ME8793 / PROCESS PLANNING

AND COST ESTIMATION

UNIT 2 - (PROCESS PLANNING ACTIVITIES)
 PROCESS PARAMETERS CALCULATION
• CUTTING SPEED (or) SURFACE CUTTING
SPEED (or) SURFACE SPEED
The relative speed between the tool and the workpiece
(metres per minute)
Factors affecting selection of cutting speed
1. Nature of the cut:
continuous cut - Higher cutting speed
shock initiated cut- Lower cutting speed
Intermittent cuts - Quite lower speeds
2. Work Material:
• Harder, stronger, heat resistant Lower cutting speed
and work hardenable materials
• Soft, non sticky and thermally
Conductive materials ` - Higher cutting speed
3. Cutting Tool material:
HSS tool - 40m/min
Cemented carbide tools - 80-300m/min
4. Cutting Fluid application :
Proper selection increases cutting speed by 20 to 50%
5. Purpose of machining:
Rough machining with large MRR - low and moderate cutting speed
6. Kind of Machining operation :
Threading, reaming , knurling - Lower cutting speed
7. Capacity of machine tool :
Powerful, strong , rigid and stable machines – Higher cutting speed
8. Condition of the machine tool:
1. A mild steel component is shown in figure has to be made from a
stock of 220mm long and calculate the maximum cutting speeds for: a)
Facing operation, b) turning operation of all surfaces and c) Parting off
operation. The maximum spindle speed of the lathe being used is
500rpm.
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2. Calculate the cutting speed for a shaping operation, if
the shaper is capable of 20 strokes per minute over a
stroke length of 1.5m, with a cutting time ratio of 3:2.
3. Determine the spindle speed required to turn a
60mm diameter stainless steel shaft using a HSS tool.
1)What will be the spindle speed if a carbide tool is
used instead of HSS tool. 2)Also find the resulting
percentage increase in the spindle speed.
4. A shaper is capable of providing the maximum
cutting speed of 75m/min with a cutting time ratio of
4:3. The stroke length is 1.5m. Calculate the number
of strokes per minute that the shape is capable of.
 FEED AND FEED RATE
FEED - Distance through which the tool advances into work piece
during one revolution.
FEED RATE - The speed at which cutting tool penetrates the
workpiece.
UNIT - mm/rev (or) mm/min.
Factors affecting feed rate :
1. Work material.
2. Capacity of machine.
3. Cutting tool .
4. Cutting fluid application.
5. Surface finish desired.
6. Type of operation.
7. Nature of cut.
 SELECTION OF FEED RATE
1.FEED RATES FOR TURNING AND BORING

To convert feed rate in mm/rev into mm/min

Feed rate in mm/min = feed rate in mm/rev x speed of rotation of the
spindle in rpm
2. FEED RATES FOR DRILLING
3. FEED RATES FOR MILLING
4. FEED RATES FOR SHAPING AND PLANING
• For shaping, feed rate = 0.05-0.75 mm/stroke.
• For planing , feed rate = 0.5-3.0 mm/stroke
5. FEED RATES FOR GRINDING
• Cross feed for grinding = 1.0 -1.5 mm/pass
• Feed rate for cylindrical grinding = 1.0 – 1.5 mm/pass
DEPTH OF CUT
• Thickness of layer of metal removed in one cut or pass
• It is measured in a direction perpendicular to machined
surface.
• Depth of cut is perpendicular to direction of feed.
• It’s unit in ‘mm’
• Feed and depth of cut depends on the material to be machined , surface
finish required and tool used.
Selection of Depth of cut:
1. Depth of cut for turning and boring.
2. Depth of cut for milling.
3. Depth of cut for drilling.
4. Depth of cut for shaping and planing.
5. Depth of cut for grinding.
Machining Time calculations:
 SELECTION OF JIGS AND FIXTURES
WORKHOLDING DEVICE:
Hold and position a work piece during manufacturing operation.
Features of Work Holding Devices : 

The work holding devices should have the following uniqueness :

(a) Work holding devices must have required accuracy and must have matching
reference surfaces with the reference system.
(b) Work holding devices are allowed to perform a number of operations on
different faces in a single setting.
(c) Work holding devices must enable quick loading and unloading.
(d) Work holding devices must be fool-proofing to avoid incorrect loading of the
job.
(e) Work holding devices must be sufficient rigidity to fully withstand the cutting
forces.
(f) Work holding devices must be safe in use and loading and unloading.
(g) Work holding devices must have a sufficient clamping force for the use of full
roughing cuts.
(h) Work holding devices must be simple in construction maximum as possible.
 TYPES OF WORKHOLDING DEVICES
1. GENERAL WORK HOLDING DEVICE
a. Vices :
It
 2. SPECIALIST WORKHOLDING DEVICES

a. JIGS
 Work holding device for locating and
holding work piece for specific operation.
 It is provided with tool guiding element
 Lighter in construction.
 Directs the tool to the correct position.
 Clamped on the machine table in order to
align the bushes in the jig.
 Drilling , reaming ,tapping and counter
boring operations.
FUNCTIONS OF JIGS
Locate and position the work piece relative to
cutting tool.
Clamp the work piece during drilling , reaming
(or) tapping
Guide the tool into proper position
b. FIXTURES
 Work holding device which only holds
and positions the work piece.
 It does not guide the cutting tool.
 Clamped to the machine table.
 Used in turning, milling, grinding,
shaping, planing and boring operation.

FUNCTIONS OF FIXTURES
 Locate and position the work piece
relative to cutting tool.
 Clamp work piece during machining,
welding, inspection or assembly
DIFFERENCE BETWEEN JIGS AND FIXTURES
JIGS FIXTURES
DEFINITION Locates and holds the Holds and position the
work piece. work piece.
Guides the cutting tool Does not guide the
cutting tool
ELEMENTS Work locating, tool Work locating, tool
guiding and work setting and work
clamping elements. clamping elements
CONSTRUCTION Light in weight Heavy in weight
APPLICATIONS Drilling, reaming, Milling, turning,
tapping, counter boring grinding, broaching
and countersinking
SPECIAL FEATURES Drill bushes used for Peeler gauges, setting
tool guiding blocks to adjust position
of tool in relation to
work.
 REASONS FOR USING JIGS AND FIXTURES
 Reduces or eliminates the efforts of marking,
measuring and setting of work piece
 Reduces product cycle time.
 Reduces production cycle time and increases
production capacity.
 Interchangeability is achieved.
 Operating conditions like speed, feed rate and depth
of cut can be set to higher values.
 Operators working becomes comfortable.
 Semi skilled operators can be assigned the work.
 Reduces cost of inspection.
 ELEMENTS OF JIGS AND FIXTURES

 CLAMPING ELEMENTS: It exerts a force to press the

workpiece against locating surfaces.
 LOCATING ELEMENTS : Position the workpiece accurately with
respect to tool guiding (or) setting
elements.
 TOOL GUIDING AND SETTING ELEMENTS
TOOL GUIDING : It is used in jigs.
TOOL SETTING : It is used in fixtures for setting the
location of the tool.
 PRINCIPLES OF JIGS AND FIXTURE DESIGN
(FACTORS INFLUENCING JIGS AND FIXTURES DESIGN)
1. LOCATION :
 It should be small.
 It should be done from the machined surface
 Sharp corners must be avoided.
 Locating pins should be visible to operators.
 Adjustable locators for rough surface.
2. CLAMPING
 Arranged directly for supporting the work.
 Quick acting clamps should be used.
 It should not cause deformation of work piece.
 Position of clamps should provide good resistance.
 Cutting forces of the tool should act against the jig.
 Clamps and adjustments should be on the sides.
 It should allow rapid loading and unloading of components.
3.LOADING
 It should be easy
 Supporting surface made of hardened material and should be renewable.
 Space should be left for hand movements between jig and workpiece.

4. STABILITY AND RIGIDITY

 High rigidity to withstand the cutting forces.
 Four legs should be there for jigs.
 Fixtures are rigidly fixed on Machine table.
 Equipment made as rigid.

5. CLEARANCE FOR CHIPS

 Metal chips to be blown by providing adequate space.
6. FOOL PROOF DESIGN
 Safe to use.
 Impossible to use the work piece and tool other than the correct one.
7. PROVISION FOR TOOL GUIDES
 Jig bushing and cutter setting devices have provisions.
8. PROVISION FOR INDEXING
 It enables the work piece to divide into any number of equal spaced faces.
9. WEIGHT
 Lighter in weight
 Below 15KG.
10.SAFETY
 Designed for safety
 Handles and levers should be large
 Sharp edges should be removed.
11. COOLANT SUPPLY
 Adequate arrangements made for reducing the friction
12. ECONOMY
 It should reduce machining and production costs for ease and manufacturing.
GENERAL FACTORS IN WORK HOLDER DESIGN AND SELECTION
1. Physical characteristics of work piece
2. Physical characteristics of finished component
3. Type and capacity of the machine
4. Provision of locating devices
5. Available clamping arrangements
6. Available indexing devices , their accuracy
7. Evaluation of variability in performance results.
8. Rigidity of machine tool.
9. Study of ejecting devices, safety devices.
10. Required level of accuracy in work and quality
TYPES OF JIGS
1. DRILL JIG
In this jig the top of the jig is open; the work piece is placed on the top
2. BORING JIG
 For holes too large in work piece.
 Holes made on odd size.
TYPES OF FIXTURES
1.Turning fixtures
The standard work holding devices or fixtures for lathe are:
·        Three and four jaw chucks
·        Collets
·        Face plate
·        Mandrels
·        Milling vice
2.Grinding Fixtures:
• The work holding devices for grinding operations
will depend upon the type of the grinding operation
and the machine used.

3.Milling Fixtures:
• A Milling fixture is a work holding
device which is firmly clamped to the
table of the milling machine.
• It holds the work piece in correct position as
the table movement carries it pass the cutter
4.Broaching fixtures
• Broaching fixtures are required to hold
Work piece rigidly and at proper position
against cutting force. This requirement is
consider while designing a broaching
fixtures.
5.Welding fixtures
• Welding fixtures are used in
welding to hold work piece in
correct position. It consists of
locating and clamping devices
to hold work piece at correct
position.
Based on construction Fixtures are classified as
1.Plate Fixture 2. Angle Plate Fixture 3. Vice-Jaw Fixtures
4. Indexing
1. Plate Fixture:
It is the simplest form of popular
fixture due to its adaptability. The
basic fixture is made from
a flat plate which has a variety of
clamps and locators to hold and
locate the part. It is useful
for most machining
operations                                                                                               
   
                                                                                                                           
.
2. Angle Plate Fixture
This is used when the part is to be machined at right angle to its locator.
Angle-plate fixtures are normally made at 90 degrees, but other angles are also
possible.
3. Vise-Jaw Fixtures:
It is used for machining small parts. The standard vise jaws are replaced with jaws
conforming to the shape of the part to be fitted. Their use in limited only by the sizes
of the vises available.

4.Indexing fixtures
It is used for machining parts having evenly spaced machined

 
surfaces .                                                                                                    
 STANDARD PARTS FOR JIGS AND FIXTURES

• MECHANICAL FASTENERS
• LOCATING AND SUPPORTING DEVICES
• INDEXING PINS
• DRILL BUSHES
• HAND KNOBS AND HANDLES