Manufacturing Eng Inner Ing

Content table

1 Draw given working drawings of the parts........................................................................22 Check up of the drawings: materials, dimensions, accuracy, thermal treatment, surface roughness, technical requirements.................................................................................2

2.1 The axle 26.00.002..........................................................................................................22.2 The sprocket 27.00.012...................................................................................................32.3 The cover 26.00.008.......................................................................................................4

3 Analyze the assembly and part drawings for corresponding manufacturing requirements (design for manufacture or producibility)..........................................................5

3.1 The axle 26.00.002..........................................................................................................63.2 The sprocket....................................................................................................................63.3 The cover 26.00.008.......................................................................................................6

4 Decide the type of production and manufacturing method..............................................75 Selection of Blank Making Process.....................................................................................9

5.1 The axle...........................................................................................................................95.2 The sprocket..................................................................................................................105.3 The cover......................................................................................................................11

6 Assign machining allowance for every part.....................................................................116.1 Maching allowances for the axle..................................................................................116.2 Maching allowance for the sprocket.............................................................................126.3 Machining allowances for the cover.............................................................................13

7 Development of Process Route for Every Part.................................................................147.1 Process Route for axle..................................................................................................147.2 Process Route for the cover..........................................................................................197.3 Process Route for the sprocket......................................................................................23

8 Machining time Calculation...............................................................................................288.1 Sprocket........................................................................................................................298.2 The axle.........................................................................................................................318.3 The cover......................................................................................................................35

9 References:...........................................................................................................................39

1

1 Draw given working drawings of the parts

From the assebly drawing 26.00.000.513 it was given three parts: the axle 26.00.002, the

cover 26.00.008 and the sprocket 27.00.012. The drawings are presented in the appendix in the

end of the course work.

2 Check up of the drawings: materials, dimensions, accuracy, thermal treatment, surface roughness, technical requirements

2.1 The axle 26.00.002

In the drawing 26.00.002 all dimensions, the roughnesses, tolerances, cilindricity of the axle

are shown. The material of this detail is constructional carbon steel CT4. Constructional carbon

steel is an alloy of iron and carbon. Chemical structure:

Carbon (0,05-0,49% );

Silicon (0,05-0,35%);

Manganese (0,3-0,8%);

Sulphur (0,05%);

Phosphorus (0,04%);

Other impurities.

Simple constructional carbon steels (GOST 380-71) includes group A wich belong to CT4. The

details manufactured from group A constructional carbon steels are strong and durable. The

greater number of expression CT4 means more carbon in steel and it is stronger and firmer. From

this type of material is produced only details that are loaded moderately.

Surfaces 5 and 10 have no adjoinment with other parts edges, so the roughness of these parst are

Ra 12,5. Surfaces 1 and 3 have adjoinment with other parts, so roughness of it is Ra 0,32.

Surfaces 11, 2 and 4 are the chamfers of 1x45 of the axle. The diameter of surface 1 is

Ø14H6+0,011 of the length 26 mm. Surface 1 like surface 3 adjoin with the corpus of an assembly.

The diameter of surface 3 is Ø12H6+0,011 of the length 12 mm. There are 3 holes inside the axle

for the lubricant. These holes compose of 3 surfaces: 13, 9, 6. The surface 13 is the horizontal

hole of diameter Ø2 mm of the lengh 35 mm. The surfaces 9 and 6 are vertical holes of diameter

Ø2 mm. The hole that is surface 9 has the length of 5 mm, while the other hole that is surfece 6

has the length of 8 mm. Beneath the axle it is drilled the groove of the width of 2 mm, the length

2

of 26 mm and the depth of 1 mm. The groove is the surface 12 and two lateral surfaces 7. The

roughness of the groove is Ra 0,32.

Figure 2.1 The drawing of the axle with numbered surfaces

2.2 The sprocket 27.00.012

In the drawing 27.00.012 all dimensions, the roughnesses, tolerances, paralellism of the

sprocket are shown. The material of the sprocket is constructional alloy steel 45X. The sprocket

have to be resistant to wear and impact of dynamic load. Constructional alloy steel has the

components:

Iron and carbon;

Impurities (Si, Mn, S, P);

Alloying additives.

Constructional alloy steel 45X is of high quality material. According to standart GOST 4543-71

in constructional alloy steel 45X it is 45% of carbon. If alloying additives in material is less than

1%, in the expression the amount of it is not written.

The outer surfaces 5 has no adjoinment with other parts and the roughness of it is Ra 12.5. The

end surfaces 4 and 9 also haven‘t connection with other parts‘ edges and the roughnesses of it

also are Ra 12.5. The diameter of surface 4 is Ø20 mm of the length 13 mm. The diameter of

surface 9 is Ø84 mm of the length 10 mm. The sprocket have 24 teeth, because the indicated

3

number z=24. The tooth is composed of surfaces: 12, 1, 11, 10. The roughness of these surfaces

is Ra 3.2, because teeth have the connection with chain ПP-9525-900 GOST 10947-64. The

height of the teeth is 6 mm. Surface 14 is the chamfer of 1x45 of the axle. Surface 6 is the fillet

of radius R3 mm. The surface 7 is the hole of diameter Ø9 mm of the length 23 mm that has an

adjoinment with the shaft and rotates on it. The roughness of it is Ra 0.8. The surface 3 is the

hole of diameter Ø3 mm of the length 20 mm with the roughness of Ra 20. The surface 13 is the

hole M6x8 GOST1476-64 of the roughness Ra 6.3.

Figure 2.2 The drawing of the sprocket with numbered surfaces

2.3 The cover 26.00.008

In the drawing 26.00.008 all dimensions, the roughnesses, tolerances, paralellism, roundness of

the cover are shown. The material of the cover is grey cast iron CЧ15. Grey cast iron is an alloy

of iron and cast with some impurities: manganese, silicon, sulphur, phosphorus and so on.

Silicon in material is to 4,2%. Grey cast iron CЧ15 is used when the walls‘ thicknes of the

product is 8-15 mm and for not important but difficult construction parts.

The aim of the cover is not to let the impurities from outside. The roughness of the parts that has

no adjoinment with other parts or don‘t make an impact is Ra 12.5. Cover contains of 8 holes of

4

diameter M4x8 GOST 1491-72 those provide better closure of the cover. The cover also

contains of 2 holes for key of diameters of 3x16 GOST3129-70. The surface 11 has contact with

other part: shaft. The roughness of surface 11 is Ra 0.8. The cover has contact with oil-filler and

the surface 9 is used. The roughness of surface 9 is Ra 6.3. The surface 7 adjoins with washer

and the surface roughness is the same Ra 6.3.

Figure 2.3 The drawing of the cover with numbered surfaces

3 Analyze the assembly and part drawings for corresponding manufacturing requirements (design for manufacture or producibility)

In the assembly drawing 26.00.000.513 is represented gear oil pump. The gear oil pump uses

internal gears in order to transfer the liquid oil product from one reservoir to another or to create

the pressure in working capacity of hydraulic cylinders. As the gears rotate they separate on the

intake side of the pump, creating a void and suction which is filled by fluid. The fluid is carried

by the gears to the discharge side of the pump, where the meshing of the gears displaces the

fluid. The mechanical clearances are small— in the order of 10 μm. The tight clearances, along

with the speed of rotation, effectively prevent the fluid from leaking backwards.

5

http://en.wikipedia.org/wiki/Fluid

The rigid design of the gears and houses allow for very high pressures and the ability to pump

highly viscous fluids.

The entire assembly consists of the axle, gears, shafts, ring, sprocket, cover, 2 washers, union,

bracket, filler-cap and other components such like keys, screws, wedges that help to carry out

the main function of gear oil pump.

The requisition for parts is quite high – 750 pieces per year. So, the annual production will be

750 units of every part separately.

3.1 The axle 26.00.002

The detail – axle 26.00.002 is very important part of the assembly 26.00.000.513 which also

contributes to transfer the liquid oil product, has the holes inside for fluid flow supply to other

parts.

The axle has a cylindrical shape and the dimensions are quit small. The part is symmetric,

rigid enough for mechanical treatment. In the drawing all the dimensions are shown with the

required tolerance (h6), the roughness of the surfaces are shown as well.

All surfaces of the axle can be mashined using standart cutting tools and the dimensions of

it can me measured by standard measuring devices.

3.2 The sprocket

Sprocket transmits rotary motion between two parts. Every sprocket is polygon, whose

angles number is equal to the number of sprocket tooth z. Tooth coincide with the chain ПP-

9525-900 GOST 10947-64 that surround the sprocket. The sprocket in oil pump is rotating on

the main shaft and fixed to it with screw M6x8 GOST 1476-64. Chain dynamic hits are less

when the number of teeth is larger. Also in this case the wear of chain is small and and decreases

noise of operation.

3.3 The cover 26.00.008

The aim of this cover is it not let the impurities from outside. The cover 26.00.008 is used to

protect gears, axle and shaft from the outside particles that not to pass into liquid oil. It‘s shape

6

http://en.wikipedia.org/wiki/Viscosity

is composed of planar, cylindrical and curvilinear surfaces. The roughness of the surfaces that

haven‘t the contact with other surfaces or don‘t make an impact for them is Ra12.5.

4 Decide the type of production and manufacturing method.

Type of production (small scale) is selected according to output and overall mass. As it is

necessary 750 pieces per year of every detail separately and the details are of small weight, the

mass of them not reaches 1kg per piece, a small-lot batch production is chosen.

No. Notation of a partNumber

of parts

Annual output,

pieces/year

Mass of a part,

kg

1. The cover 26.00.008 1 850 0,714

2. The sprocket 27.00.012 1 850 0,340

3. The axle 26.00.002 1 850 0,041

The calculation of the masses:

, ƍ – density of a material, V – volume of a part.

Volume of the cylinder:

, where r – radius of the cylinder, h – height of the cylinder, V – volume of the

cylinder.

Volume of the sphere:

, where R- radius of sphere

Volume of ellipsoid:

, where a, b, c are the semi-axis of ellipsoid.

Volume of parallelepiped:

, where a, b, a are the edges of parallelepiped.

Calculation of the mass of the axle:

when and

7

when and

, and are the volumes of the holes that are inside the axle

when and

when and

when and

Calculation of the mass of the cover:

, when a=56 mm, b=30 mm, c=8 mm (half area of

parallelepiped)

, when R=28 mm (half area of the sphere)

(half area of ellipsoid)

(area of cutted sphere)

, when and

, when and (area of 8 holes)

, when and ( area of 2 plugs)

, when and

, when and

, when and

when

when a=30 mm, b=56 mm, c=3 mm (half area of parallelepiped)

8

We know that density of cast iron is:

Calculation of the mass of the sprocket:

, when and

, when and

, when and

, when and

, when and

, when and

We know that density of steel is:

5 Selection of Blank Making Process

5.1 The axle

The axle is a part with cylindrical surfaces. The most efficient way to manfucture this

product is by turning and by drilling the holes inside in it. A rod of cunstructional carbon steel

CT4 can be chosen as a blank, because it is the most suitable for manufacturing the axle. The

lengh of the rod is 6000mm. For manufacturing 850 axles it is neccesarry 6 rods of the steel C T4.

From one rod we can produce 139 axles.

9

5.1. fig. The drawing of the axle‘s blank

5.2 The sprocket

The sprocket is also a cylindrical detail. The best way to manufacture is by turning, by

drilling and reaming the holes and milling the gears in it. A rod of constructional alloy steel 45X

is chosen as a blank whose legth is 6000mm. For manufacturing 850 units of this detail it is

necessary 5 rods of the steel 45X. From one rod it is possible to manufacture 196 sprockets.

5.2. fig. The drawing of the sprocket‘s blank

10

5.3 The cover

The cover is manufactured using casting method in metal forms, because this way is the

most economical and productive, although the cost of metal forms is expensive. Metal forms are

used when the sample size is more than several hundred of pieces. The entire corps is casted and

some surfaces are milled in order to reach better accuracy. All holes are also drilled and reamed

after the casting process also. The material used for casting is grey cast iron CЧ15.

5.3. fig. The drawing of the cover after casting

6 Assign machining allowance for every part

6.1 Maching allowances for the axle

Surface No.

Technologicalprocess

Surfaceroughness

Machiningaccuracy

Allowancee, mm

Tolerance T, mm

Marginal dimensions, mm


Final dimension

,mm

2Zmin 2Zmax min max

5, 10L=38

Rough turningSmooth turning

Rz4012.5

IT14IT12

1,01,0

0,620,25

2,02,0

2,622,25

42,040,0

42,8740,25

42,8740,25

1Ø14H6


Preparative grindingSmooth grinding

Rz40Rz201.25

0.32

H14H12H10

H6

1,80,70,22

0,22

0,430,180,07

0,011

1,80,70,22

0,22

2,230,880,29

0,231

16,9415,1414,44

14,22

17,63115,40114,521

14,231

17,63115,40114,521

14,231

11

3Ø12H6


Preparative grindingSmooth grinding

Rz40Rz201.25

0.32

H14H12H10

H6

1,80,70,22

0,22

0,430,180,07

0,011

1,80,70,22

0,22

2,230,880,29

0,231

14,9413,1412,44

12,22

15,63113,40112,521

12,231

15,63113,40112,521

12,231

12Groove

DrillingSmooth grinding

1.250.32

H10H6

1,00,1

0,040,006

1,00,1

1,040,106

0,961,994

1,92,0

1,92,006

9,6,12Ø2(3

holes)Drilling Rz20 H10 1,0 0,04 1,0 1,04 1,96 2,04 2,04

6.2 Maching allowance for the sprocket

Surface No.


Surfaceroughness

Machiningaccuracy

Allowancee, mm

Tolerance T, mm



Final dimension,

mm2Zmin 2Zmax min max

9,4L=24


Rz40Rz12.5

IT14IT12

1,01,0

1,50,7

2,02,0

3,52,7

2826

30,226,7

30,226,7

12z=24m=23

Rough turningGear shapingGear shaving

12.53.23.2

H14H12H10

3,61,050,12

0,8700,3500,140

3,61,050,12

4,471,40,26

88,7785,1784,12

90,1385,6684,26

90,1385,6684,26

5Ø20


Rz40Rz12.5

H14H10

2,00,7

0,520,21

2,00,7

2,520,91

23,221,2

23,99621,476

23,99621,476

7Ø9

DrillingReamingSmooth grinding

Rz202.50.8

H10H9H8

0,30,20,1

0,0580,0360,022

0,30,20,1

0,3580,2360,022

8,6428,7649,0

8,78,9

9,037

8,78,9

9,037

3Ø3 Drilling Rz20 H10 1,0 0,04 1,0 1,04

2,963,04 3,04

13M6x8

DrillingScrew-tap

Rz206.3

H10H8

0,20,04

0,0480,018

0,20,04

0,2480,058

5,7526,04

5,86,058

5,86,058

2Ø84 Smooth turning Rz 12.5 H12 3,6 0,160 3,6 3,76 84,16 87,76 87,76

12

6.3 Machining allowances for the cover

Surface No.


Surfaceroughness

Machiningaccuracy

Allowancee, mm

Tolerance T, mm



Final dimension,

mm2Zmin 2Zmax min max

1 Rough millingSmooth milling

Rz2012.5

H10H12

0,50,08

0,3500,140

0,50,08

0,850,22

83,5883,08

84,0783,22

84,0783,22

6 Smooth milling 12.5 H10 0,11 0,120 0,11 0,23 66,11 66,23 66,23

11Ø12H6

DrillingReamingSmooth grinding

Rz202.50.8

H10H9H8

1,00,470,1

0,070,0430,045

1,00,470,1

1,070,9

0,145

10,9311,5312,0

11,011,9

12,045

11,011,9

12,045

7Ø13

DrillingReaming

Rz206.3

H10H8

1,00,05

0,070,033

1,00,05

1,070,083

11,9313,05

12,013,0850

12,013,0850

9M5

DrillingScew-tap

Rz206.3

H10H8

0,20,04

0,0750,002

0,20,04

0,2750,062

4,7255,04

4,85,062

4,85,062

16Ø5x8 Drilling Rz20 H10 1,0 0,048 1,0 1,048 4,952 5,048 5,048

5Ø3x2 Drillimg Rz20 H10 1,0 0,04 1,0 1,04 2,96 3,04 3,04

10, 12L=24

Rough millingSmooth milling

Rz2012.5

H10H12

1,01,0

0,0480,04

1,01,0

1,2101,084

2625

26,29425,084

26,29425,084

7 Development of Process Route for Every Part

The turning machine, milling machine and grinding machine were chosen from the products

catalog of www.staklija.lt . The turning tools, milling tools were chosen from products catalogs

of the company “Tungaloy“. The grinding tools were chosen from products catalog of Yinglong

13

http://www.staklija.lt/

Superhand Materials Manufactury. Measuring tools were chosen from the book “Inžinieriaus

mechaniko žinynas“.

7.1 Process Route for axle

The entire process route is taken in the following table:

Operation No. Operation Machine Cutting tools and measuring devices

Notes

005Rough turning of the end of a blank of the

axle of diameter Ø 12

mm, that is surface 5,

taking of 1mm

Rough turning of outer surface 1 from Ø 17,63

mm mm to Ø15,40 mm in the distance of

26 mm by 2 passes

Rough turning of outer surface 3 from Ø15,63 mm to Ø13,40 mm in the distance of 12 mm by 2 pass

Universal turning machineGS5264

3 jaw chuckTurning knife:

JCCWSR/L1616K2 p.21

Insert:JCCN200F p.21

Turning knife:Toolholder:

JSVJ2BR-L1616H11 p.14

Insert:VBGT110300-FR/L-

J10p.23




J10p.23

During this operation the

The axle is fixed in 3 jaw chuck.

Taking off 1 mm of end surface by one pass ap=1.0, f=0.2

Rz40

1 pass 2 mmØ 17,63mm Ø15,63mm2 pass Ø

15,63mm Ø 15,40mm

ap= 1 mm, f=0.2 mm/revRz40

1 pass 2 mmØ 15,63mm Ø13,60mm

2 pass 13,6013,40mmap= 1 mm, f=0.2

Rz40

14

Smooth turning of the end of a blank of the axle of diameter Ø 12 mm, that is surface 5, taking of 1mm.

Smooth turning of surface 3

from 13,40 mm to 12,52 mm in the distance of

26 mm by 1 pass


from 15,40 mm to 14,52 mm in the distance of

12 mm by 1 pass

Making chamfers of 45 degrees of 1mm of surfaces 4, 2, 11 by 1 pass

Cutting of the end of a blank of the axle of diameter Ø 14

Turning knife:JCCWSR/L1616K2

p.21Insert:

JCCN200F p.21




J10p.23




J10p.23


PSSNR/L202K12EInsert:

SNGN120408-DIA


p.21Insert:

Taking off 1mm of end surface by one pass ap=1.0, f=0.2

Rz12.5

.





by one passap= 1 mm, f=0.2

mm/revRz12.5

1 pass 2 mmRz12.5

15

mm, that is surface 10

taking off 2 mm

JCCN200F p.21

010

Technical control

Control table Control board 100x100

Calipers ШЦ-1-125-01 GOST 166-89

Checking the surface roughness

andchecking the

dimensions of surfaces 5, 1, 3, 4,

2, 11

015

Drilling of the surface 13 of

diameter Ø2,04 mm of the

depth 35 mm.

Drilling machine GS2116

GIGA JET DRILL:DSX0300F08

p.450

In this case hole is drilled up to 2,04 mm, ap= 0.3 mm,

f=0.3 mm/revRz20

020

Drilling of the groove (2 mm) of the length 26

mm, that is surface 12.

Drilled up to Ø 1,9 mm.



p.450

In this case groove is drilled up to 1,9 mm; ap= 0.3 mm,

f=0.3 mm/revRz1.25

025Drilling of the surface 9 of diameter Ø2 mm of the

depth 6 mm

Drilling of the



p.449


In this case hole is drilled up to 2,006 mm, ap= 0.3 mm,

f=0.3 mm/revRz20

In this case hole is

16

surface 6 of diameter Ø2 mm of the

depth 6 mm

p.449 drilled up to 2,006 mm,

ap= 0.3 mm, f=0.3 mm/revRz20

030

Technical control




andchecking the

dimensions of surfaces 13, 12, 9,

6

035HardeningHRC=62

Furnace of heating

Oil reservoir Temperature of oil is

(840 - 860)°C

040

Preparative grinding of the surface 3 of the length 12 mm from12,52 mm till 12,23 mm

Smooth grinding of the surface 3 of the length 12

mm from12,23 till 12 mm

Preparative grinding of the surface 1 of the length 26 mm from14,52 mm till 14,23 mm

Combined grinding machineBP-100

Plain WheelsIAI/T2(P)

D-150mm W-4mm Y-20mm H-32mm

CBN Content (carat/ piece): 121.09







from12,52 mm till 12,23 mm

Rz1.25

from12,23 mm till 12,0 mmRz0.32

from14,52 mm till 14,23 mm

Rz1.25

17

Smooth grinding of the surface 1 of the length 26 mm from14,23 till 14 mm

Smooth grinding of the surface that is groove, up to

the width 2,006mm







from14,23 mm till 14 mmRz0.32

From 1,9 mm to 2,006 mm

Rz0.32

045Washing of a

partPressure water

jet cleanersMachine clamps

Pressure water jetby removing all

metal remainders from work

050

Technical control




andchecking the

dimensions of surfaces: 3, 1, 12

7.2 Process Route for the cover


Operation No. Operation Machine Cutting tools and measuring devices

Notes

005

18

Casting of the cover

Casting of the coverin metal form

010

Rough milling of the surface 10 of diameter the cover 83 mm

taking off 1 mm (ap=1,0 mm,

f=0,1 mm/rev)

Smooth milling of the surface 10 of diameter 83

mm taking off 1 mm (ap=1,0 mm, f=0,1 mm/rev)

Rough milling of the surface 1 of length 25 mm from 84,07 mm

to 83,22mm.

Smooth milling of the surface 1 from 83, 22 mm

to 83,00 mm

Universal milling machine

PROMA FHV-50

3 jaw chuckMill:

TM054001/317p.317Insert:

TMD5404R/LIEp.339

3 jaw chuckMill:

TM054001/317p.317Insert:

TMD5404R/LIEp.339

3 jaw chuckMill:

TM054001/317p.317Insert:

TMD5404R/LIEp.339

3 jaw chuckMill:

TM054001/317p.317Insert:

TMD5404R/LIEp.339

The part is fixed in 3 jaw chuck.taking off 1 mm

(ap=1,0 mm, f=0,1 mm/rev)

Rz20

taking off 1 mm (ap=1,0 mm,

f=0,25 mm/rev)Rz12.5

from the length of the cover 84,07 mm to 83,22mm by 1 pass (ap=1,0 mm, f=0,1 mm/rev)

Rz20

from the length of the cover 83,22 mm to

83,00mm by 1 pass

(ap=1,0 mm, f=0,25 mm/rev)

Rz12.5

Smooth milling Mill: from 66,22 mm

19

015of the surface 6 from 66,22 mm

to 66 mm.

Drilling of the surface 16 of diameter Ø5

mm ( 8 holes).It is drilled the

hole to diameter of Ø 5,048 mm


diameter Ø3 (2 holes).

Drilling of surface 9 of diameter M5 mm. We get

hole of diameter Ø4,8 mm.


diameter Ø13 mm. Firstly,

hole is drilled to 12,0 mm

Reaming of surface 7 from

Ø 12 mm to Ø13 mm.

TN4405 R/LIE p.317Insert:

SEKN1203AGTN p.346

Tool:DSX0500F03

p.449

Tool:DSX0300F03

p.448

Tool:DSX0700F03

p.448

Tool:DSX1210F03

p.448

Tool holder:JS08H-SEXPR047

Inserts:EPGT040102L-J08

to 66 mm by one pass (ap=1,0 mm, f=0,25

mm/rev)Rz12.5

The hole is drilled to

diameter of Ø 5,048 mm


Rz20




Rz20




Rz20




Rz20

The hole is reamed from 12,0 mm to Ø 13,085 mm

20

Screw-tapping of the surface 9 of diameter M5 and after screw-tapping we get the hole of M5

mm.

Insert:11NR15ISO


Rz6.3

The hole is screwed toM5, Rz20

020

Technical control Control table

Control board 100x100


Checking the surface

roughness andChecking thedimensions of

surfaces: 1, 7, 9, 6

025


diameter Ø12 of the depth 22

mm. Firstly, it is drilled the hole of diameter of

Ø11.

Reaming of the surface 11 of diameter Ø12 of the depth 22 mm. It is reamed the hole to 11,8 mm.

Tool:DSX1100F03

p.448

Tool holder:JS08H-SEXPR047


The hole is drilled of diameter

Ø11mm (ap=1,0 mm, f=0,3 mm/rev)

Rz20

The hole is reamed from Ø11mm to Ø

11,9 mm(ap=1,0 mm,

f=0,3 mm/rev)Rz2.5

030Technical

control Control tableControl board

100x100Calipers ШЦ-1-125-


roughness and

21

01 GOST 166-89 Checking thedimensions of

surface: 11

035

Smooth grinding of the surface 11 of

diameter Ø12 of the depth 22

mm from 11,8 to 12 mm




From Ø 11,9 mm to Ø 12

mm,Rz0.8

040

Washing of a part

Pressure water jet cleaners

Machine clampsPressure water jet

by removing all metal

remainders from work.

05

Technical control

Control tableControl board

100x100Calipers ШЦ-1-125-

01 GOST 166-89


roughness andChecking thedimensions of

surface: 11

7.3 Process Route for the sprocket


Operation No.

Operation Machine Cutting tools and measuring devices

Notes

005Rough

turning of the end of a

blank of sprocket of diameter 20 mm, that is surface 4

taking off 2

Universal turning machineGS5264

3 jaw chuckTurning knife:

JCCWSR/L2020K2 p.21

Insert:JCCN200F p. 21

The part is fixed in 3 jaw chucks taking off 1 mm

(ap=1, f=0.3),Rz40

22

mm

Rough turning of

outer surface 12 from 90,13

mm to 85,66 mm in the distance of 13 mm by 3

passes.

Rough turning of outer surface 5 from 84,0 mm to 24,0 mm in the distance of 11 mm by 30 passes

Making chamfers of 45 degrees of 1mm of surface 14

by one pass

Smooth turning of

the end of a blank of

sprocket of

Turning knife: JTTACR/

L0810K08 p.12Insert:

TCMT110204-PMp.11

Turning knife: JSCACR/L1010H06

p.15Insert:

CCMT060204PMp.10


p.15Insert:

CCMT060204PMp.10


p.21Insert:

JCCN200F p. 21

1pass2mm90,13mm88,13mm

2pass 88,13mm86,13mm3pass86,13mm85,66mm

where ap=1 mm, f=0,3 mm/rev.Rz12.5

by 30 passes, where ap=1 mm, f=0,3 mm/rev,

1 pass 2mmRz40

1pass 1mmby 1 pass, (ap=1.0 mm,

f=0.3 mm/rev)Rz12.5

taking off 1 mm(ap=1, f=0.15)

Rz12.5

23

diameter 20 mm, that is surface 4taking of

1mm


from 21,47mm to

20mm

Smooth turning of the surface 2 of width 10 mm from 13,76 mm to 10 mm by 2 passes

Drilling of the surface

7 of diameter Ø9 mm of the depth 24

mm. hole is drilled to 8,7 mm

Reaming of the hole 7 of diameter Ø9 mm of the depth 24 mm. The hole is


p.15Insert:

CCMT060204PMp.10

Turning knife: JCGSSR/L1616K3

p.20Insert:

JTGR/L3095Fp.20


p.448

Toothholder:JS08H-SEXPR047





2pass2mm11,36mm10mm


The hole is drilled to 8,7 mm

ap= 0.3 mm, f=0.3 mm/revRz20

The hole is drilled to 8,9 mm

ap= 0.3 mm, f=0.3 mm/revRz2.5

24

reamed to 8,9 mm

Cutting off the end of a blank of the shaft of diameter Ø 14 mm, that is surface 10 takking off 2 mm


JSTGR/L1616K3p.20

Insert:JTGR/L3050F

p.20

by 1 pass taking off 2 mm (ap=1,0 mm, f=0,3 mm/rev).

Rz12.5

010 Technical control



Checking the surface roughness and

checking the dimensions of surface: 4, 12, 5, 9, 7

015

Drilling of the surface

3 of diameter Ø3 mm of the depth 20

mm.

Vertical drilling machine

GIGA JET DRILL:

DSX0300F03

p.449

Drilling of the surface 3 of diameter Ø3 mm of the

depth 20 mm, where (ap=0,3 mm, f=0,3 mm/rev).

Rz20

020Drilling of the surface

13 of diameter

M6x8. Hole is drilled of Ø5,8 mm

Vertical drilling machine

GIGA JET DRILL:

DSX0530F03

p.448

Hole is drilled of Ø5,8 mm of the depth 20 mm.

(ap=0,3 mm, f=0,3 mm/rev).Rz20

25

of the depth 20 mm

Screw- tap of surface

13 of diameter

M6x8 from diameter of 5,8 mm M6.

Insert:

11NR15ISO

Screw tapping pf the hole to M6,

(ap=0,3 mm, f=0,3 mm/rev).Rz6.3

025Technical

control




checking the dimensions of surfaces: 13, 3

030

Gear shaping of

the surfaces 1, 11, 10.Making

teeths of the sprocket,

when z=24, m=24

PROMA FPX-25E

Mill:CoroMill® 245

Holder:P/N 3077 (8.0 mm End Mill Holder)Pneumatic clamps

Making teeths of the sprocket, when z=24, m=24,

where ap= 0.3 mms=0.2mm/rev

Rz3.2





checking the dimensions of surfaces: 1, 11, 10

040

Smooth grinding of the teeth of surfaces 1, 11, 10 to length of

Combined grinding machine BP-100




Smooth grinding of the teeth of surfaces 1, 11, 10

to the length l=6mm, where ap= 1.0mm, f=0.2mm/rev.

Rz3.2

26

teeth 6mm

045

Grinding of the hole 7

of diameter Ø9 mm of

the depth 24 mm from


till Ø 9 mm.

Combined grinding machine BP-100

Elaboric grinding disk:

1A1-1 (LLP-1)p.435

Grinding of the hole 7of diameter Ø9 mm of the

depth 24 mm from diameter of Ø 8,9 mm till Ø 9 mm.

Rz0.8

050Washing of

a partPressure water jet cleaners

Machine clampsPressure water jet Removing all metal

remainders from work.





checking the dimensions of surface: 1, 10, 11, 7

060

Coating Combined grinding machine BP-100

The part is coated by the layer of lubricant

8 Machining time Calculation

, where z= number of teeth of the sprocket

- formula used screw-tapping

27

Where

Sm= , mm/min

s- feed for one revolution, mm/rev

n- frequency of a blank:

, rev/ min

where v- cutting speed, m/min

d- diameter of the blank before machining, mm

L- full required length L=l+l1+l2, mm

l- length of the surface to be machined, mm

l1 – length of the travel required for tool aproach, mm

l2 – length of the overtravel of the tool or workpiece in the direction of the feed, mm

i- numer of passes

8.1 Sprocket

Operation No.015

Time required for the drilling surface 3

s=0.3mm/rev

v=230m/min

d=3mm

Calculation:

L=l+ l1+l2

l=20 mm

l1=l2=0,54mm

L=20+0,54+0,54=21,8mm

min

28

Operation No.020

Time required for the drilling surface 13

s=0.3mm/rev

v=140m/min

d=6mm

Calculation:

L=l+ l1+l2

l=5,5 mm

l1=l2=1,09mm

L=5,5+1,09+1,09=7,68mm

min

Time required for the screw-tapping for the surface 13:

s=0.3mm/rev

v=140m/min

d=6mm

L=5,5mm

Calculation:

min

Operation 030

Shaping of surface (making teeth) 1,11,10 (sides of the teeth)

d=84mm

s = 0,2 mm/rev (feed),

29

v = 180 m/min (cutting speed)

In this case .

Machining time:

min

8.2 The axle

Operation 005

Time required for rough turning of the surface 5

The data for Tm1, which is taken from the table:

s= 0.2 mm/rev

v=120m/min

d=12 mm

L=12mm

Calculation:

min



s= 0.2 mm/rev

v=150m/min

d=14mm

L=26mm

Calculation:

30

min



s= 0.2 mm/rev

v=120m/min

d=12mm

L=12mm

Calculation:

min

Time required for smooth turning of the surface 5:


s= 0.2 mm/rev

v=180m/min

d= 12mm

l=1mm

Calculation:

L=l+ l1+l2

l1= l2 =0,84mm

L=1+0,84+0,84=1,68mm

min

31



s= 0.2 mm/rev

v=180m/min

d= 12mm

l=12mm

Calculation:

L=l+ l1+l2

l1= l2 =0,84mm

L=12+0,84+0,84=13,68mm

min



s= 0.2 mm/rev

v=180m/min

d= 14mm

l=26mm

Calculation:

L=l+ l1+l2

l1= l2 =0,84mm

L=14+0,84+0,84=15,68mm

min

Time required for making chamfers of surface 4:

32


s= 0.2 mm/rev

v=180m/min

d= 12mm

l=1mm

Calculation:

L=l+ l1+l2

l1= l2 =6mm

L=1+6+6=13mm

min



s= 0.2 mm/rev

v=180m/min

d= 14mm

l=1mm

Calculation:

L=l+ l1+l2

l1= l2 =7mm

L=1+7+7=15mm

min



s= 0.2 mm/rev

33

v=180m/min

d= 14mm

l=1mm

Calculation:

L=l+ l1+l2

l1= l2 =7mm

L=1+7+7=15mm

min

Time required for cutting of the surface 10:


s= 0.4 mm/rev

v=250 m/min

d=14 mm

L=1mm

Calculation:

min

Total time required for operation 005

Tm=Tm1+Tm2+Tm3+Tm4+Tm5+Tm6+Tm7+Tm8+Tm9+Tm10=

0,06+0,076+0,04+0,0002+0,016+0,02+0,013+0,018+0,018+0,0004=0,261min

8.3 The cover

Operation 010

Time required for rough milling of the cover end (surface 10):

34


s= 0,2 mm/rev

v=150m/min

n= 477rev/min

L=56mm

Calculation:

min

Time required for smooth milling of the cover end (surface 10):

The data for Tm, which is taken from the table:

s= 0,3 mm/rev

v=200m/min

n= 636rev/min

L=56mm

Calculation:

min

Time required for rough milling of the surface 1:


s= 0,2 mm/rev

v=150m/min

n= 477rev/min

L=25mm

Calculation:

min

Time required for smooth milling of the surface 1:


35

s= 0,3 mm/rev

v=200m/min

n= 636rev/min

L=25mm

Calculation:

min

Total time required for operation 010

Operation 020

Time required for drilling the hole of surface 11:


s=0.25mm/rev

v=100m/min

d=12mm

L=22mm

min

Time required for rough boring of the surface 6:


s= 0.2 mm/rev

v=150m/min

d= 30.13mm

Calculation:

L=l+ l1 +l2

l1=l2=0.63mm

36

L=25+0.63+0.63=26.26mm

min

Total time time required for operation 020:

Tm=Tm1+Tm2= 0,033+1,48=1,513min

37

9 References:1. Mašinų gamybos technologijos pagrindai : vadovėlis / Antanas Juozas Bražiūnas. Kaunas, 2004.

512, [1] p. ISBN 9955-09-558-X2. Užlaidų mechaniniam apdirbimui analitinis apskaičiavimas ir parinkimas : mokomoji knyga /

Ramutis Krančiukas. Kaunas, 2007. 102 p. ISBN 978-9955-25-341-93. Inžinieriaus mechaniko žinynas / Balys Dragūnas, Kęstutis Pilkauskas, Antanas Stasiūnas,

Raimundas Stasiūnas. Vilnius, 1988. 526 p. ISBN 5-420-00028-84. UAB Staklija produktų katalogas. www.staklija.lt;5. „Tungaloy“ įrankių katalogas. www.tungaloy.co.jp/ttj/english/products/cutting/cutting_11.html

38

Documents

Manufacturing Eng Inner Ing