Download to read offline
![[Deck] What's New in Spark-Iceberg Integration via DSV2.pptx](https://cdn.slidesharecdn.com/ss_thumbnails/deckwhatsnewinspark-icebergintegrationviadsv2-260210005337-25955b12-thumbnail.jpg?width=640&height=640&fit=bounds)
Process engineering and computer applications
- 1. 4- 1 10/12/25 Process Engineering Basicsof Process Planning for computer implementation IE550 -- Manufacturing Systems Fall 2008 Dr. R. A. Wysk
- 2. 4- 2 10/12/25 Chapter 6-- Process Engineering
- 3. 4- 3 10/12/25 The EngineeringProcess Stock Material Processes Finished part Design specifications Process planning Process capability Inspection Need to understand the process capabilities.
- 4. 4- 4 10/12/25 PROCESS CAPABILITIES Process:certain way an operation is carried out, e.g. turning, drilling, milling. Tool: physical object which is used to carrying out a process, e.g. twist drill, spade drill, gun drill. Machine tool: machine on which process is carried out, e.g. lathe, drill press, milling machine, machining center. Process capability: The geometry and tolerance a manufacturing process can produce, and its limitations, . i.e. shape and size, dimensional and geometric tolerances, material removal rate, relative cost, other cutting constraints.
- 5. 4- 5 10/12/25 LEVELS OFPROCESS CAPABILITIES Universal level: Handbook and textbook level data. Aggregate characterization of what can be expected. General measures of the process capability such as shape and size. What the process can accomplish in an average shop on a typical machine tool. Shop level: Specific to a particular manufacturing system. What is the best attainable capability in one specific shop, e.g. the turning capability of the student machine shop is far worse than that in the shop of a precision spindle manufacturer. Machine level: Specific to a machine. Machines in the same shop has very different capability. A table top lathe can machine a small part, yet a large slant bed lathe may be able to handle a 20"x 10' part.
- 6. 4- 6 10/12/25 PROCESS KNOWLEDGECOLLECTION Few scientific data available or published. Most process knowledge are gained during actual manufacturing practice. Practical manufacturing knowledge is still an art instead of a science. Certain information can be found in the textbooks, handbooks, machining data handbook, etc. Tolerance capability may be obtained from control charts, inspection reports, and on-line sensor data.
- 7. 4- 7 10/12/25 EXPERIENCE-BASED PLANNING Relay onone's experience. Most frequently this is the way industry operates. Problems: a. Experience requires a significant period of time to accumulate. b. Experience represents only approximate, not exact knowledge. c. Experience is not directly applicable to new processes or new systems. Need to automate.
- 8. 4- 8 10/12/25 MACHINIST HANDBOOKS Universal orshop level knowledge. e.g. Surface-finish chart - limiting extremes of process 8 in - use grinding, polishing, lapping Usually not with milling, however, finish milling may achieve the specification. The information is general. It does not mean every machine or shop can achieve that accuracy. Turning limit (6.3 - 0.4 m or 250 - 16 inch) Diamond turning at Lawrence Livermore Lab (12.5 nm or 0.47 inch)
- 9.
- 10.
- 11. 4- 11 10/12/25 Dimensional accuraciesfor Process Planning
- 12. 4- 12 10/12/25 HOLE MAKINGKNOWLEDGE Following data is taken from a manufacturer's process planner's handbook. I. Dia < 0.5" A. True position > 0.010" 1. Tolerance > 0.010" Drill the hole. 2. Tolerance < 0.010" Drill and ream the hole. B. True position < 0.010” 1. Tolerance < 0.010" Drill, then finish bore the hole. 2. Tolerance < 0.002" Drill, semi-finish bore, then finish bore the hole. II. 0.05" < dia < 1.00"
- 13. 4- 13 10/12/25 DECISION TABLES Tocomputerize the decision making, one simple way is to use decision tables. If the conditions set in an entry are satisfied, the actions in the entry are executed. The stub contains the condition or action statements. Entries mark which conditions or actions are applicable. Each entry contain one rule. Conditions Actions Stub Entries
- 14. 4- 14 10/12/25 EXAMPLE DECISIONTABLE Dia < 0.5 0.5 < Dia < 1.0 T.P < 0.010 T.P < 0.010 Tol > 0.010 0.002 < Tol < 0.010 Tol < 0.002 Drill Ream Semi-finish bore Finish bore X X X X X X X X X X X X X X X X X X X X X X X
- 15. 4- 15 10/12/25 DECISION TREES Node Branch Tocomputerize the decision making, one simple way is to use decision trees. Decision tree is a graph with a single root and branches emanating from the root. Each branch has a condition statement associate with it. Actions are written at the terminal. Probabilities may be assigned to the branches. In this case, the tree represents probabilistic state transitions. Root terminal The node may be "AND" nodes or "OR" nodes.
- 16. 4- 16 10/12/25 EXAMPLE DECISIONTREE Dia < 0.5 0.5 < Dia < 1.0 T.P < 0.010 T.P < 0.010 Tol > 0.010 Tol < 0.010 0.002 < Tol < 0.010 Tol < 0.002 Drill Drill, then ream Drill, then finish bore Drill, semifinish bore, then finish bore
- 17. 4- 17 10/12/25 PROCESS-CAPABILITY ANALYSIS ; ; twistdrilling (code 1) ; 111: hole ( ( if (shape ! 111 = ) ( length ! 12.0 diameter ! * <= ) ( diameter! 0.0625 >= ) ( diameter! 2.000 <= ) ( tlp ! diameter ! 0.5 ** 0.007 * >= ) ( tln ! diameter ! 0.5 ** 0.007 * 0.003 + >= ) ( straightness ! length ! diameter ! / 3. ** 0.0005 * 0.002 + >= ) ( roundness ! 0.004 >= ) ( parallelism ! length ! diameter ! / 3. ** 0.001 * 0.003 + >= ) ( true ! 0.008 >= ) ( sf ! 100 >= ) ) PROCESS BOUNDARY Data
- 18. 4- 18 10/12/25 PROCESSES, TOOLS,AND MACHINES • Process Sub-Process Cutters Milling Plain Shell end Hollow end Ball end End milling Peripheral milling Plain Slittting Saw Form Inserted-tooth Staggered-tooth Angle T-slot cutter Woodruff keyseat cutter Form milling cutter Face milling Plain Inserted-tooth Drilling Twist drill Spade drill Deep-hole drill Gun drill Trepanning cutter Center drill Combination drill Countersink Counterbore Reaming Shell reamer Expansion reamer Adjustable reamer Taper reamer Boring Adjustable boring bar Simple boring bar Broaching Form tool Machines Vertical milling machine Horizontal milling machine Column-and-knee Bed type Planer type Special type Machining center Column & upright Gang drilling machine Radial drilling machine Multispindle drilling machine Bench type Deepth hole drilling machine Drill press Lathe Lathe Boring machine Jig bore Turning Turning Facing Parting Knurling Boring Drilling Reaming Plain Inserted Knurling tool Boring bars Drills Reamers Speed lathe Engine lathe Toolroom lathe Special lathe Turret lathe Screw machine Broaching press Vertical Pull-down Vertical Pull-up Surface broaching machine Horizontal broaching machine Surface broaching machine Rotary broaching machine
- 19. 4- 19 10/12/25 PROCESSES, TOOLS,AND MACHINES Shaping Form tool Planing Inserted tool Sawing Hacksaw Bandsaw Circular saw Process Sub-Process Cutters Machines Grinding Cylindrical grinding Centerless grinding Internal grinding External grinding Surface grinding Reciprocating saw Band saw Circular saw Shaper Horizontal & Vertical Double housing planer Open-side planer Edge planer Pit Planer Grinding wheels Points External cylindrical grinder Internal cylindrical grinder Surface grinder Creep feed grinder Tool grinder Disk grinder Honing Honing stone Honing machine Lapping Lap Lapping machine Tapping Tap Drill press Milling machine Machining center
- 20. 4- 20 10/12/25 CUTTING EDGEAND FEED Drill cutting edge Boring Reaming Turning Peripheral Milling minor feed Face Milling feed range Ball End Milling Broaching Sawing
- 21. 4- 21 10/12/25 VOLUME PRODUCINGCAPABILITIES Process Sub-Process Cutters Milling Plain Shell end Hollow end Ball end End milling Peripheral milling Plain Slittting Saw Form Inserted-tooth Staggered-tooth Angle T-slot cutter Woodruff keyseat cutter Face milling Plain Inserted-tooth Drilling Twist drill Spade drill Deep-hole drill Gun drill Trepanning cutter Center drill Combination drill Countersink Counterbore Reaming Shell reamer Expansion reamer Adjustable reamer Taper reamer Boring Adjustable boring bar Simple boring bar Broaching Form tool Volume Capabilities flat bottom volume round hole round hole deep round hole deep round hole large round hole shallow round hole multiple diameter round hole countersink hole counterbore hole thin wall of round hole thin wall of round hole thin wall of round hole thin wall of round hole thin wall of round hole thin wall of round hole Turning Turning Facing Parting Knurling Boring Drilling Reaming Plain Inserted Knurling tool Boring bars Drills Reamers ? disk disk ? thin wall of round hole round hole thin wall of round hole flat bottom volume slot step polyhedral through hole formed through volume flat bottom volume slot formed volume T-slot Internal groove pocket, slot, flat sculptured surface, flat
- 22. 4- 22 10/12/25 VOLUME PRODUCINGCAPABILITIES Shaping Form tool Planing Inserted tool Sawing Hacksaw Bandsaw Circular saw Process Sub-Process Cutters Volume Capabilities Grinding Cylindrical grinding Centerless grinding Internal grinding External grinding Surface grinding ? flat bottom volume, slot flat bottom volume Grinding wheels Points ? internal wall of round hole flat bottom volume Honing Honing stone ? Lapping Lap most surfaces Tapping Tap threaded wall of hole
- 23. 4- 23 10/12/25 PROCESS TOLERANCE RANGE ProcessSub-Process Cutters Milling Plain Shell end Hollow end Ball end End milling Peripheral milling Plain Slittting Saw Form Inserted-tooth Staggered-tooth Angle T-slot cutter Woodruff keyseat cutter Form milling cutter Face milling Plain Inserted-tooth Drilling Twist drill Spade drill Trepanning cutter Center drill Combination drill Countersink Counterbore Deep-hole drill Gun drill Reaming Shell reamer Expansion reamer Adjustable reamer Taper reamer Boring Adjustable boring bar Simple boring bar Broaching Form tool Turning Turning Facing Parting Knurling Boring Drilling Reaming Plain Inserted Knurling tool Boring bars Drills Reamers Tolerances, surface finish, etc. capabilities roughting finishing tol 0.002 0.001 flatness 0.001 0.001 angularity 0.001 0.001 parallelism 0.001 0.001 surface finish 50 30 roughting finishing tol 0.002 0.001 flatness 0.001 0.001 surface finish 50 30 roughting finishing tol 0.004 0.004 parallelism 0.0015 0.0015 surface finish 60 50 length/dia = 3 usual =8 maximum mtl < Rc 30 usual < Rc 50 maximum Dia Tolerance 0 - 1/8 +0.003 -0.001 1/8-1/4 +0.004 -0.001 1/4-1/2 +0.006 -0.001 1/2- 1 +0.008 -0.002 1 - 2 +0.010 -0.003 2 - 4 +0.012 -0.004 usuall best True position 0.008 0.0004 roundness 0.004 surface finish 100 Dia Tolerance < 5/8 0.0015 >5/8 0.002 surface finish > 100 straightness 0.005 in 6 inch Dia T olerance 0 - 1/2 0.0005 to 0.001 1/2- 1 0.001 1 - 2 0.002 2 - 4 0.003 roughting finishing roundness 0.0005 0.0005 true position 0.01 0.01 surface finish 125 50 length/dia 5 to 8 Dia Tolerance roughing finishing 0 - 3/4 0.001 0.0002 3/4- 1 0.0015 0.0002 1 - 2 0.002 0.0004 2 - 4 0.003 0.0008 4 - 6 0.004 0.001 6 - 12 0.005 0.002 straightness 0.0002 roundness 0.0003 true position 0.0001 surface finish 8 diameter tolerance to 1.0 0.001 1 - 2 0.002 2 - 4 0.003 surface finish 250 to 16 tolerance 0.001 surface finish 125 to 32
- 24. 4- 24 10/12/25 PROCESS TOLERANCE RANGE ShapingForm tool Planing Inserted tool Sawing Hacksaw Bandsaw Circular saw Process Sub-Process Cutters Grinding Internal grinding Cylindrical grinding Centerless grinding External grinding Surface grinding Honing Honing stone Lapping Lap Tapping Tap Tolerances, surface finish, etc. capabilities length tol squareness surface finish cutting rate material 0.01 0.2 200 - 300 3-6 sq in/min to Rc45 0.01 0.2 200 - 300 4-30 sq in/min to Rc45 0.008 0.2 125 7-36 sq in/min to Rc45 roughting finishing location tol 0.005 0.001 flatness 0.001 0.0005 surface finish 60 32 (cast iron) surface finish 125 32 (steel) Dia Tolerance roughing finishing 0 - 1 0.00015 0.00005 1 - 2 0.0002 0.00005 2 - 4 0.0003 0.0001 4 - 8 0.0005 0.00013 8 - 16 0.0008 0.0002 Dia Tolerance roughing finishing 1 +0.0005-0.0 +0.0001-0.0 2 +0.0008-0.0 +0.0005-0.0 4 +0.0010-0.0 +0.0008-0.0 surface finish 4 roundness 0.0005 roughing finishing tolerance 0.000025 0.000015 flatness 0.000025 0.000012 surface fin 4-6 1-4 tolerance 0.003 roundness 0.003 surface fin 75 roughing finishing tolerance 0.0005 0.0001 parallelism 0.0005 0.0002 roundness 0.0005 0.0001 surface fin 8 2 roughing finishing tolerance 0.001 0.0001 parallelism 0.001 0.0001 surface fin 32 2 center ground flat and centerless Internal
- 25. 4- 25 10/12/25 AUTOMOTIVE PARTSREQUIREMENTS • Cylinder bore 13 - 25 in honed • Main bearing bore 63 - 200 in • Crankshaft bearing 3-13 in polished • Brake drum 63-125 in turned • Clutch pressure plate 25-100 in turned
- 26. 4- 26 10/12/25 BASIC MACHINING CALCULATIONS tm= L + L v f Machining time Total amount of time to finish a workpiece. For drilling, one pass turning, and milling: L : clearance or overhang distance. For multipass turning n p = Do – Di 2 a p + integer round up For milling n p = h a p + w D + n p : # of passes h : total height of material to be removed w : workpiece width : cutter overlapping factor = effective cutting width / tool dia 1.0
- 27. 4- 27 10/12/25 BASIC MACHINING CALCULATIONS Machinecontrol parameters are: f, V, ap. a. Feed and feedrate f : inch / rev turning or drilling milling rp m N: # of teech in milling 1 in drilling n : rpm V f = f nN V f = f n V f : inch / min Vf
- 28. 4- 28 10/12/25 BASIC MACHINING CALCULATIONS Cuttingspeed D: Diameter Depth of cut a p inch a p = Do – Di 2 D V surface speed V in sfpm Di D0 V = D n 12
- 29. 4- 29 10/12/25 BASIC MACHINING CALCULATIONS Metalremoval rate MRR cutting time tool life MRR in3 min in3 min Drilling Turning Milling W v f a p MRR = D 2 4 v f = 3D f V MRR = ( D 2 o – D 2 i) 4 v f = 6(Do – Di ) f V v f (D 2 o –D 2 i) 4 MRR = a p w v f = 12 a p w n D f V D 2 4 v f
- 30. 4- 30 10/12/25 BASIC MACHINING CALCULATIONS tm= L + L v f Machining time Total amount of time to finish a workpiece. For drilling, one pass turning, and milling: L : clearance or overhang distance. For multipass turning n p = Do – Di 2 a p + integer round up For milling n p = h a p + w D + n p : # of passes h : total height of material to be removed w : workpiece width : cutter overlapping factor = effective cutting width / tool dia 1.0 L
- 31. 4- 31 10/12/25 CUTTING FORCEAND POWER Process Sub-Process Milling End milling Peripheral milling Face milling Drilling Reaming Boring Shaping Planing Broaching Turning Facing Turning Cutting Force F Power (hp) KF fF ap F Dt F bw z KF v Faf F ap F bw F zF Dt F KF f F ap F KF fF ap F Dt F KF ap F Dmzc c (lb) Fc Vc 33,000 m Fc Vc 33,000 m Fc Vc 33,000 m Ts rpm 63,030 m where: Vc :: cutting speed fpm m : machine efficiency Ts : Torque torque
- 32. 4- 32 10/12/25 MATERIAL REMOVALRATE Process Sub-Process Milling End milling Peripheral milling Face milling Drilling Boring Shaping Broaching Turning W: width of the cutter ap : depth of cut f : feed n : number of teeth N : spindle rpm D : tool diameter tr : rise per tooth W : Width of the tool V : cutting speed n : number of tooth in contact with part 12 tr W V n ( D 2 /4)f N 12 V f ap 12 V f ap Facing Turning 6 V f ap L t f Ns L : strock length Ns: number of strock per minute W ap f n N MRR
- 33. 4- 33 10/12/25 CONSTRAINT S nmin nwnmax ntmin nt ntmax Fc Fc,max Spindle-speed constraint: workpiece tool Feed constraint: Cutting-force constraint: P m Pmax Power constraint: Ra Ra,max Surface-finish constraint: f min f fmax
- 34. 4- 34 10/12/25 MODELS Multiple passmodel t pr th + (ti m i =1 n p + ti m t tt ) c pr cb nb + cmth + ci pr i = 1 n p i : pass number Additional constraint: depth of cut : number of passes is a function of the depth of cut. a p n p Productivity model: p r s – c pr t pr s: sale price/piece