Introduction about process planning

1. ME6005
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

4. Design the
product
Manufacturing
Process
planning
Stages

7. PROCESS PLANNING DOCUMENTATION
• Process planning is to document clearly all the
information in detail.
• The route sheet lists the production
operations and associated machine tools for
each component and subassembly of the of
the product.

13. Computer Aided Process Planning

14. Retrieval (or variant) CAPP System

17. Selection of Process planning system
Major factors to be considered while selecting the
best process planning system are:
i. General Environment
ii. Organisational Structure
iii. Technical Expertise
iv. Needs and Objectives of the company

18. DRAWING INTERPRETATION

19. The following information can be obtained from the
interpretation of an engineering drawing:
i. Material of the product
ii. Number of parts to be produced
iii. Weight of the component
iv. Dimensions of the parts
v. Dimensional and geometric tolerances
vi. Size and Accuracy

20. TYPES OF DRAWINGS

21. 1)DETAIL DRAWINGS

22. 1.1) SINGLE –PART DRAWINGS

23. 1.2) COLLECTIVE SINGLE –PART
DRAWINGS

24. 2) ASSEMBLY DRAWINGS

25. 2.1) SINGLE –PART ASSEMBLY
DRAWINGS

26. 2.2) COLLECTIVE ASSEMBLY DRAWINGS

31. INFORMATION IN THE DRAWING SHEET
REQUIRED FOR PROCESS PLANNING
• DIMENSIONS

32. • MATERIAL SPECIFICATION
• SPECIAL MATERIAL TREATMENTS

33. • TOLERENCES, LIMITS AND FITS

34. • SURFACE FINISH

38. FERROUS MATERIALS
• Major constituent as iron
• Iron based components are easily available and
distributed throughout the world.
• Ferrous materials can be produced very
economically.
• Ferrous materials achieve Mechanical and Physical
properties.
• DISADVANTAGE: CORROSION

39. CLASSIFICATION OF FERROUS MATERIALS

40. STEELS
• Steels are alloys of IRON and CARBON, not only carbon
other elements like silicon, manganese, sulphur, nickel, etc.
• CLASSIFICATION OF STEELS
1. PLAIN CARBON (NON-ALLOY) STEELS
1. Low carbon steels
2. Medium carbon steels
3. High carbon steels
2. ALLOY STEELS
1. Low alloy steels
2. High alloy steels
CARBON

41. PLAIN CARBON STEELS
• DEF: Carbon is the alloying element that essentially
controls the properties of alloys, and in which the
amount of manganese cannot exceed 1.65% and
copper and silicon must be less than 0.6%
• COMPOSITION:
– CARBON UP TO 1.5% COPPER UP TO 0.6%
– MANGANESE UP TO 1.65% SILICON UP TO 0.6%

42. PLAIN CARBON STEELS
• CHARACTERISTICS:
– Moderately priced steels (Due to absence of large
amount of alloying elements)
– Sufficiently ductile
– PRODUCTS: Sheet, Plates, Tube, Wire.
• APPLICATIONS:
– Mass production in automobile appliances.
– Ball bearings, base plates, structural members, etc.

43. CLASSIFICATION OF PLAIN CARBON STEELS
1. LOW-CARBON STEELS
– Less than 0.25% carbon containing
2. MEDIUM-CARBON STEELS
– Containing between 0.25% to 0.60%carbon
3. HIGH-CARBON STEELS
– Containing more than 0.60% carbon

44. LOW CARBON STEELS
• Low carbon steels that contain less than 0.25%
carbon
• Low carbon steels are knows as MILD STEELS.
• CHARACTERISTICS:
– Soft and weak Ductility and toughness
– Good formability and weldability
– Least expensive to produce
• APPLICATIONS:
– Automobile body components Bridges
– Structural shapes( I- beams etc)
– Pipelines, Buildings.

45. MEDIUM CARBON STEELS
• Low carbon steels that contain between 0.25%
and 0.60% carbon
• These steels may be Heat treated by
Austenitizing, Quenching and then tempering to
improve MECHANICAL PROPERTIES.
• CHARACTERISTICS:
– Low hardenabilities
– High strength and hardness properties are
achieved.(Sacrifice of Ductility and Toughness)
• APPLICATIONS:
– Railway tracks, gears, crankshafts.

46. HIGH CARBON STEELS
• Low carbon steels that contain more than 0.60%
carbon.
• CHARACTERISTICS:
– Hardest and strongest Least ductile( more brittle)
– More wear resistant
– Sharp cutting edge tools.
• APPLICATIONS:
– Cutting tools and dies
– Knives
– Blades
– High strength Wire

47. ALLOY STEELS
• Alloy steels mean any steels other than CARBON
STEELS.
• ALLOYING ELEMENTS:
– Chromium, nickel, tungsten
– Molybdenium, vanadium, cobalt
– Boron, copper others
• PURPOSE OF ALLOYING:
– To increase strength, To improve hardness
– To improve Toughness, Machinability, Ductility
– To improve resistance to abrasion and wear
– To enhance grain size control.

48. CLASSIFICATION OF ALLOY
STEELS
1. LOW ALLOY STEELS
1. AISI steels
2. HSLA steels
2. HIGH ALLOY STEELS
1. Tool and die steels
2. Stainless steels
STEELS

49. LOW ALLOY STEELS
• Low alloy steels are steels which contain upto 3 to
4% of one or more alloying elements
• They have similar microstructure and require
similar heat treatment like plain carbon steels.
• Presence of alloying elements increase strength
and hardenability.

50. TYPES OF LOW ALLOY STEELS
1. AISI STEELS
• American Iron and Steel Institute steels that are generally
used in machine construction.
• AISI steels normally have LESS THAN 5% OF total
addition elements such as Cr, Ni, V, etc,.
2. HSLA STEELS
• High Strength and Low Alloy steels is also knows as
micro alloyed steels
• Elements are Al,V, etc.

51. HIGH ALLOY STEELS
• High alloy steels are steels which contain 5% of
one or more alloying elements
• They have similar microstructure and require
different heat treatment than of plain carbon steels.
• The room temperature structures after normailising
may be austenitic, martensitic

52. TYPES OF HIGH ALLOY STEELS
1. TOOLAND DIE STEELS
• High quality alloys are used which require special
characteristics like HARDENABILITY, WEAR
RESISTANCE, TO SOFTENIG ON HEATING,.
2. STAINLESS STEELS
• Used for improving corrosion resistance.

53. TYPES OF CAST IRON
• Alloy cast iron --- ( Special Purpose)
1. Grey cast iron --- (General Purpose)
2. White cast iron – ( Heat and wear resistant)
3. Malleable cast iron-- ( Heat treated for
ductility)
4. Spheroidal Graphite cast iron – -(some
ductility)

54. GREY CAST IRON
• Least Expensensive
• Most commonly used
• It is an alloy of carbon and silicon with iron.
Composition:
• Carbon - 2.5 – 4 %
• Manganese – 0.4 – 1%
• Sulphur – 0.02 – 0.15%
• Silicon – 1 – 3 %
• Phosphorus – 0.15 – 1 %
• Remaining iron

55. Grey Cast iron
• Its Consists of graphite flakes ( like potato Chips)
• Graphite flakes are surrounded by alpha ferrite or
pearlite matrix.
• Because of graphite it shows grey in colour
• These flakes not having much strength --- this lead
to crack formation in edges and brittleness.
• The shape, size and distribution of flakes decide the
property of grey cast iron.

56. Characteristics
• Good strength
• Excellent compressive strength
• Good torsional and shear strengths
• Good corrosion resistance
• Excellent fluidity
• Good wear resistance
• Excellent Machinability
• Good vibration damping capacity

57. Applications of Grey cast iron
USED IN
• Machine tool bodies
• Engine blocks
• Engine cylinders
• Brake drums
• Crank shaft
• Pipe and pipe fittings
• Rolling mills
• Agriculture appliances

58. White cast iron
• White cast iron derives its names fact that fracture
surface has a white or silvery appearance
• White iron combined with cementite.
• The broken cast iron area looks like silvery white.
• When the cooling is fast ----- Carbon content
changes to cementite results white cast iron

59. composition
• Carbon --- 1.8 – 3 %
• Silicon ---- 0.5 – 1.9 %
• Manganese – 0.25 – 0.8 %
• Phosphorus – 0.05 – 0.2 %
• Sulphur ------- 0.1 – 0.3 %
• Remaining is a iron

60. Microstructure
• Cementite is caused by quick cooling of molten
iron it produces White cast iron is very hard and
brittle.
• RAPIDLY COOLED FROM THE CASTING
TEMPERATURE The Cast iron is termed as
“CHILLED IRON”

61. Characteristics of white cast iron
• Very hard and brittle
• Very high resistance to abrasion
• High tensile strength and low compressive
strength
• Cannot be machined because its hard.

62. Applications of white cast iron
• White cast iron is Used as a raw material in the
production of malleable cast iron.
• Used in rolls, wear plates(brakes), pump linings,
balls
• Used in outer surface for car wheels.

63. MALLEABLE CAST IRON and its
MICROSTRUCTURE
• By heat treating the white cast iron we get malleable cast
iron.
• For having malleable and ductile property .
• During heat treatment the cementite breaks into ferrite
and graphite nodules.
• The graphite nodules called as tempered carbon-- it
appears like popcorn.
• This rounded graphite permits a good combination of
strength and ductility

64. Composition
• Carbon --- 2 – 3%
• Silicon ----- 0.6 – 1.3%
• Manganese --- 0.2 – 0.6%
• Sulphur ------ 0.1 %
• Phosphorus – 0.15%
• Remaining iron

65. Types of Malleable irons
• Ferritic malleable iron,
• Pearlitic malleable iron

66. 1. Ferritic Malleable cast iron
• Here the white iron is heated up to upper critical
(815 ͦ
c to 1230 ͦ
c) temperature and hold it for
prolonged time, so carbon in the cementite
converts in to graphite.
• Subsequently the low cooling through the eutectoid
reaction results in a ferritic matrix
• Finally the cast iron obtained is called ferritic
malleable cast iron.

67. 2.Pearlitic Malleable cast iron
• The Rapid cooling of molten white cast iron in eutectoid
transformation range results pearlitic matrix.
• This is due in fast cooling , the carbon in austenite will have
not enough time to form additional graphite. So its retained
in the pearlite matrix
CHARACTERISTICS:
• It has higher strength and Lower ductility

68. Micro structure of eutectoid to pearlite

69. CHARACTERISTICS OF
MALLEABLE CAST IRON
• Good ductility and malleability than grey cast iron
• High yield and tensile strength
• Its not brittle as grey cast iron
• High young’s modulus and low co-efficient of expansion
• Excellent impact strength
• Good wear resistant
• Good vibration damping capacity
• Excellent machinability

70. Applications of Malleable cast iron
USED IN
• Due to their Castability , machinability and shock
resistance it Most widely used in automobile industries
• In brake shoe
• Wheel hub
• Axle housing
• Transmission gears
• Connecting rod
• Levers
• Pipe fittings
• Agriculture machineries and parts
• Switch gear equipments

71. SPHEROIDAL GRAPHITE
OR
NODULAR CAST IRON
• Its also called ductility cast iron
• In the grey cast iron they are adding magnesium
or cerium
• This magnesium converts flakes graphite into
perfect nodules.
• This perfect nodules improves the ductility of
the cast iron. (nearly 20 % increased)

72. Characteristics of
spheroidal graphite cast iron
• Excellent ductility
• Good toughness than grey cast iron
• Good fatigue strength
• Good impact strength
• Good hardness
• High modulus of elasticity
• Good wear resistance
• Good machinability
• Good oxidation resistant
• Excellent castability

73. Applications
Used in
• Valves
• Pump bodies
• Crank shaft ,
• Pinion and gears
• Rollers
• Rocker arm
• Flanges
• Power transmission equipments
• Earth moving machineries

74. ALLOY CAST IRON
• The cast iron Discussed so far called Plain cast
irons.
• The cast irons contains only small amount of
impurities.
• The ALLOY CAST IRONS can be produced by
adding Ni, Cr, Mo, Cu, Si and Mn.
PURPOSE:
• For High strength materials
• Hard and abrasion resistance
• Corrosion resistance irons

75. Purpose of alloying elements in cast iron
S.N
O
ALLOYING
ELEMENT GENERAL EFFECTS
1 Ni Graphitize the cementite and help to produce grey
iron
Reduce the formation of coarse grains
Give toughness to thin sections
2 Si Same effect as that of nickel
3 Cr For hard and wear resistant irons
4 Mo Increase hardness and toughness
5 V Increase strength and hardness
Give heat - resistance to metal
6 Cu It gives resistance to corrosion

76. Applications of alloy cast irons
• Cylinder block
• Brake drums
• Clutch castings
• Automobile components like piston rings,
crank shaft.
• Corrosion and heat resisting areas

77. NON FERROUS MATERIALS
• Elements other than iron
(OR)
• Other than iron is a major constituent
• More costly than ferrous materials
CHARACTERISTICS:
1. Lighter in weight
2. Electrical and thermal conductivity
3. Resistance to corrosion

78. A metal containing little or no iron content
NON-FERROUS METAL
- Aluminum Copper
- Bronze
- Brass
- Copper
- Lead
-Nickel
-Tin

79. Engineering
Materials
Metals
Ferrous
Iron
Steel
Pig iron
Cast iron
Wrought
iron
Non-
Ferrous
Copper &
Alloys
Aluminium
Zinc
Tin
Lead
Non-Metals
Rubber
Plastics
Resin

80. CERAMICS
Inorganic solid

81. Introduction
• It’s a man made non metallic and inorganic solid

82. Traditional products
• Bricks
• Cook wares
• Cements
• Concretes
• Tiles
• potteries

83. Traditional products

84. Other engineering applications
Used as
• tool for grinding and Cutting
• Bearings
• And many in electrical and electronics fields.

85. Other engineering applications

86. Characteristics of ceramics
• Used in high temperature places
• Its strong, hard and brittle
• High melting point
• Good thermal and electrical insulators
• Resistant to oxidation and corrosion
• Having high compressive strength but are weak intension

87. Engineering ceramics
• Its specially for engineering applications
• They are basically oxides, carbides, sulphides
and nitrides of metal.

88. Characteristics of engineering ceramics
• High resistance to abrasion and wear
• High strength at high temperature
• Good chemical stability
• Good electrical insulation characteristics.

89. Important engineering ceramics
• Alumina (Al2O3)
• Silicon Carbide (SiC)
• Silicon Nitride (Si3N4)
• Partially stabilized Zirconia
• Sialons

90. COMPOSITES
TO GET A REQUIRE PROPERTIES
IN METALS

91. .

92. COMPOSITES
• Two or more materials added to get require qualities in
a material.
• The weakness of one metal rectified by the strength of
second metal
• Example
Aerospace components
• That should have low weight , stiffness, impact and
corrosion resistance, good abrasive properties.

93. ,

94. Particle re-inforced (FIBER)
composites
• Its consist of particles of one material dispersed in a matrix of
a second material
• The fine dispersion particle posses
good strength in composites.
• The size, distribution and orientation of particles defines the
strength of the composite.
• Types
1. dispersion strengthened composites
2. Large particle composites

95. .

96. 1.Dispersion strengthened composites
• The particles are smaller and having diameter 0.01 –
0.1 microns and volume concentration 1 – 15 % of fiber
• This method is similar to that for precipitation hardening.
• Due to this , the composites have good yield and
tensile strength. And the plastic deformation is
restricted.

97. 2. Large particle composites
• The particles diameter greater than 1 micrometer and volume
concentration are greater than 25 %
• Here the load on this composite is shared by both matrix and
particles.
• It posses good strength
• Tungsten carbide or Titanium carbide embedded in a metal
matrix of cobalt or nickel.
• These composites used as a cutting tool

98. FIBRE REINFORCED COMPOSITES
• Here the dispersed phase is in the form of fibers.
• These fibre reinforced composites having improved
strength, fatigue resistant, stiffness and strength-to-
weight ratio

99. .

100. Material Selection Process

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

102. Material Evaluation Method
1. Shape or Geometry Consideration
2. Material Property Requirements
3. Manufacturing Considerations

103. Shape or Geometry Consideration
Some of the important shape or Geometry considerations are:
• Relative size
• Complexity
• Dimensional Tolerance
• Surface Finish
• Allowances
• Design for Assembly
• Design for Manufacturability

104. Some raw materials forms for common manufacturing processes

105. Process selection
• Manufacturing process families
1. Shaping
2. Joining
3. Finishing

107. Factors in Process Selection
• Material form
• Component size and weight
• Economic considerations
• Dimensional and geometric accuracy
• Surface finish specification
• Batch size
• Production rate

109. Material Property Requirements
i. Mechanical Properties
ii. Physical Properties
iii. Service Environment
Manufacturing Considerations
• Standard Components
• Ease of Manufacture
• Quantity and rate of components
• Minimum and Maximum
• Level of Quality
• QA and Inspection Requirements
• Ease of Assembly

111. Process Selection
Method

116. Factors considered for machine
selection

123. Steps in Machine Selection

124. Factors in tooling selection
• Manufacturing practice
• Manufacturing process
• Machine tool characteristics
• Capability
• Processing time
• Cutting tool availability

128. Operating requirements for tool
selection
• Work piece material
• Operation
• Part geometry
• Tooling data

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

134. TOOLING SELECTION METHOD
• Stage1:Evluation of process and machine selection
• Stage2: Analysis of machining operations
• Stage 3: Analysis of work piece characteristics
• Stage4: Tooling analysis
• Stage 5: Selection of tooling