INTRODUCTION TO PROCESS PLANNING

1. ME8793
PROCESS PLANNING
AND COST
ESTIMATION

2. • UNIT I INTRODUCTION TO PROCESS PLANNING
• UNIT II PROCESS PLANNING ACTIVITIES
• UNIT III INTRODUCTION TO COST ESTIMATION
• UNIT IV PRODUCTION COST ESTIMATION
• UNIT V MACHINING TIME CALCULATION

3. UNIT I
INTRODUCTION TO PROCESS PLANNING

4. PROCESS PLANNING

5. Design the
product
Manufacturing
Process
planning
Stages

6. DESIGN/MANUFACTURE INTERFACE

7. Process Planning: Link between Design
and Manufacturing

8. Process Planning Activities

9. PROCESS PLANNING DOCUMENTATION

10. ROUTE SHEET

11. Process Planning Methods

14. Computer Aided Process Planning

15. Benefits of CAPP
1. Process rationalization and Standardization
2. Productivity Improvement
3. Product cost reduction
4. Elimination of human error
5. Reduction in time
6. Reduced clerical effort and paper work
7. Faster response to engineering changes
8. Incorporation of other application programs

16. Retrieval (or variant) CAPP System

19. Components of a CAPP System
a) A Part description
b) A subsystem to define the machining
parameters
c) A subsystem to select and sequence
individual operations
d) A database
e) A report generator

20. MATERIAL SELECTION AND EVALUATION
• Though the material selection for a component/product is the
responsibility of design engineers, the process planner should
evaluate the materials specified along with design engineers,
based on the availability of manufacturing processes.
• It should be noted that the material and process selections
should be made taking into consideration the products to be
manufactured, and the materials and processes available
within the organisation.
• Also the selection of materials influences the selection of
appropriate manufacturing processes.

21. CLASSIFICATION OF MATERIALS FOR MANUFACTURE

22. PROPERTIES OF ENGINEERING MATERIALS

23. METALS AND THEIR CLASSIFICATION

24. FERROUS MATERIALS
• The ferrous materials are those materials
which contain iron as their prime constituent.
Steels generally contains between 0.05 and
2.0% weight carbon.
The cast iron generally contain between 2.0
and 4.5% weight carbon.

25. 1. steels:
• Steels are alloys of iron and carbon.
 Carbon steels:
i) Low carbon steel(mild steel): less than 0.25% carbon.
ii) Medium carbon steels: 0.25 to 0.60% carbon
iii) High carbon steels: more than 0.60% carbon
 Alloy steels:
The alloying elements such as chromium, nickel,
molybdenum, vanadium, tungsten, cobalt, etc., are added to
achieve the required properties.
i) Low alloy steels: 3 to 4% of alloying elements
ii) High alloy steels: more than 5% of alloying elements

26. 2. Cast Iron
• Cast irons are ferrous alloys consists of iron 2-
4.5% carbon and upto 3.5% silicon.
i) Grey cast iron- most common type
ii) White cast iron- very hard and brittle
iii) Malleable cast iron- good ductility and
malleability, high yield and tensile strength
iv) Spheroidal graphite cast iron- excellent
ductility, tensile, and yield strength

27. Non-Ferrous Materials
• Metals which contain elements other than
iron as their chief constituent.
Characteristics:
i) light in weight
ii) higher electrical and thermal
conductivity
iii) better resistance to corrosion
iv) easy of fabrication
v) colour
ex: copper, aluminium, lead, magnesium, nickel,
tin, titanium, zinc.

28. POLYMERS
• Characteristics:
i) Low density
ii) Good thermal and electrical insulation
properties
iii) High resistance to chemical attack.
iv) Easy of fabrication
v) Relatively low cost

29. POLYMERS

30. COMPOSITES

31. MATERIAL SELECTION PROCESS AND METHODS
MATERIAL SELECTION PROCESS:

32. MATERIAL SELECTION METHODS
1. Selection with computer-aided databases
2. Performance indices
3. Decision matrices
4. Selection with expert systems
5. Value analysis
6. Failure analysis
7. Cost-benefit analysis

33. MATERIAL EVALUATION METHODS
1. Shape or geometry considerations
2. Material property requirements
3. Manufacturing considerations

34. MATERIAL PROPERTY REQUIREMENTS
1. Mechanical properties
2. Physical properties
3. Service environment

38. Process Selection
Method

43. Factors considered for
Machine/Equipment selection

50. MACHINE SELECTION METHOD( STEPS IN MACHINE
SELECTION)

51. STAGES OF MACHINE SELECTION
• STAGE 1: First-cut selection
• STAGE 2: Power/force analysis
• STAGE 3: Capability analysis
• STAGE 4: Operational analysis

52. Factors in tooling selection

53. Constraints on tooling selection
• Manufacturing practice
• Manufacturing process
• Machine tool characteristics
• Capability
• Processing time
• Cutting tool availability

57. Operating requirements for tool
selection
• Workpiece material
• Operation
• Part geometry
• Tooling data

60. Factors affecting tooling performance
• Cutting tool materials
• Cutting tool geometry
• Cutting fluids

63. TOOLING SELECTION METHOD
• Stage 1: Evaluation of process and machine
selections
• Stage 2: Analysis of machining operations
• Stage 3: Analysis of workpiece characteristics
• Stage 4: Tooling analysis
• Stage 5: Selection of tooling

64. DRAWING INTERPRETATION

65. TYPES OF DRAWINGS

66. 1)DETAIL DRAWINGS

67. 1.1) SINGLE –PART DRAWINGS

68. 1.2) COLLECTIVE SINGLE –PART
DRAWINGS

69. 2) ASSEMBLY DRAWINGS

70. 2.1) SINGLE –PART ASSEMBLY
DRAWINGS

71. 2.2) COLLECTIVE ASSEMBLY DRAWINGS

73. INFORMATION ON THE DRAWING SHEET
REQUIRED FOR PROCESS PLANNING
• DIMENSIONS

74. • MATERIAL SPECIFICATION
• SPECIAL MATERIAL TREATMENTS

75. • TOLERENCES, LIMITS AND FITS

76. • SURFACE FINISH