Mechanical Manufacturing Process Overview
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ScribdTranslationsMechanical Manufacturing Process Overview
Translated by
ScribdTranslationsIntroduction to mechanical manufacturing Manufacturing File
A- Preliminary Project of Manufacturing Study
1- Introduction
A preliminary study project of manufacturing is a possible ordered sequence of
different phases involved in the execution process of the piece. Its
Elaboration is a difficult synthesis work that requires extensive
technical and economic knowledge that cannot be approached effectively
only by experienced technicians who have acquired good knowledge of
technical possibilities of machines, tools, and equipment that will have to
support this knowledge with ongoing trials conducted in the workshops.
2- Basic data:
2-1- the 'program' of manufacturing:
It allows to know:
the number of parts to be manufactured;
the manufacturing pace
the nature and qualification of the workforce;
the nature of the machine park;
the technical datasheets of the machines;
the manufacturing time;
the hourly cost of the workstation.
2-2- the definition drawing of the product:
This drawing must be limited to expressing only the functional conditions intended.
at the reception control. Non-functional forms can be returned
caused by the preparer.
2-3- the unscaled drawing of the raw part:
This sketch can be provided to the preparer by the crude methods office. It has
to provide information on the disturbed areas of crude (joint plan, areas of
casting, of massing, of stripping, of burr, etc.
3- Machining (or manufacturing) range:
Establishing a manufacturing range means organizing the process into ordered phases.
of manufacturing mechanical parts.
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Phase: set of operations carried out on the same workstation.
Sub-phase: set of operations carried out on the same workstation
without disassembling the part.
Operation: set of actions for transforming matter in the same way
tool for creating a particular shape (turning, facing, drilling, etc.).
4- Criteria for developing an APEF:
4-1- Technological criteria:
Technical possibilities of the machines:
Nature of the surfaces that can be machined on each machine;
Type of possible association of surfaces taking into account the number of the
tools available on the machine, their nature, their trajectory and the
control of their movement (stops);
Predictable dispersions around their theoretical position (fidelity,
capability) ;
Quality of machinable surfaces (condition,...) ;
Cutting parameters (speed, power, ...).
Technical possibilities of the tools:
Type of machining possible (roughing, finishing);
Nature and hardness of the machined materials;
Allowed cutting conditions (speed, depth of cut);
Nature of trajectories;
Quality of achievable surface condition;
Nature and value of foreseeable wear.
Technical possibilities of the tools:
Nature of the taking of parts and tools;
Nature of the holding in position of the parts and tools;
Ease and safety of use;
Predictable dispersions in the repositioning of parts and
tools.
4-2- Economic criteria:
Estimated hourly cost of workstations;
Manufacturing lead time;
Quantity of parts to manufacture (type of series);
Manufacturing cadence;
Operator qualification.
4-3- Physical criteria related to the part:
mass of the piece;
Material characteristics (hardness, state...)
deformability of the part;
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Aesthetic aspect of the finished piece.
4-4- Geometric criteria related to the part:
oVolume envelope of the part (bulk);
Area of surfaces;
Surface precision (tolerance on the dimension);
Shape surfaces (flatness...);
Condition of surfaces (roughness...) ;
Relative positions of surfaces (parallelism, coaxiality, ...).
Note: Given the large number of criteria recorded, it is difficult during
the development of an APEF to simultaneously take into account all these criteria.
5- Constraints:
When a machining operation must be carried out before another, it constitutes for
this last one a 'constraint'.
We distinguish between constraints: dimensional, technological, and economic.
5-1- Quotation constraint:
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5-2- Technological constraints:
5-2-1- Technological operational constraint:
The groove of the previous drawing will be carried out in 3 operations because it is a surface.
precise (20H7): roughing, semi-finishing, and finishing.
5-2-2- Technological recovery constraint:
The specification of coaxiality and the need to guide the tool to achieve the
The schedule requires that D1 be completed before D2.
5-2-3- Technological constraint: intersecting holes:
To avoid the bending of the drills, D2 is drilled following D1.
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5-3- Economic constraints:
5-3-1- Economic constraint of reduced machining:
D1 being precise in relation to D2, executing D1 first avoids machining on
a large expanse of D2.
5-3-1- Economic constraint of the finishing tool:
The machining of D1 requires a grinding operation. Therefore, it is necessary to plan for a
removal of the wheel by the prior machining of a groove G.
6- Different steps of analysis:
Inventory and identify the raw surfaces
and the machined surfaces concerned.
Establish the groupings of the surfaces
associated
Draw a graph of the connections between the
different surfaces
Deduce the level table
Define the order of machining phases
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7- Example of application: Lid
7-1- Data
The definition drawing (see page 7) represents a lid in 35 Cr Mo 4.
sand cast to be manufactured at a rate of 100 pieces per month
for a year.
Available machines: Lathe; Universal milling machine; Drill;
boring machine...
7-2- Possible association of surfaces:
G1 = {D1 ; F2} G2 = {D3 ; F3} G3 = {D5 ; F4}
7-3- Graph BE (study office) or sagittal graph:
Between D2 and G2, there is a technological operation constraint: drilling then boring.
7-4- Levels graph:
7-5- Pre-Study Project of Manufacturing:
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B- Manufacturing process or (machining process)
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C- Phase contract:
Reducer 1
2
Lid
35 Cr Mo 4
10
100 pieces/month for 1 year
shooting
Parallel tour
Reference:
…………………………………
…………………………………
…………………………………
…………………………………
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Reducer 2
2
Lid
35 Cr Mo 4
20
100 pieces/month for 1 year
Filming
Parallel tour
Reference:
…………………………………
…………………………………
…………………………………
…………………………………
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