INTRODUCTION

The purpose of course work of manufacturing engineering is to test, to deepen one's knowledge and to specialize to all knowledge in practice.

In this project student deal with manufacturing engineering tasks, creatively using all theoretical knowledge attained in lectures. Student should learn to use literature: directories, standards, tables and catalogues.

The course works tasks are to precisely study assembly drawings, its parts and define service function (to draw necessary parts). Decide the type and production and manufacturing method, select the blank making process for all parts, and to develop process route for every of them. Assign machining allowance and plan one machining operation for every part. Fill in process chart forms. In procedure all process planning steps should be described. All decisions should be motivated and explained. Calculations should be complete.

Procedure:

1. Study the assembly drawings and define service function of the joint.
2. Study the parts drawings and define service function of the parts and purpose of different surfaces.
3. Check-up drawings: materials, dimensions, accuracy, thermal, treatment, surface roughness, and technical requirements.
4. Analyze the assembly and part drawings for corresponding the manufacturing requirements (design for manufacture or productivity).
5. Decide the type of production and manufacturing method.
6. Select the blank making process for all parts.
7. Develop part process route for every part.
8. Assign machining allowance for very part.
9. Plan one machining operation for every part.
10. Fill in process chart forms.
11. Develop assembly process.

Drawings:

1. Additional working drawings
2. Blanks
3. Set up Drawings
4. Assembly flow charts

1. Study the assembly drawings and define service function of the joint.

Our joint is called bearing box. It is used as bridge for transferring rotation and velocities. One shafts end is driven by proper rotation, than transferred to another end of the shaft.

Construction contains such details:

1. 1 shaft
2. 2 bush
3. 1 plate
4. 2 edges
5. 1 pipe
6. chock
7. 1 ring

2. Study the parts drawings and define service function of the parts and purpose of different surfaces.

Shaft

Shaft is used for carrying rotating machines elements and secures its constant position. In our bearing box we have transferring shaft- it always rotates and transfers moment of rotation.

Surface roughness is different on proper surface of the shaft. So it has different purposes and detail to be attached on it.

Bush

Bush is used for support the metal tube 5.

This fixing bush serves to fix inner part (shaft).

Chock

Chock - a piece of wood or other material put next to cargo to prevent it from shifting. In our case it is made according to standards GOST 23360-78. It is of dimensions 8x7x40 . Chock no. 7 is put in proper gap in the shaft. It prevents of the shaft hole from slipping out in the thrust direction.

Chock "Inzinerinės mechanikos zinynas" 270page

Edge

Edge is used for holding bearing box, which consists of shaft, 2 hubs, pipe, wedge and ring, and it is directly attached to beam (denoted by 5) by welding according to standards T1-Δ3-15/30, with 7^th surface of edge's. Height of edge is 64mm and length 130mm.

Edge is also attached to the plate (foundation of all bearing box) number 3 by welding according to standards T1-Δ3-15/30 with surface 1^st in length 130mm.

It is also necessary to mention that 2 edges are used in bearing box, attached at the ends of beam no 5.

Surfaces of the edge do not play important role in bearing box - it is used for welding it to plate no3, and beam no6. So edge's roughness of surfaces is big Rz80, it is enough to cut it from sheet.

Plate

It is used as foundation for all the bearing box. It supports such details like 2 edges, shaft, 2 hubs, pipe, wedge and ring. 2 edges stand of the machine on it. Plate and 2 edges are welded by standard T1-∆3-15/30.

In our bearing box we have 1 plate. It is quadrant and its dimensions are 130x130mm. It has 4 holes of diameter 9mm. Clear plate's scheme is added to course works drawings.

Surface of the plate does not take important role in bearing box- just used for welding of 2 edges, so it roughness is big.

Pipe

In bearing box we have 1 pipe of length 95mm. outher diameter is 60mm, inner 53.6mm, thickness of wall is 3.2mm. Pipe is the outer detail of the machine - housing. It is attached on the 2 hubs. Pipe does not let hubs to move. It is welded with hubs by standard T1-∆3-15/30.

Ring

Retaining spring flat concentric rings for shafts. It is of diameter of 34mm. It is put in proper gap in the shaft. It prevents of the shaft hole from slipping out in the thrust direction.

Bush

3. Check-up drawings: materials, dimensions, accuracy, thermal, treatment, surface roughness, and technical requirements

Shaft

For shaft used steel is 35 GOST 1050-74. It is carbonic good quality constructional steel. Marks number 35 shows mean quantity in percent hundredth part of carbon. This steel is used for thermally processed, which needs hard and strong surface. Such details surface during tempering is heated fastly by high frequency electric current (ADES) or by the flame of gas and then cooled. Standarts 35 GOST 1050 is compared with mark EN 86-70C36. The chemical composition is strictly regulated, and the damaging impurities are less than in simple steel. That's why in all cases the such mechanical properties like hardness and strength is stable. The normal magnetic properties of this type of steel will be accepted.

The chemical analyses for the product and heat analyses shall tall within the following ranges (%):

Carbon (C)  0,05 min - 0,12 max

Manganese (Mn)  0,35 min - 0,65 max

Silicon (Si)  0,17 min - 0,37 max

Chromium (Cr) - 0,10 max

Sulphur (S)  - 0,04 max

Phosphorus (P)  - 0,035 max

Nickel (Ni)  - 0,25 max

Copper (Cu)  - 0,25 max

Arsenic (As)  - 0,08 max

The steel shall conform to the following minimum mechanical requirements:

Tensile strength (s_max) - 330 MPa

Yield strength (s - 230 MPa

Elongation to failure (A5) - 27 %

The dimensions are represented on the fallowing picture.

Bush

Bush mterial is textolite PTK 20 GOST 5-72. The length of part is 20 mm. Textolite is a layered leaf electrotechnics material with a cotton base and binding thermosetting material manufactured due to pressing sopping binding material of the cotton texture, which base is formed by phenol formaldehyde resin. Becsause of its specific consist this plastic is very rigid, strike resistant and have an excellent insulating properties. The plates and sticks is compression resistant, simple drilling, cutting, punching. Textolite is wide used in the manufacture of parts, which are strongly acted by electrical or mechanical charges and friction. Textolite is simply machined by all mechanical machining methods. This material is used in the manufacture of different mechanical parts, bushing, rollers, pump rotor plates, insulating plates and so on. Parts of textolite secure low work, significantly long working time, comparatively less weight to compare with metal ones. It can be used in work with transformer oil and in the environment with temperature from

۫C to +105 ۫C.

Length of bush is 20 mm, width and height are 60 mm, so it is a small part of the joint.

Because of tolerance H11 it has enough high accuracy. It means that spread of deflections in respect to a nominal dimension is very small.

Roughness of an outer and inner surfaces is 20 and 40 correspondingly. It means, that these surfaces are not very high manufactured.

Edge

The material of the detail (edge) is used steel 4GOST 19903 - 74 / Cm3 GOST 14637 - 89.

It is carbonic simple constructional steel. Cm - is the mark of steel and it shows steels tension, how strong steel is (in our case it is 240 MPa). It is used for important part of machine elements: roller, gearings, some parts of machines of agriculture. Also welded or riveted from sheets and other profile metal, not important rollers, axles, split chucks, gears, screws, levers and other, commonly thermally not processed details, are maid from steel Cm.

All detail dimensions and surface roughness are shown in the drawing. In our case surface roughness is Rz80 for all surfaces and it belongs to 3^rd class of roughness. It means that surface is rough and does not need additional work to do, during the procedure of manufacturing of edge. Number 4 shows the thickness of the sheet, it is also denoted in the drawing by S4. Overall mass of the edge is 0.25 kg. Detail has trapezium shape, and is rigid for mechanical manufacturing. Edge is simple to manufacture because all surfaces are easily processed and it's accuracy class is not high (do not need extra operations). During all manufacturing process we use universal tools. Detail is connected to others by welding according to standards T1-Δ3-15/30. 2 edges should be made to complete assembly and annual output should be 600. We manufacture a little bit more due to failures.

The chemical composition of simple constructive steels. Quantities are given in %.

Due to standards there may be some chemical composition deviations.

Sheets are made using hot rolling method.

Mechanical properties of steel (GOST 14637 - 89):

Plate

For plate used steel is .

It is carbonic simple constructional steel. - is the mark of steel and it shows steels tension, how strong steel is. It is used for important part of machine elements: roller, gearings, some parts of machines of agriculture. Also welded or riveted from sheets and other profile metal, not important rollers, axles, split chucks, gears, screws, levers and other, commonly thermally not processed details, are maid from steel.

Number 6 shows the thickness of sheet.

Chemical composition %

Due to standart there may be some chemical compositions devation.

Mechanical properties:

The roughness of plate is for all the surface. It means that surface is rough and does not need additional procedures during the production of plate.

The dimensions are represented on the fallowing picture.

Pipe

For pipe used steel is DIN59410. This standard applies to seamless or welded hot formed steel, used primarily for structural steel engineerng.

The outer pipes surface roughness is not important, so we take it Rz80. it is rough and no additional processing is needed. Inner surface roughness is Rz20. It is enough rough.

Ring

The material used for ring is A34 GOST 13940-86

There are represented dimentions of the ring.

4.Analyze the assembly and part drawings for corresponding the manufacturing requirements (design for manufacture or productivity).

As was mentioned previously our bearing box is used as bridge for transferring rotation and velocities. One shafts end is driven by proper rotation, than transferred to another end of the shaft. In order to improve the rotation bearing may be used. They should be attached to the shaft and in the hub. Then no additional lubrication will be needed, as they are needed in this construction of project now.

5. Decide the type of production and manufacturing method.

We need to make 300 pieces of bearing box. There are needed 2 details like edge and hub in the bearing box. So we need to make twice of them pieces. 600 pieces are referred to the medium-lot production.

300 bearing boxes are refered to the small-lot production. Small-lot production makes use of universal equipment, universal tooling and measurement means.

Bearing box mass is:

6. Select the blank making process for all parts.

Shaft

The sold bars of 35 GOST1050-74 are sold of such parameters:

Need to mention, that bars can be sold in needed length.

The needed deviations are:

deviation for the end milling is 2.5mm so -

deviation for the saw is 2.5mm

the deviation for last detail attachment is 40mm

So first and subsequent blanks parameter are: 205mm+5mm=210mm

The lasts blanks parameters are: 205mm+5mm+40mm=245

The blanks of the shaft example:

Calculation of 14 bars length:

So lost metals length is:

The number of needed bars of length of 3000mm is:

We take 21 bar length of 3000mm, so we get . It is not enough (we need 6more detais), so we take one more bar length of

During economical calculations the decision is to take:

21bars of length 3000mm

1 bar of length 1300mm

Bush

After each manufactured part we cutting it off, so the length of all blank, attached in chuck of the lathe, becomes smaller by the length of the machined part (20)+allowance (1)+ cutter edge length (3)= 24 (mm).

Drawings of the blank

Edge

Edge 771.13 - 1.5 - 04 blank making process.

Detail's (edge) material - steel Cm3GOST14637, thickness of the edge is 4mm. Choosing standard hot rolled steel sheet B4GOST19903/Cm3GOST14637 of dimensions 710 x 2000 mm. Specimen should be cut of the sheet using plasma cutting device. From 1 sheet it is possible to make 160 details, 10 x 16 = 160 details/sheet. So we need to buy 4 sheets of this kind. The output will be 640 details, 40 details leaves due to possible failures.

Core

Core's material is steel Cm3GOST380. Detail's maximum diameter is M24x1. For core manufacturing choosing standard hot rolled beam B27GOST2590/Cm5GOST380 of dimensions: in length 3000 and diameter 27 mm. Detail (core) will be simply made just from beam using turning turret machine, this method is efficient and cheap because we do not need high accuracy of surfaces (all surfaces should be Ra6.3). From 1 beam it is possible to make 93 details, so we will need 4 beams.

Plate

The sold sheets of are sold of such parameters:

Need to mention, that sheets can be sold in needed length and width.

Chosen deviation for processing (p. 44):

The blank and dimensions are represented on the fallowing picture.

7. Develop part process route for every part.

Shaft

Detail shaft 771.13-1.5-01 is made by medium-lot production, from steel 35GOST 1050-74.

Shaft technological way

Bush

Plate

Detail plate 771.13-1.5-03 is made by medium-lot production, from sheets.

Plate technological way

Edge

Edge 771.13-1.5-04

Core

Core 1.25.00.07

8. Assign machining allowances for every part

Shaft

Bush

Turning cutters provide the necessary roughnesses of surfaces such as Rz20 and Rz40. Therefore it does no require additional treatments to be made.

Because of good properties of textolite blank material and lack of importance surfaces 1,2,5,6 it do not require any treatment to be made.

Cutter ГОСТ 18884-73 has width a=3-8 mm,we can take a=3 to provide less losses of material during manufacture. It means that we will loss 3 mm of material with each finished bush during the cutting off from the blank.

Plate

Edge

Allowances for edge 771.13-1.5-04

Core

Plan one machining operation for every part.

OPERATION NR. 10

Milling operation

Machine - centering milling semiautomatics 4815

Device - the workpiece is on bolsters and clamped with catch

Tool for milling is end pull-on mill 2214-0001 GOST 24359-80, diameter D=100mm, number of teeth z=8

Rought milling from every end depth of 2.5mm

Calculation of minutely feed mm/min:

here s- feed for one mills revolution, mm/rev;

n- frequency of a mill rotation, rev/min:

rev/min

Cutting speed [m/min] for milling is found according to this formula:

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

- coeficient depending on milling material and processing conditions

D - milling diameter

T- average stability of tool of normal gradual working =180min, when mills diameter=100mm

t - depth of cut

- pass for 1 tooth

B - milling width

z - teeth number of mill

q,m,x,y,u,p- - degree index

q=0.25

x=0.1

y=0.2

u=0.15

p=0

m=0.2

B=40

D=100

m/min

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife 2102-0056 T15K6 GOST 18877-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=1.0, because tool T15K6 is of constructional steel

Rought milling from every end depth of 0.5mm

Calculation of minutely feed mm/min:

here s- feed for one mills revolution, mm/rev;

n- frequency of a mill rotation, rev/min:

rev/min

Cutting speed [m/min] for milling is found according to this formula:

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

- coeficient depending on milling material and processing conditions

D - milling diameter

T- average stability of tool of normal gradual working =180min, when mills diameter=100mm

t - depth of cut

- pass for 1 tooth

B - milling width

z - teeth number of mill

q,m,x,y,u,p- - degree index

q=0.25

x=0.1

y=0.2

u=0.15

p=0

m=0.2

B=40

D=100

m/min

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife 2102-0056 T15K6 GOST 18877-73, and it inserts are of hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=1.0, because tool T15K6 is of constructional steel

Centering operation

Machine - centering milling semiautomatics 4815

Device - the workpiece is on bolsters and clamped with catch

Tool for centering is chosen drill 2317-0108 GOST 14952-75

Centering both ends:

Cutting speed [m/min] for drilling is found according to this formula:

q=0.4

x=0.2

y=0.5

m=0.2

s=0.1

T=8min

D=5

Cutting depth :

OPERATION NR. 15

Machine - lathe 16K40

Device- the workpiece is between 2 centers

Tool- hooked turning knife with a hard-alloy plates T15K6,GOST 18877-73, cross-section of the stem 25x16, the length of tool L=140mm

Rough turning of the surface 2:

Surface 2, L=205mm from 40mm to 38mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife 2102-0056 T15K6 GOST 18877-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=1.0, because tool T15K6 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 1.0mm

s= 0.5mm/rev

=350

y = 0.35

Rough turning of the surface 3 and 4:

Surface 3and 4, L=122.6mm from 38mm to 35mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 1.5mm

s= 0.5mm/rev

=350

y = 0.35

Smooth turning of the surface 3 and 4:

Surface 3and 4, L=122.6mm from 35mm to 34mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 0.5mm

s= 0.5mm/rev

=350

y = 0.35

Rough turning of the surface 6:

Surface 6, L=50mm from 38mm to 34mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 2.0mm

s= 0.5mm/rev

=350

y = 0.35

Rough turning of the surface 6:

Surface 6, L=50mm from 34mm to 31mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 1.5mm

s= 0.5mm/rev

=350

y = 0.35

Smooth turning of the surface 6:

Surface 6, L=50mm from 31mm to 30mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 0.5mm

s= 0.5mm/rev

=350

y = 0.35

Rough turning of the surface 7:

Surface 7, L=2, from 30mm to 28mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife 2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 1.0mm

s= 0.5mm/rev

=350

y = 0.35

Smooth turning of the surface 8:

Surface 8, L=50mm from 34mm to 33.1mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T5K10 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 0.9mm

s= 0.5mm/rev

=350

y = 0.35

Smooth turning of the surface 8:

Surface 8, L=50mm from 33.1mm to 32.2mm

Cutting depth:

here d- diameter of the blank after machining

D-diameter of the blank before machining

Calculation of minutely feed mm/min:

here s- feed for one revolution, mm/rev;

n- frequency of a blank, rev/min:

Calculation of a cutting velocity for turning, m/min:

here:

- coefficient, depending on path

T - average stability of tool of normal gradual working, =60min

m, x, y - degree index, x=0.15; m=0.20; y- depend path

t - depth of cut

s - path

- coefficient, evaluating:

- influence of workpiece material

- influence of surface state

- influence of tool material

Coefficients calculations

=

- coefficient depending on tool material and egual to 1.0, because chosen tool is knife2101-0052 T5K10 GOST 18879-73, and it inserts are of   hard-alloy.

- degree index =1.0

, because no skin is on workpiece

=0.65, because tool T15K6 is of constructional steel

m/min

Coefficient and indexes selected from the tables:

t = 0.9mm

s= 0.5mm/rev

=350

y = 0.35

TIME CALCULATIONS:

Rough turning of the surface 2:

L= 205+2+2+1=210mm

Rough turning of the surface 3,4:

L=150+2+1.5=153.5

Smooth turning of the surface 3,4:

L=150+2+0.5=152.5

Rough turning of the surface 6:

L=50+2+2=54mm

Rough turning of the surface 6:

L=50+2+1.5=53.5

Smooth turning of the surface 6:

L=50+2+0.5=52.5mm

Rough turning of the surface 7:

L=1+2+1=4

Smooth turning of the surface 8:

L=1.4+0.9=2.3

Smooth turning of the surface 8:

L=1.4+0.9=2.3

All

Edge

End Mill 63-P18 GOST 17026

Z=8

Vertical programable milling machine M-230

Nmachine=10kW

Spindle's motor 2hp/3hp.

Cutting depth t=2mm.

Sz=0.1 mm/tooth

Determening cutting velocity:

Choosing n_machine=400rots/min

Calculating V_machine

Calculating T operational time for every necessary operation

010 operation

015 operation

020 operation

Calculation of Tunit time.

Calculating Tp

T_p1- time for setting or removing tool;

T_p2- time for machine operation;

T_p3- time for measurements;

Mass=0.35

(Tapt+Tasm)=(1.135+0.65)*0.06=0.12min

Calculating Tvnt

Calculation of T_p.p

Develope assembly process

Welding

Inserted

	Pressed

Mounted