Manufacturing Course - Manufacturing Ranges 107

1. INTRODUCTION TO MANUFACTURING RANGES

1.1. Principle
The manufacturing range is an archive document that clearly specifies the different phases of product manufacturing.
The document is developed in several stages depending on:
· the progress of the study,
· the fine-tuning of manufacturing,
· the possible modification of the product, etc.

Theoretical study Calibration Production

Specifications Preliminary draft of

Manufacturing project Range of
+
fabrication fabrication
Definition drawing

Weather
Generally, to develop a production range, it is necessary to:
· propose several solutions in the form of a nomenclature,
· make a choice,
· establish the preliminary manufacturing project,
· establish the manufacturing project by detailing each projected phase contract,
· draft the manufacturing range consisting of the final phase contracts.

MANUFACTURING RANGE

Phase 10 Phase 20 Phase 30 Phase 40

Post 1 Post 2 Post 3 Position 4

Sub-phase Sub-phase
20 A 20 B

Operation Operation Operation Operation Operation Operation Operation Operation Operation Operation Operation Operation
a b c a b a b a a b c d

1.2. Definitions of some important terms

Term Definition

Phase It is the set of operations performed on the same workstation.

It is the set of operations performed on the part with a unique positioning. We talk about
Subphase
sub-phase when the part is disassembled but remains at the same workstation.
Operation This is the realization of machining with the same tool.
It is a document that lists the phases of manufacturing with details of the positions used. For example:
Phase 10: Control of the crude at the control station
Phase 20: Shooting
Nomenclature of
Phase 30: Milling
phase
Phase 40: Heat treatment
Phase 50: Rectification
Phase 60: Final control on three-dimensional measuring machine
It is a document that succinctly describes for each phase:
Preliminary project of · the machine used,
· the diagram of the part with the machined surfaces
fabrication
· the position of the part on the post as well as its isostaticity,
· the location of the ribs made without their value,
· the name of the operations with the tools used,
It is a document that can be provisional or definitive. In addition to the elements indicated in the APF, it
indicate precisely for each phase:
Phase contract · the positioning of the part with the technological elements and its maintenance in position,
· the reference of tools with their cutting parameters (Vc, f), and their graphical representation,
· the value of the manufactured ribs,
· the useful cutting times.
 Manufacturing course - Manufacturing ranges 108

2. APPROACH FOR CARRYING OUT A MANUFACTURING STUDY

2.1. Presentation
The implementation of a manufacturing range must meet the company's objectives while taking into account the resources it has available:

OBJECTIVE
Optimization of the production process according to the criteria:
• Minimum cost
• Sufficient quality to satisfy the customer
• Deadline to be respected
• Minimum manufacturing time
• Minimum stock between each manufacturing phase

THE DATA
THE MEANS They depend on:
Machines available in the company or · From the definition drawing of the part:
on the market (subcontracting):
• Tolerance interval
• Capacity in number of operations
• Geometric specification
• Precision
• Surface condition
• Implementation cost
• Shape of the piece
• Capacity in number of axes for
• Material of the part
avoid rework
· Economic data:
RANGE OF • Production continues or
discontinue
• Importance of the series
PRODUCTION • Deadline

2.2. Analysis of the definition drawing

The reading of the definition drawing is crucial and must receive particular attention. The information provided
The definition drawing of the manufacturing process is numerous and is detailed below.
2.2.1. The ratings
It is necessary to aim for the achievement of average ratings while taking into account the tolerance intervals (TI). The smaller the TI, the more the average of
production must be precise. For example:
· a cylinder of Ø 20h7 (minimum 19.979 - maximum 20.000) can be made by turning, whereas a cylinder of Ø 20h5
(minimum 19,991 - maximum 20,000) can only be achieved through correction,
· A hole Ø 10 H11 can be made directly with a drill, while a Ø 10 H7 must be finished with a reamer.

2.2.2. The geometric specifications

As with the dimensions, the method of fabrication must be adapted to the accuracy of the geometric specification. But if the
The specification between the two surfaces is very precise; the manufacturing of these two surfaces with the same tool must be considered.
the same operation.

2.2.3. Surface states

The chosen machining process results in a known surface condition. The Ra can be predominant in the choice of the process.
of manufacturing (see table in paragraph 14.6. of the course on the control of manufactured parts).

2.2.4. The shape of the piece

The shape of the room affects several criteria:
· positioning of the piece; stability, sufficiently large plans, etc.
· tightening; deformation of the part due to tightening,
· cutting efforts; deformation of the piece due to cutting efforts,

2.2.5. The material of the piece

The material affects the choice of tools and cutting conditions. See machining course.

2.2.6. Economic data

Economic data corresponds to:
· the importance of the series,
· production continue ou non, etc.

For example, we will use:

• a numerical control machine for a complex part, in a renewable series of 1500 units every month,
• a stitching machine for simple internal machining for a batch of 10,000 pieces,
• a turning tour for a small part of simple revolution shape in very large series.
 Manufacturing course - Manufacturing ranges 109

2.3. Association of surfaces (determination of machining entities)

The elementary surfaces are few in number and we particularly encounter a plane, a cylinder, a cone, a surface.
helical (threading)... But these surfaces are rarely machined alone and are often associated for different criteria:
2.3.1. Technological Criteria
Some surfaces can only be done simultaneously with the same tool, such as:
IN SHOOTING IN MILLING
A shoulder in turning: plan + cylinder A diagram: plan + cylinder

A turning throat: plan + cylinder + plan A shoulder in milling: plane + plane

A front throat in turning: cylinder + plane + cylinder A groove: plane + plane

2.3.2. Criteria for geometric positioning

When the tolerance interval of a geometric positioning specification between two surfaces is reduced, it is impossible
to create these surfaces in different phases. Generally, for a tolerance interval of less than 0.05 mm, it is
preferable to machine both surfaces in the same phase (or sub-phase), as for example:

Geometric specification Cylinder / Cylinder Plan / Plan Cylinder / Plan

Creation of the two holes on Creating a work plan Making the hole and the plan
center 4 axes by rotation of the at the end and the other in work ofon the same side
piece profile on 3-axis milling machine

//
Realization directly on Obtaining the two plans by
strawberry train on milling machine Drilling the hole and milling of
drill, boring machine or
horizontal profile of the face
milling machine

Machining of the two holes on

two-point milling machine
 Manufacturing course - Manufacturing ranges 110

2.3.3. Economic criteria

To reduce manufacturing costs, it is useful to combine certain surfaces as in the following examples:
Drilling + Countersinking Drilling + Chamfering + Tapping Identical drillings Profile turned: Cylinders + chamfers + planes

2.4. Determination of the number of operations per machining entity

Based on dimensional analysis and roughness, it is possible to determine the number of operations to be performed for each
Machining. For dimensions less than 200 mm, the following table indicates the number of possible operations:
Type of rating Criteria 1 operation 2 operations 3 operations
IT > 0.4
0.15/IT > 0.4
Length edges
0.05/IT > 0.15
IT < 0.05
Quality > 11
Quality 9 - 10 - 11
Diameter codes
Quality 7 - 8
Quality < 7 RECTIFICATION
Ra/3.2
Ra = 1,6
En fonction de l’état de surface
Ra = 0,8
Ra < 0.8 + RECTIFICATION

2.5. Determination of the machining order

2.5.1. Mapping of surfaces State of the Letter
Surface
surface associated
On the drawing, the machined surfaces are reinforced by BRUT All raw surface B
thicker lines. The surfaces
Surface plane (likeFace) F
geometric simple (machined surfaces or surfaces
brutes can be identified by capital letters Cylindrical surface (likeDiameter) D
Factory
affected by a numerical index. The uppercase letters ConicalSurface C
selected for the marking are: AnyOther surface (threading, notching, etc.) A

Example: for the base piece

 Cours de fabrication – Gammes de fabrication 111

2.5.2. Principles to be respected

In addition to respecting the priorities defined by the design definition, the order of operations must adhere to the following principles:
Do not destroy fragile surfaces whose manufacturing cost is high. Prevent a fragile tool from machining a raw surface.

Rough surface Reject if

possible the
Machined surface smudges on the
most surfaces
accessible
Bore

Example: drilling is performed first on the side of the machined face. Example: the groove must be machined first.
The lapping is then carried out. We finish with the boring. The boring is then carried out.

2.5.3. The ordered graph

The definition drawing specifies, for each elementary surface, the dimensions and tolerances of the connections between surfaces. The
The ordered graph is established by taking as a constraint the connections with the raw surfaces as the primary precedence.
reference. To represent these connections, we will take as a convention:
REPRESENTATION AGREEMENT
Graph element Representation
Surface F1

Associated surfaces D2 F4

Set of surfaces

Existing liaison on the definition drawing

Implicit liaison

Liaison for principle to be respected (see paragraph 2.5.2.)

2.5.4. Application of the ordered graph for the base

The ordered graph below shows the precedence constraints between each surface for the base. In addition to the connections
Defined by the definition drawing, a connection has been added between F1 and A1 because it is desirable to drill a small hole.
diameter on a machined surface (so F1 before A1). Two implicit coaxiality connections were also taken into account between
D1 and D2 and D2 and C1. 10.5±0,1
A2
0.03
B1
8±0.5
F1 F3
21±0.2et //0.03 F2
It is better to drill A1
on a machined surface therefore
after F1

A1 48±0.05

0.01

1
B2 D1 D2 F4 C1

After analyzing the graph, we can observe several possible levels:

45±0.5
B3 ó level 1: including raw areas B1, B2, and B3,
ó level 2: including F1 and D1,
ó level 3: including F3, F2, A1 and A2,
ó level 4: including D2 F4,
ó level 5: including C1,
But F2, A1 and A2 could be machined at level 4 or 5. Without taking into account the machines used or isostatic conditions, we can therefore
consider several machining orders as follows:
Solution Machined surfaces
1 F1 D1 F3 F2 A1 A2 D2 F4 C1
2 D1 F1 F3 F2 A1 A2 D2 F4 C1
3 F1 D1 F3 D2 F4 C1 F2 A1 A2
4 F1 D1 F3 D2 F4 C1 A1 A2 F2
5 D1F1 F3 D2 F4 C1 A2 F2 A1
etc. etc.
 Manufacturing course – Manufacturing ranges 112

2.6. Proposal of solutions

2.6.1. Basic Rules
It is clear that to machine the 7 sets of surfaces (6 surfaces + 1 set of 3 surfaces), we will not use 7
machines with 7 machining phases. Economically, we have an interest in having a minimum number of phases as much as possible.
must take into account certain rules:
· if possible, use a large flat surface in the first phase to reposition on it in
the next phase,
· depending on the available resources, use machines that allow a large number of machining operations; for example
a vertical conventional milling machine can only machine a flat surface in series, while a machine for
a 4-axis numerical control machine could fully complete the part in a single phase,
· For each phase, consider the clamping of the piece and the tightening with the surfaces.
used.

2.6.2. Search for possible solutions

Based on the timeline established using the ordered graph, several solutions can be proposed. The 4 detailed solutions
Below are not the only possible ones; there are many other possibilities.
♦ Solution 1
F1 on horizontal milling machine,
D1, F2, D2 F4, C1 and F3 on 3-axis CNC milling machine
A1 and A2 on drilling setup on online drilling machines (2 positions)
♦ Solution 2
F1, D1, A1 and F3 (draft) on 3-axis CNC milling machine
F2, D2 F4 and C1 on CN Tower
F3 (finish) and A2 on 3-axis CNC milling machine
♦ Solution 3
F1, D1, A1 and F3 (draft) on 3-axis CNC milling machine
F2, C2, F2 F4, C1 F3 (finishing) and A2 on a 4-axis machining center
♦ Solution 4
F1, D1, A1, F2, C2, F2 F4, C1 F3 and A2 on 4-axis machining center

2.7. Choice of the solution

Among the 4 proposed solutions, we can briefly outline their advantages and disadvantages for each:
Solution Advantages Disadvantages
Using only one CNC, the other machines having the specific drilling setup can be expensive.
a low cost.
Requires operators with very high qualifications
Machining the F1 plan alone allows for a different assembly.
1
of rather simple machining.
Requires 3 machining phases.
Interesting solution for a workshop having a
limited number of CN.
Using a CNC lathe is more advantageous for the
2 Production of D1 (quality H7) and for a larger one requires 3 machining phases.
chip volume (time saving).

3 Only 2 machining phases

Difficult assembly to enable the tools to reach

4 Only 1 machining phase
all surfaces; difficult assembly envisaged.

The solution that seems the most advantageous is solution number 3.

 Manufacturing course - Manufacturing ranges 113

3. PHASE NOMENCLATURE
3.1. Document model
Below is an example of a phase nomenclature model:
 Manufacturing Course - Manufacturing Ranges 114

3.2. Phase nomenclature of the base

 Manufacturing Course - Manufacturing Ranges 115

4. PRELIMINARY MANUFACTURING PROJECT

4.1. Presentation of the pre-manufacturing project document
 Manufacturing course - Manufacturing ranges 116

Z
4.2. Isostasy
4.2.1. Presentation TZ
Isostasy allows the positioning of the part using simple symbols. The movement
A solid in 3-dimensional space can generate 6 possible movements:
· [] RZ
TY
• translation around x
• around y,
RX RY
• around z. Y
· 3 rotations : TX
• rotation around x, X
• rotation around y,
• rotation around z,

These 6 possible movements are called degrees of freedom. To position the part correctly, it will be necessary to eliminate these 6 degrees.
of freedom. Isostasy allows for the removal of the possibility of these displacements. One must not confuse positioning
(isostatic) with maintenance in position (tightening). The first allows for positioning the part and the second allows for immobilization.

4.2.2. Elimination of degrees of freedom

To eliminate degrees of freedom for any part (even of very complex shape) there is a reduced number of
simple connections as defined by the following table:
Other name used by
Name of the link Rotation removed Translation removed
isostasy
Punctual Stop 0 (or 1) 1 (or 0)
Linear Orientation 1 1
Plane Support plan 2 1
Annular linear Short centering 0 2
Sliding pivot Long centering 2 2

4.2.3. Possible connections for positioning a part

Name Graphical representation Concrete example
One-time support
or
stop 1 1
Piece

Straight line 1 2 1-2

you Piece
orientation

1 1 Piece
Liaison plane
or
support plan 2 3 2-3

2 2
Annular Linear Piece
or
short centering

1 1

1 2
Sliding pivot Piece
you
Long centering
3 4 3-4
 Manufacturing Course - Manufacturing Ranges 117

4.2.4. Some rules of isostasis

We seek to place, as far as possible, the connection that eliminates the greatest number of degrees of freedom on the largest one.
surface.

Rule Example
The degrees of freedom are removed only once.
times. For example, for a prism, one cannot
set up 3 support connections plan; what
would remove 9 degrees of freedom.

Case of short revolution parts.

It is considered that a coin is a short cylinder.
when D > 1.5 L (D: diameter, L: length), in this
as the positioning will be:
• support plan on one side,
• short centering on the cylinder,

For long revolving parts.

It is considered that a piece is long when D < L,
• long centering on the cylinder,
• stop on one face,

One must also pay attention to the position of the

short centring or orientation that must be
parallel to the plane support and not perpendicular:

4.2.5. Application of the isostasy of phases 20 and 30 of the base

[Link]. For phase 20
The support surfaces that must be used are the flat surface B1, the flat surface B2, the flat surface B3.

Isostasy will therefore only be a plane support with orientation and stop.

By applying the rules of isostasy, we will take:

ß the largest surface for the plane support;
it is the B1 surface that is the largest,
ß The intermediate surface for orientation;
it is the surface B2,
ß The least extensive surface for the stop;
it is surface B3 that is the narrowest.

[Link]. For phase 30

The support surfaces that can be used are the flat surface F1, the cylindrical surface D1, the flat surface F3.

The isostatic support will therefore only be a flat support with a short centering and a stop.

By applying the rules of isostasy, we will take:

ß the largest flat surface for the flat support;
it is the F1 surface that is the largest,
ß The surface allowing orientation;
it is the D1 surface,
ß The least extensive surface for the stop;
It is surface F3 that is the narrowest.
 Manufacturing course - Manufacturing processes 118

4.3. The manufacturing costs

4.3.1. Definition
A manufacturing dimension (or manufactured dimension) is a dimension made during the phase that concerns it. This dimension can:
· appear on the definition drawing; we will try to use as many dimensions indicated on the definition drawing as possible,
· to be unknown from the definition drawing; in this case it will need to be calculated based on the other known dimensions.

For example, we want to mill the two planes.

spaced from the coastufrom the following piece; the lu lb
work will be carried out in 2 milling phases.
In its raw state, the piece has a height of lb.
Definition drawing of the part Drawing of the raw part

First phase: machining of F1

The part is positioned on a flat support 123 and the dimension of e
fabrication carried out theiis located between the support surface and the surface
machined; it is an intermediate dimension that does not exist in the drawing of li
definition.

This rating must therefore be calculated based on two known ratings: 1 2 3

· luwho is a drawing definition rating,
· e: the machining thickness determined with luwhich is a raw quote; e = (lblu) / 2.

Second phase: machining of F2 e lU

As for the first phase, it is positioned with a flat support on the
on machined surface F1. The manufacturing dimension is a direct dimension that exists
on the definition drawing.
1 2 3
4.3.2. The different manufactured ratings
There are three main categories of manufacturing cost:
· the reference ratings; these are very important ratings that position
the machining in relation to the positioning surfaces of the part; in Cf
Generally, there are 3 reference axes (one for x, one for y, one for z);
6
· machine dimensions; these are dimensions made directly by the machine;
for example, a spacing made on a CNC and which is obtained by
machine axis movement.
· The tool dimensions; these are dimensions obtained directly by a tool; by Cf1 Cf2
example the diameter of a bore made by a reamer. Cf1machine side
Cf2referential code
4.3.3. Calculation of unknown manufactured dimensions (dimension
Cf side tool
transfer)3

[Link]. Definitions
C1 Condition C2
Transfer of odds: it is a calculation method allowing the determination of odds.
tools for manufacturing.
Chain of odds: the odds involved in the calculation are replaced by some
vectors; this is what is called a chain of dimensions.
C3
Edge condition: it is the edge that is transferred; it belongs to the drawing of
definition but it is not a manufacturing rating and it is related to
Machining. There is only one reference dimension in a dimension chain.

[Link]. Principle
To find the value of the missing odds, two calculations need to be made:
· calculation of the rating; it is a vector sum,
· calculation of the IT; the IT of the score condition = the sum of the IT of the other scores; it is therefore imperative that the IT of the score
condition should be greater than the other ITs. 26± 0.05
+ 0.15
12 0

[Link]. Example Stop Surface

processed
Let it be a shoulder to be made in milling. We perform the calculation of the odds:
Cmin= C2 min– See1 max ⇒ Cf1 max = C2 minCmin
The manufacturing cost Cf1is not known.
+ 0.15 Cf1 max 25.95 - 12 = 13.95
The condition rating is . 12 0
Cf1= ?
Then the calculation of the IT:
We build the rating chain with the IT C = ΣIT = IT Cf1+ IT C2⇒ IT Cf1= IT C - IT C2
side condition (C) and the two other sides
(Cf1etc2). IT Cf1= 0.15 - 0.1 = 0.05 C
-0.05
Cf1
-0.10
Where from Cf1= 14 C2
 Manufacturing Course - Manufacturing Ranges 119

4.4. Application of the manufacturing draft to the base

1 2 3

4 5

1 2 3

4
5
6
 Manufacturing course - Manufacturing ranges 120

5. PHASE CONTRACT

5.1. Presentation of the phase contract

A phase contract is a document developed from the manufacturing draft describing chronologically for
each phase the elements allowing:
· to study the machining setups to be carried out,
· to specify the manufacturing dimensions,
· to design numerical control programs,
· to set up the machining phase on the machine,
· to foresee the tooling,
· to know the cutting parameters,
· to provide the control equipment,
· to evaluate machining times.

5.2. Formation of the phase contract

The phase contract is said to be 'provisional' as long as the manufacturing process has not been validated by production. When the
production is stabilized the phase contract becomes definitive and can be archived to enrich the company's know-how.

The phase contract contains a lot of information and is composed of 3 distinct parts:
· The upper part; which indicates the descriptive elements of the piece and its manufacturing program with:
• the name of the piece and its set,
• the phase number and its designation,
• the machine used,
• the number of pieces to be manufactured, the size of the batches, the rhythm.

· The central part; which describes the information

graphics with:
• the positioning of the part,
• the maintenance in position,
• reinforced machined surfaces,
• the manufacturing quotation with the values,
• the potential representation of tools and
of their trajectory.

· The lower part; which details the operations

machining with:
• the description of the operations,
• the description of the tools,
• the description of the control means,
• the cutting parameters,
• the technological times of each
operation.

Below is presented a model contract of

phase :
 Manufacturing course - Manufacturing procedures 121

5.3. Symbolization of technological elements

In the phase contract, isostasy is represented with more elaborate symbols that provide information.
complementary information on the nature of the different elements ensuring positioning and maintaining position.
This is the second part of Standard NFE 04-013, which precisely defines these elements called technological elements.
Each element is constructed with elemental symbols that indicate:
· the function of the technological element: positioning (MIP) or maintaining position (MAP)
· the nature of the contact with the surface: flat touch, domed touch, ridge, etc.
· the nature of the surface of the part: raw or machined,
· the type of technology of the element: fixed, reversible, etc.

Type of technology Nature of the contact

Nature of the surface Function of the technological element

Note: It is not necessary to represent elements in all views if they are sufficiently explicit.

5.3.1. Function of the technological element

Function Symbol Description

Positioning Filled triangle

Maintenance in position Empty triangle

5.3.2. Nature of the surface

Nature of the surface Symbol Description

Machined surface Simple trait

Raw surface Double trait

5.3.3. Type of technology

Type of technology Symbol

Fixed support

Fixed centering

Clamping system

Concentric clamping system

Irreversible support system

Reversible support system

Reversible centering
 Manufacturing course - Manufacturing ranges 122

5.3.4. Nature of the contact

Function Symbol Function Symbol

Striated contact Clear contact

Occasional contact Cuvette

Contact surface Centering wheel

Fixed point swivel point

Guide Lifting beam

5.3.5. Projection Representation

Function Symbol

Support

Fixed centering

Locating

5.3.6. Example of devices

Device and function Symbol

Fixed contact surface on a surface

sliced

Striated clamping morse used

as a coach on a rough surface

Fixed punctual contact on a surface

brute

Fixed open contact on a raw surface

Cuvette on a machined surface

Fixed point on a machined surface

Rotating doll mobile point for

holding in position

Clamping spreader with grooved jaws

on a raw surface

Fixed vice on a machined surface

Angular guide with point contacts

on a machined surface
 Manufacturing course - Manufacturing ranges 123

5.4. The cutting parameters

See course on machining

The cutting parameters are:

· Vc: cutting speed,
· N: rotation frequency,
· f: advance
· Vf: Speed of advance.

They depend on many elements:

ó material of the tool,
ó material of the piece,
ó type of operation,
ó etc.

5.5. The calculation of technological times Tt

It is the time during which the machine operates. It is generally expressed in hundredths of an hour (ch).

To determine this time, it is necessary to know:

ó the machining length: L,
ó the speed of the tool movement: Vf.

5.5.1. Determination of L

The determination of L depends on:

• machined length Luit corresponds to the tool path in the material,
• guard; it is an additional safety distance where the tool moves in advance of work.

L = Lu+ guard

guard
Lu
5.5.2. Determination of Tt

To find out the time in minutes: Tt= L / Vf

To convert it to ch, it must be multiplied by 100 / 60

Lx100
Tt=
Vfx60
 Manufacturing course - Manufacturing ranges 124

5.6. Contract for phase 20 of the foundation

 Manufacturing course – Manufacturing ranges 125

5.7. Contract for phase 30 of the base