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1995 | Buch

Introduction Kapitel lesen Erstes Kapitel lesen

Principles of Process Planning

A logical approach

verfasst von: Gideon Halevi, Roland D. Weill

Verlag: Springer Netherlands

Enthalten in: Professional Book Archive

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Über dieses Buch

Process planning determines how a product is to be manufactured and is therefore a key element in the manufacturing process. It plays a major part in determining the cost of components and affects all factory activities, company competitiveness, production planning, production efficiency and product quality. It is a crucial link between design and manufacturing. There are several levels of process planning activities. Early in product engineering and development, process planning is responsible for determining the general method of production. The selected general method of production affects the design constraints. In the last stages of design, the designer has to consider ease of manufacturing in order for it to be economic. The part design data is transferred from engineering to manufacturing and process planners develop the detailed work package for manufacturing a part. Dimensions and tolerances are determined for each stage of processing of the workpiece. Process planning determines the sequence of operations and utilization of machine tools. Cutting tools, fixtures, gauges and other accessory tooling are also specified. Feeds, speeds and other parameters of the metal cutting and forming processes are determined.

Inhaltsverzeichnis

Frontmatter
Chapter 1. Introduction
Abstract
The objective of the manufacturing process is to transform an idea into a saleable product.
Gideon Halevi, Roland D. Weill
Chapter 2. Logical design of a process plan
Abstract
To give a global idea of the preparation of a process plan, it seems appropriate to analyze a typical mechanical part and to define the different stages of decisions to be taken. The intention is not to present a complete set of methods of analysis — these are developed in the course of the book — but, rather, to give a general feeling of the nature of process planning as an introduction to the following chapters.
Gideon Halevi, Roland D. Weill
Chapter 3. Geometric interpretation of technical drawings
Abstract
When a technical drawing of a mechanical part is handed over to the production planning department, this drawing must be considered as a contract, to be honored in all its details. This drawing, prepared by the design department, expresses certain functional requirements which have been defined in relation to the functionality of the part in the framework of the complete product.
Gideon Halevi, Roland D. Weill
Chapter 4. Dimensioning and tolerancing for production
Abstract
A part is defined by an engineering drawing which gives complete information on its geometry and associated data. It is the fundamental means of communication between the designer, the process planner and all other functions in the enterprise; it is the medium by which the designer’s intentions and wishes are expressed in an unambiguous manner.
Gideon Halevi, Roland D. Weill
Chapter 5. General selection of primary production processes
Abstract
The process planner defines in detail the process that will transform raw material into the desired shape. The shape is defined by the product designer and is expressed in engineering drawings and GDT — geometric dimensioning and tolerances. The process planner is bound by the defined drawing.
Gideon Halevi, Roland D. Weill
Chapter 6. Selecting detailed methods of production
Abstract
Forming material removal is a most comprehensive process. There is almost an infinite number of combinations of machines and tools that will produce the part as specified by the drawing. However, cost and machining time will vary substantially according to the selected process. Therefore, it requires a skillful handling of the operating conditions in order to arrive at the economic optimum. In this respect, the sensitivity of the machining conditions in relation to the time and cost of machining, can be seen in the following examples.
Gideon Halevi, Roland D. Weill
Chapter 7. Elements of positioning and workholding
Abstract
In order to produce a mechanical part correctly, it must be on a suitable set-up (or jig) which guarantees a well-defined location (position and orientation) in space. The surfaces of the jig represent data references for the coordinate system in which the different features of the part are defined. As an example, Fig. 7.1 shows a prismatic part located on three orthogonal planes simulating datum surfaces existing in the physical jig. These planes are used to set the manufacturing dimensions of the features in the part. As mentioned already in Chapter 2, the exact definition of datum features is found in a recent standard (ISO Standard 5459, 1981) distinguishing between simulated and real datum surfaces.
Gideon Halevi, Roland D. Weill
Chapter 8. How to determine the type of operation
Abstract
Much energy has been devoted over the years in trying to establish theories and algorithms for complete metal cutting optimization. However, most of them have been concerned with the cutting speed parameter. It is an important parameter and it is directly proportional to the machining time. However, if the operation being performed is superfluous, is not an optimum one, or is not carried out with the correct tool, then not only is an unessential operation being performed, but it is uneconomic.
Gideon Halevi, Roland D. Weill
Chapter 9. How to select cutting speed
Abstract
In Chapter 8, operation planning was analyzed. It was shown that selecting an operation plan is not an independent decision; it depends on the selected depth of cut. However, the decision of selecting a depth of cut was partially based on the feed rate decision. Moreover, it will be shown that selecting a cutting speed depends on the depth of cut and feed rate.
Gideon Halevi, Roland D. Weill
Chapter 10. How to select a machine for the job
Abstract
When selecting a machine for a job, one has to consider many parameters, such as the machine’s physical size, power, torque at the spindle, machine accuracy, available speeds and feeds, number of tools, tool change times, hourly rate, batch quantity, etc.
Gideon Halevi, Roland D. Weill
Chapter 11. How to select tools for a job
Abstract
The selection of tools for a job involves many parameters, such as, insert shape, insert grade, tool holder type, method of holding the insert in the holder, etc. Furthermore, there are many tool manufacturers offering a large variety of tools. Only standard tools will be considered. It is not the purpose of this book to promote the use of special tools that may perform an operation in a more efficient way.
Gideon Halevi, Roland D. Weill
Chapter 12. SPC — statistical process control
Abstract
Statistical process control (SPC) is a technique for error prevention rather than error detection. SPC products will be of the required quality because they are manufactured properly rather than because they are inspected. Thus, it increases productivity by reducing scrap and rework and provides continuous process improvement. Other methods — such as flexible manufacturing systems (FMS), computer integrated manufacturing (CIM) and just-in-time (JIT) — which have aimed at increasing productivity, concentrate on hardware flexibility, integration of information flow or reduction of inventory. Seldom does a system use technology flexibility to produce the correct product.
Gideon Halevi, Roland D. Weill
Chapter 13. Hole-making procedures
Abstract
Hole producing seems at first sight to be a simple task. However, there are so many tools and process options available for this operation that care must be taken to select a process which minimizes cost and machining time. The scatter of hole-making time and cost can be within a range of up to 10:1, as shown in Table 6.1.
Gideon Halevi, Roland D. Weill
Chapter 14. Milling operations
Abstract
The logical approach to process planning, as outlined in the previous chapters, holds true for almost all types of processes. In selecting process details and cutting conditions, there are several topics that are unique to milling such as: tool diameter, tool motion direction, tool motion interpolation, length of cut, etc. These special topics are discussed in this chapter.
Gideon Halevi, Roland D. Weill
Chapter 15. Computer-aided process planning (CAPP)
Abstract
In spite of the importance of process planning in the manufacturing cycle, it is still predominantly a labor-intensive activity, leaning heavily on experience, skill and intuition. Dependence on practical experience often precludes a thorough analysis and optimization of the process plan and nearly always results in higher-than-necessary production costs, delays, errors and non-standardization of processes.
Gideon Halevi, Roland D. Weill
Chapter 16. Example of a fully-developed process plan
Abstract
Having analyzed the different aspects of planning the manufacturing of a mechanical part in the previous chapters, it seems appropriate now to apply these general rules to a specific example. The part used in this example is represented in Fig. 16.1.
Gideon Halevi, Roland D. Weill
Backmatter
Metadaten
Titel
Principles of Process Planning
verfasst von
Gideon Halevi
Roland D. Weill
Copyright-Jahr
1995
Verlag
Springer Netherlands
Electronic ISBN
978-94-011-1250-5
Print ISBN
978-94-010-4544-5
DOI
https://doi.org/10.1007/978-94-011-1250-5