The document describes the design of a dual brake caliper bracket including: 1) A 3D model and 2D drawings created in Creo Parametric with dimensions in mm. 2) Material and tool selection for milling and drilling operations using carbide tools. 3) Process planning sheet outlining the milling, drilling and pocketing operations, cutting speeds, feeds, and tolerances. 4) Tool path simulations and G-code programs for drilling operations.

1. Design of Dual Brake
Caliper Bracket
Submitted to
Dr. Salman Sagheer Warsi

2. Group Members
• Awais Saeed BME153090
• Rao Shahid Iqbal BME153086
• Muhammad Usama BME153092

3. Introduction
• Dual Brake Caliper Bracket
• Designing of 3D model (Creo Parametric)
• 2D Drawing with Dimensions(mm)
• Tool Selection
• Manufacturing process sheet
• Generation of Tool Path
• APT & NC Code generation

4. Methodology
Carbide

5. 3D Model

6. Detailed Drawing
D001
D002
D003

7. Material Selection
Work Piece Material Low carbon Steel
Tool Material Carbide
Operation Milling
Cutting Speed for Drilling
and End Milling 𝑽 𝒄
105
𝑚
𝑚𝑖𝑛
Cutting Speed for Face
Milling
360
𝑚
𝑚𝑖𝑛
Feed per Tooth 𝒇 𝒛 1 mm
Number of Fluent Z 4
Work piece Dimensions(mm) 175*105*17.5
Final Product Dimensions 170*105*17.5

8. Operating Conditions
Spindle
Speed
n =
𝑽 𝒄∗𝟏𝟎𝟎𝟎
𝝅∗𝑫
Feed 𝑉𝑓= 𝑛 ∗ 𝑓𝑧∗ 𝑍
Feed per
Revolution 𝑓𝑛=
𝑉𝑓
𝑛

9. Process Planning Sheet
S/No Operation
Description
(Process)
Tool
Radius
(mm)
Spindle
Speed
𝐫𝐞𝐯
𝐦𝐢𝐧
Feed
𝐦𝐦
𝐦𝐢𝐧
Drawing
No
Feed
per
Revolu
tion
Tolerance/
Fits
/Allowance
Name of
Machine,
Tools
Tool
Material
1 Face Milling 12 9550 382.16 D001 4 0.05 mm T001 Carbide
2 Profile Milling 6 5500 110.00 D003
D002
2 0.05mm T000 Carbide
3 Pocket Milling 5 6500 130.00 D001 2 0.05mm T002 Carbide
4 Drilling 5 6500 130.00 D001 2 0.05mm T002 Carbide
D No D001 D002 D003

10. Tool Path Simulation

11. APT For Drilling
1>MACHINE/DRILL 01
2>CLPRNT
3>OUTOL/0.05
4>P1=POINT/-74.96,9.69
5>P2=POINT/-74.96,89.69
6>P3=POINT/74.96,89.69
7>P4=POINT/74.96,9.69
8>C1=CIRCLE/CENTER P1,RADIUS 5.
9>C2=CIRCLE/CENTER P2,RADIUS 5.
10>C3=CIRCLE/CENTER P1,RADIUS 5.
11>C4=CIRCLE/CENTER P1,RADIUS 5.
12>PL1=PLANE/P1,P2,P3
13>SPINDL/RPM,6500,CLW
14>RAPID
15>GOTO /-74.966128,9.69,7.5
16>CYCLE/DEEP,FEDTO,17.5,STEP,.5,
MMPM,105000,CLEAR,3,RETURN,2
17>GOTO /-74.966128,9.69,2.5
18>GOTO /-74.966128,89.69,2.5
19>GOTO /74.966128,89.69,2.5
20>GOTO /74.966128,9.69,2.5
21>CYCLE/OFF
22>RAPID
23>GOTO /74.966128,9.69,7.5
24>SPINDL/OFF
25>FINI

12. NC Program for Drilling
N0 G54
N5 G71
N10 ( / MFG0001)
N15 G0 G17 G99
N20 G90 G94
N25 G0 G49
N30 T2 M06
N35 S6500 M03
N40 G0 G43 Z7.5 H2
N45 X-74.966 Y9.69
N50 G83 X-74.966 Y9.69 Z-15. R5.5
F4064.
N55 Y89.69
N60 X74.966
N65 Y9.69
N70 G80
N75 G1 Z7.5 F2540.
N80 M30