPEED CHART

Cs m/min
250 dmm
160 500 400 320 200 160 125
100 80 63 50 40 32 25
20
125
16
100 12,5
80
10
63
8
50
6,3
40
5
32
4
25 3

20

16

12

10

N rev/min
40 63 100 160 250 400 630 1000 1600
50 80 125 200 320 500 800 1250

10

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 SYMBOLISATION OF NORMALS LOCATION

SYMBOLS FOR NORMALS LOCATION

(SECOND PART OF THE NORMS)
d- Technological type of element c- Nature of contact with piece

b- Nature of the surface a- Function of the technological element

a
Functions of technological Symbols Projected representation
elements
Centrings
Accurate positioning BLACK Triangle
Dimensioning start point
Definition of an axis
Support Complete Released
Blocking of the piece
WHITE
Pre-localisation Triangle
Opposition to deformation and vibration
b Nature of surface Symbol

MACHINED Surface (Single line)

ROUGH Surface (Two lines)

c Symbols indicating the nature of contact with the surface

Flat Serrated Curved Fixed Turning

touch touch touch point point

Articulation Released
Dish Vee
control touch

d Symbols of technological types of elements

Fixed support Concentric
clamping
System

Fixed centring Non-return

support
Clamping Reversible
s

system support

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 STANDARD DIMENSION CHART FOR HOLES AND SHAFTS

HOLES in microns
Fro 1 3 6 10 18 30 50 80 120 180 250 315 400
m to 3 6 10 18 30 50 80 120 180 250 315 400 500
+6 +8 +9 +11 +13 +16 +19 +22 +25 +29 +32 +36 +40
H6
0 0 0 0 0 0 0 0 0 0 0 0 0
+10 +12 +15 +18 +21 +25 +30 +35 +40 +46 +52 +57 +63
H7
0 0 0 0 0 0 0 0 0 0 0 0 0
+14 +18 +22 +27 +33 +39 +46 +54 +63 +72 +81 +89 +97
H8
0 0 0 0 0 0 0 0 0 0 0 0 0
+25 +30 +36 +43 +52 +62 +74 +87 +100 +115 +130 +140 +155
H9
0 0 0 0 0 0 0 0 0 0 0 0 0

SHAFTS in microns

Fro 1 3 6 10 18 30 50 80 120 180 250 315 400

m to 3 6 10 18 30 50 80 120 180 250 315 400 500
-6 -10 -13 -16 -20 -25 -30 -36 -43 -50 -56 -62 -68
f6
-12 -18 -22 -27 -33 -41 -49 -58 -68 -70 -88 -98 -108
-6 -10 -13 -16 -20 -25 -30 -36 -43 -50 -56 -62 -68
f7
-16 -22 -28 -34 -41 -50 -60 -71 -83 -96 -106 -119 -131
-2 -4 -5 -6 -7 -9 -10 -12 -14 -15 -17 -18 -20
g5
-6 -9 -11 -14 -16 -20 -23 -27 -32 -35 -40 -43 -47
-2 -4 -5 -6 -7 -9 -10 -12 -14 -15 -17 -18 -20
g6
-8 -12 -14 -17 -20 -25 -29 -34 -39 -44 -49 -54 -60
0 0 0 0 0 0 0 0 0 0 0 0 0
h6
-6 -8 -9 -11 -13 -16 -19 -22 -25 -29 -32 -36 -40
0 0 0 0 0 0 0 0 0 0 0 0 0
h7
-10 -12 -15 -18 -21 -25 -30 -35 -40 -46 -52 -57 -63

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 TABLE OF ROUGHNESS VALUES

Surface roughness values produced by common production process and materials

Process Roughness value, Ra (

25 6,3 1,6 0,4 0,1 0,025
50 12,5 3,2 0,8 0,2 0,05 0,0125
Flame cutting
Snagging
Sawing
Planning, Shaping
Drilling
Chemical milling
Electro-discharge machining
Milling
Broaching
Reaming
Boring, Turning
Barrel finishing
Electrolytic grinding
Roller burnishing
Grinding
Honing
Polishing
Lapping
Superfinishing
Sand casting
Hot rolling
Forging
Permanent mould casting
Investment casting
Extruding
Cold rolling, Drawing
Die casting

Key
Average application
Less frequent application
Note: The ranges shown above are typical of the processes listed.
Higher or lower values may be obtained under special conditions.

INTERNATIONAL TOLERANCE GRADES RELATED TO MACHINING PROCESSES

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 IT GRADES
4 5 6 7 8 9 10 11
Lapping & Honing
Cylindrical grinding
Surface grinding
Diamond turning
Diamond boring
Broaching
Powder metal-sizes
Reaming
Turning
Powder metal-sintered
Boring
Milling
Planning & Shaping
Drilling
Punching
Die casting

CUTTING SPEEDS AND FEEDS (TURNING)

HSS tools Carbide tools Ceramic tools

Material being
F Cs F Cs F Cs
turned
mm/rev m/mn mm/rev m/mn mm/rev m/mn
Steels 70<Rm<100 0.2 45 0.2 200
cutting speed with
a coefficient from
Same feed with

Steels 100 ≤ Rm 0.2 25 0.2 150

Carbide tools
carbides.

1.5 to 3.
Steels 100 ≥ Rm 0.1 20 0.2 120
EN-GJL 200 0.3 40 0.3 150
EN-GJL 400 0.2 18 0.2 55
EN-GJS 0.3 50 0.3 150
EN AC-AlCu5MgTi 0.2 600 0.3 850
EN AC-AlSi4Mg 0.3 450 0.3 700
EN AC-AlSi13 0.3 300 0.2 500
Cu Zn 0.2 250 0.3 300
Cu Sn 0.15 150 0.3 250
Z-Al4Mg 0.2 100 0.3 150

ANSWER FILE 14

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 This file has 12 sheets numbered from 11/20 to 21/21

11/21: Presentation of file;

12/21: Dimension link graph;
13/21: Table of elementary operations;
14/21: Table of association of surfaces;
15/21: Table of machining restrictions;
16/21: Table of machining levels;
17/21: Table for grouping of phases;
18/21: Draft of machining sequence;
19/21: Phase contract sheets
2021: Phase contract sheets
21/21: Transfer of dimensions sheet.

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 DIMENSION LINK GRAPH

Ox Direction

Oy Direction

Oz Direction

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 TABLE OF ELEMENTARY OPERATIONS

REFERENCE FUNCTIONAL EXIGENCES TECHNOLOGICAL EXIGENCES FUNCTIONAL OPERATIONS

SURFACE
√ IT OTHERS NBR SYMBOLISATION

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 TABLE OF ASSOCIATION OF SURFACES

SURFACES TO JUSTIFICATION NEW

BE DESIGNATION
ASSOCIATED Cutting tool Tool holder Others

Ex D10; F18; Multi- G0

A10 diameter drill

G1

G2

G3

G4

G5

G6

G7

G8

G9

G10

Example: The surfaces D10; F18; A10 are associated by the use of a multi-diameter
drill are subsequently designated G0 for the remaining part of study.

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 TABLE OF MACHINING RESTRICTIONS

RESTRICTIONS (CONTRAINTS)
Surfaces

Geometrical Technological Economic

Dimensional
Minor Finishing
∕∕ Forms Others Repeat Operation Burr
machining tool

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 TABLE OF MACHINING LEVELS
PREVIOUS TOTAL LEVELS

B F1E F1F F2E F2F G1 F5F D1E D1F/2 D1F D2E D2F/2 D2F C1F C2F X1E X1F 1 2 3 4 5 6 7 8 9
B 0
F1E 1 1 2 2 2 2 1 1 0
F1F 1 1 1 1 1 1 1 1 0
F2E 1 1 2 1 1 1 0
F2F 1 1 1 1 1 1 0
G1 1 1 1 3 2 2 2 1 1 1 1 1 0
1
PRESENT

F5F 1 1 1 1 0
D1E 1 1 0
D1F/2 1 1 1 0
D1F 1 1 1 1 0
D2E 1 1 2 2 2 2 1 1 0
D2F/2 1 1 1 1 1 1 1 1 0
D2F 1 1 1 1 1 1 1 1 1 0
C1F 1 1 2 2 2 2 1 1 1 1 0
C2F 1 1 2 2 2 2 1 1 0
X1E 1 1 1 3 3 3 3 2 1 0
X1F 1 1 1 1 1 1 1 1 0

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 TABLE FOR GROUPING OF PHASES
(GANTT GRAPH)

LEVEL ELEMENTARY OPERATIONS

10

11

12

13

14

DRAFT OF MACHINING SEQUENCE

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 PHASE DESIGNATION SURFACES MACHINED
REF

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

MINESUP Time: 02 hrs

Coef:

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Session: PHASE CONTRACT SHEET 19/21

Phase No: Machine tool used:

Referential:
MACHINING OPERATIONS TOOLS CUTTING ELEMENTS
Cs N F a Lc
Ref. Description Cutting Verification m/mm Rev/mn mm/rev mm mm

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MINESUP Time: 02 hrs
Coef:
PHASE CONTRACT SHEET
Session: 20/21

Phase No: 50 TURNING Machine tool used: Centre lathe

Referential: - Long Centring 1, 2, 3, 4 on D1

- Stop 5 On F2
- Clamping on D1
MACHINING OPERATIONS TOOLS CUTTING ELEMENTS
Cs N F a Lc
Ref. Description Cutting Verification m/mm Rev/mn mm/rev mm mm
Face F1
a Mdm1 =

Chamfer X2
b Mdm2 =

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Calculation of the machining dimension Mdm2.

Cond. min

Dimensions min max Tolerances

C 0.3
0.5

Mdm1 47.95 0.023

Mdm2 47.45 0.277

Sum 47.95 47.95

47.45

Mdm2 =

47.173

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