Experiment No 09

Aim: - Planning the sequence of machining operations along with selection of machining operations
along with selection of machine tools, cutting tools, jigs and fixtures, cutting variables as well as fixing
in process dimensions and gauging.

Prepared By: -
642413004 Batch D Suhel Rajendra Koli
642413002 Batch D Mahesh Bhorkade
642413005 Batch D Shruti Kulkarni
642413013 Batch D Vasundhara Janawade

PROCESS PLAN
Part No: ET-001-A Changes: NA Remark: Approved 12/10/2025
Part Name: Equal Tee Date: 14/10/2025
Material: Carbon Steel (ASTM A234 WPB)
Original: ABC Ltd
Date: 12/10/2025 Checked: Mr. ABC; Date: 12/10/2025

Operation
Description Workstation Setup Tool Time (Min)
No.
Receiving Visual Measuring
Inspection & Receiving/Storage Inspection, tools 10 setup/20
10
Material Area Dimensional (calipers, processing
Preparation Check tape)
Abrasive
V-block Cut-off
Cutting (Pipe to Automatic Pipe 5 setup/15
20 Supports, Length Wheel or
Length) Cutter cutting
Stop Cold Saw
Blade
Induction
Heater (for
Forming (Tee Hot Hydraulic Press /
Die Set (Tee hot 20 setup/45
30 Extrusion/Hydraulic Tee Forming
Die), Mandrel forming), forming
Bulging) Machine
Hydraulic
Rams
Temperature
Heat Treatment Fixture to hold Controllers, 30 setup/90
40 Heat Treatment
Furnace Tee Quenching treating
Tank

Shot Blasting & Shot Blasting Rotating Steel 10 setup/25

50
Cleaning Machine Basket/Conveyor Shot/Grit blasting
 Experiment No 09
Beveling
V-blocks,
Beveling (Branch Pipe Beveling Cutter 15 setup/30
60 Clamping
and Ends) Machine (Milling beveling
Fixture
Type)

Spray Gun
Coating (e.g., Black Coating Booth / Hanging Racks, or 10 setup/20
70
Varnish) Dipping Tank Drip Tray Immersion coating
Tank

Measuring
Visual
Final Inspection & tools, 15 setup/25
80 Inspection Station Inspection,
Packaging Packaging processing
Gauges
materials
 Experiment No 09
ROUTE SHEET
Part
Part No: ET-001-A Equal Tee Planner: XYZ Checked by:
Name:
A234
WPB Stock 150 × 6 Manufactured via Hot
Material: Comments:
Carbon Size: mm Forming/Extrusion
Steel Pipe

Std. Time
No. Operation Description Dept Machine Tooling
(hr)

Calipers,
Receiving Inspection and Measurement
10 Inspection Micrometer, 0.30
verify pipe dimensions. Station
Tape

Cut pipe blank to Cold Saw

Automatic Pipe
20 specified length for Cutting Blade, 0.25
Cutter (Cold Saw)
forming. Measuring Stop

Forming (Hot Tee Die Set,

Hydraulic
Extrusion/Bulging) the Mandrel,
30 Forming Press/Tee 0.75
branch from the pipe, Induction
Forming Machine
creating the tee shape. Heater

Heat Treatment
(Normalizing or Stress Heat Treatment Furnace Fixture,
40 Heat Treating 1.50
Relief) to relieve stresses Furnace Pyrometer
and control microstructure.

Shot Blasting & Cleaning

Shot Blasting
50 to remove scale and Finishing Steel Shot/Grit 0.35
Machine
prepare the surface.

Beveling the ends (and

branch) to the required Pipe Beveling Carbide
60 Machining 0.40
weld preparation (e.g., Machine (CNC) Beveling Cutter
37.5$\degree$ angle).

Final Inspection Gauges,

Inspection
(Dimensional/Visual/NDT) MPI/UT
70 Final Insp. Bench/Coating 0.50
and apply temporary Equipment,
Booth
Coating (Black Varnish). Spray Gun
 Experiment No 09
Cutting
Step Process Machine Cutter/Tool Fixture
Condition/Setting

Selection of
Carbon Steel Stock Rack
Material and Nominal Pipe Size
1 N/A Pipe (A234 / Inspection
Dimensional (NPS) × Schedule
WPB) Bench
Check

V-block
Speed: Optimized for
Automatic Abrasive Supports
Cutting Pipe Blank material & diameter;
2 Pipe Cutter Wheel or Cold with
to Length Feed:
(Cold Saw) Saw Blade Length
Mechanical/Hydraulic
Stop

Hydraulic
Forming the Tee Temperature: 950∘C - Press Base
Press/Tee Tee Die Set
3 Branch (Hot 1100∘C (Hot forming and Upper
Forming and Mandrel
Extrusion/Bulging) range) Platen
Machine

Temperature: 880∘C -
Heat Furnace
Heat Treatment 920∘C (Soaking time
4 Treatment N/A Support
(Normalizing) based on wall
Furnace Fixture
thickness)

Time: 10-15 minutes;

Shot Blasting & Rotating
Shot Blasting Speed:
5 Cleaning (Scale Steel Shot/Grit Basket or
Machine Conveyor/Basket
Removal) Conveyor
RPM

Carbide Self-
Pipe End
Beveling Ends and Beveling RPM: 200-300; Feed: Centering
Beveling
6 Branch (Weld Cutter 0.2 mm/rev (Standard Clamping
Machine
Prep) (37.5$\degree$ Bevel Prep) and V-
(CNC)
angle) blocks

Inspection
Final Inspection, Inspection Low-Stress Visual & Dimensional
Bench &
7 Stamping & Bench/Coating Stamp Set / Check (GO/NO-GO
Hanging
Coating Booth Black Varnish Gauges)
Racks
Experiment No 09