This document provides an overview of process planning. It begins by defining process planning as selecting and sequencing processes to transform raw materials into finished components. This includes selecting manufacturing processes, equipment, tooling, and quality assurance methods. The document then discusses different types of process planning, including manual and computer-aided methods. It describes the key activities in process planning like drawing interpretation, material evaluation, process selection, and choosing production equipment and tooling.

1. ME8793- PROCESS PLANNING & COST ESTIMATION
Dr.C.DHARMARAJA
Assistant Professor
Department of Mechanical Engg,
University College of Engineering -Dindigul

2. INTRODUCTION TO PROCESS PLANNING 9
Introduction – Methods of process planning – Drawing
Interpretation – Material evaluation – Steps in process
selection – Production equipment and Tooling selection.
Unit – I

3. Introduction
• Manufacturing:
making of products from raw materials using
various processes, equipment, operations and
manpower according to a detailed plan.

4. Manufacturing System

5. Process planning
• Activities involved to convert design into
the product.

6. PROCESS PLANNING
comprises the selection and sequencing of processes and
operations to transform a chosen raw material into a
finished component.
•
• It is the act of preparing detailed work instructions to
produce a component. This includes the selection of
manufacturing processes and operations, production
equipment, tooling and jigs and fixtures.
• It will also normally include determining manufacturing
parameters and specifying criteria for the selection of
quality assurance (QA) methods to ensure product quality

7. Process planning

8. Design / Manufacturing Interface

10. Process Planning Activities

11. Process Planning Activities

12. Process Planning Methods

13. Types of process planning
• Manual process planning
– Traditional approach
– Workbook approach
• Computer aided process planning
– Retrieval process planning (variant)
– Generative process planning

14. Traditional approach
• Manual
• Based on process planner experience
and intuition it will vary.
• Stages
Stage 1 process planner interpret
product drawing
Stage 2 refer manual
Stage 3  documenting routing sheet

15. Workbook approach
• Modified version of the traditional
approach
• Referring workbook
• Workbook which contains
predetermined sequence of operation
(standard procedures).

16. Advantages of manual process planning
• Suitable for small scale industries.
• Highly flexible.
• Low investment costs.

17. Disadvantages of Manual process planning
• Time consuming process.
• Need a skilled process planner.
• Possibilities for human error.
• Inconsistent process plan.

18. Computer aided process planning (CAPP)
why we need to go for CAPP?
• Overcome the drawbacks of Manual process
planning.
• Reduce the routine work of manufacturing
engineer.
• Act as an interface between CAD and CAM.

19. Benefits of CAPP (2 mark)
• Productivity improvement.
• Production cost reduction
• Elimination of human error.
• Product standardization.

20. Approaches of CAPP
• Retrieval CAPP system (variant
approach)
• Generative CAPP system

21. Retrieval CAPP system
• Concept similar parts will have
similar process plan.
• Process plan for a new product is created
by recalling, identifying or retrieving the
existing plan for similar product.

22. Retrieval CAPP system (procedure)

23. Advantages of retrieval CAPP
• Once a standard plan is produced,
similar plans can be produced using
existing plan.
• Simple programming (when compared
to Generative type).
• Easy to learn and use.
• Commercially available retrieval CAPP
systems are  MultiCapp and MIPLAN

24. Generative Process plan
• In generative approach, the process plan
were generate process plan automatically
without any reference to prior plan.
• Concept the concept is based on
decision logics and pre-coded
algorithms.

25. Components of Generative process
plan
Part
description
Sub system (define
machining
parameters)
Subsystem (define
sequence of
operation )
databas
e
Report
generator

26. Advantages of generative CAPP
• Generate consistent process plan.
• New components can planned easily
• Integrating with an automated
manufacturing facility.
• Example APPAS,CMPP,EXCAP,XPLAN

27. Drawing interpretation
• First step
• Getting information from the drawing.
• Prepared by design department.
• Details required
– Material of the component, its designation
– Number of parts to be produced
– Weight of the component
– Dimensions of the part
– Dimensional and geometric tolerances
– Size and accuracy of the parts

28. Engineering drawing
• Universal language
• Projection
– Orthographic
– Pictorial
• Types of drawing
- Detailed drawing
– Assembly drawing
– Combined drawing

29. Detailed drawing
• Detailed
drawing
– Single part drawing
– Collective single part
drawing

30. Single part detailed drawing

31. Collective part detailed drawing

32. Assembly drawing
• Assembly drawing
– Single part assembly
drawing
– Collective assembly
drawing

33. Single part assembly drawing

34. Collective assembly drawing

35. Combined drawing

36. Information on the drawing sheet
required
• Geometric and dimensions (complete dimensions)
• Material specifications (material code , example SS310)
• Notes of special material treatments (like heat treatment)
• Dimensional tolerances (upper limit and lower limit eg: 10±0.2)
• Geometric tolerances (straightness, flatness, roundness)
• Surface finish specifications (roughness and waviness)
• Tool references
• Gauge references
• Quantity to be produced
• Part lists

37. Material Evaluation
• Second activity of process planning.
• Material selection (done by design engineer)
– Choose the material
• Material evaluation (done by process
planning engineer)
– Check the chosen material for further process

38. Material properties

39. Classification of materials

40. Metals and their classification

41. Metals
• Based on iron content
– Ferrous(iron more)
– Non ferrous (iron content
less)

42. Ferrous
• Ferrous
– Steels (carbon percentage less than
2%)
– Cast iron (carbon percentage more than
2%)

43. Steels
• Steels
– low alloy steel (percentage of alloying element is
less than 5 %)
• Low carbon steel (mild steel) (carbon percentage less
than 0.25%)
• Medium carbon steel (0.25 % to 0.6 % )
• High carbon steel (more than 0.6 %)
– High alloy steel (percentage of alloying
element is more than 5 %)
• Tool steel
• Stainless steel (chromium content is more than 12 %)

44. Cast Iron
• Cast iron (carbon percentage more than 2 %)
– Grey most widely used
– White hard and brittle
– Malleable  highly malleability
– Spheroidal Graphite cast iron (SG cast iron)
high ductility.

45. Non ferrous materials
• Non Ferrous materials (iron content low)
Example Aluminium, Copper, Lead, Tin, Zinc,
Nickel, Titanium, Magnesium
• Properties
– Light in Weight.
– High electrical and thermal conductivity.
– Better resistance to corrosion.
– Ease of fabrication.
– Colour.

46. Polymer
• Polymers a substance which has a
molecular structure built up chiefly or
completely from a large number of
similar units bonded together.

47. Polymers Classification

48. Ceramics
• Ceramics A ceramic is any of the
various hard, brittle, heat-resistant and
corrosion- resistant materials made by
shaping and then firing a nonmetallic
mineral, such as clay, at a high
temperature.

49. Ceramics Properties
• Ceramics are strong, hard and
brittle.
• Can be used at high temperature.
• They are good thermal and
electrical insulators.

50. Ceramic Example
• Alumina
• Silicon
Carbide
• Silicon nitride
• Sialons

51. composites
• Composites composites are the
combination of two or more materials
having superior properties than the
original materials.

52. Composites Classification

53. Material selection process
(procedure)

54. Material evaluation
method
• Steps
– Shape and geometry
considerations
• Dimension
• Size
• Surface finish
– Material property requirements
• Mechanical
• Physical
• service
– Manufacturing considerations
• Interchangeability
• Quality assurance
• Ease of manufacturing and
assembly

55. Steps in process
selection
• Process method of shaping, joining
and finishing
• We need to choose right process.

56. Manufacturing Process

57. Classification of
process

58. Factors in process
selection
• Material form
• Component shape and size
• Economic consideration
• Dimensional and geometric
accuracy
• Surface finish
• Batch size
• Production rate

59. Steps in Process
Selection
• Drawing interpretation (process-shape matrix)
• Identification of critical processing factors
(process material matrix)
• Comparison of potential manufacturing process
(compare)
• Identification of suitable process (select)

60. Process shape
matrix

61. Process material
matrix

62. Production equipment and
tooling selection
• Selection of production equipment (machine)
• Selection of tooling (tool)

63. Factors consider Production
equipment selection (machine)
• Technical factors
– Physical size
– Machine accuracy
– Surface finish
– Cutting force
• Operational factors
– Batch size
– Capability
– availability

65. Tooling selection
constraints

66. Stages in tooling selection
• Evaluation of Process and tooling selection
• Analysis of machining operations
• Analysis of workpiece characteristics
• Tooling analysis
• Selection of tooling