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NATIONAL AEROSPACE UNIVERSITY

by N.E. ZHUKOVSKY
“Kharkov Aviation Institute”

Aircraft Manufacturing Department (№104)

HOME TASK
Technologies of Aircraft Manufacturing technology

Student of 4th Year 144FJ Group

Specialization Construction and
manufacturing of Aircraft and
Helicopters
Vatsalkumar Sorathiya.
(Student’s Name)

National Scale ____________________

Points ___________________________

Checked prof. Pavlenko A.

(Signature, Date, Name)
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Kharkov – 2021
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INDEX

Introduction:...........................................................................................................4
1. Development of Workpiece for a Part Machined............................................5
1.1. To conduct a structural and technological analysis of the part. Make
detailed view from model................................................................................5
1.2. Choose the type of blank for a part and justify the method of its
manufacture......................................................................................................7
1.3. Calculate allowance for each processing step, determine the dimensions
of the blank and develop its 3D model. Make detailed drawing model..........9
2. Defining of Operation-Routing Sequence and Technological Operations of a
Part Machining.....................................................................................................10
2.1. Work out the route for manufacturing a part. Based on 3D model of the
part to select datum face for each operation..................................................10
2.2. Develop a chart of sketches for locating the part during processing......11
2.3. Working out one of processing operations of the part machining in
details. Developing technological chart for CNC processing........................12
Bibliography........................................................................................................15
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Introduction
Machining is manufacturing process that involves removing materials using
cutting tools for getting rid of the unwanted materials from some work piece and
converting it into the shape you desire. A large piece of stock is used for cutting the
work piece. The large stock might be in any shape such as solid bar, flat sheet, beam or
even hollow tubes. The process can also be performed on some existing part like forging
or casting.
Machining is part of the manufacturing of many metal goods, but it can also be us
ed in materials such as wood, plastics, ceramics and composites. A person who specializ
es in machining is called a machinist. A room, a building or a business where machining 
is carried out is called a machine shop. Most of modern machining is carried out by com
puter numerical control (CNC) in which computers is used to control the movement and 
operation of mills, lathes and other cutting machine.
This metalworking technique actually involves many types of processes that can
be used to give metal the desired shape and finish. These techniques are often divided
into four categories, and may be used together to produce a single product.
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1. Development of Workpiece for a Part Machined

1.1. To conduct a structural and technological analysis of the part. Make

detailed view from model.

Figure1 – Drawing of Part

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Mass = 164.5 grams

Volume = 60813.34 cubic millimeters
Surface area = 33893.90 square millimeters
The additional parameters are the follows:
-Material utilization factor – 0.92%
-The highest degree of surface finish- Ra 6.3
-The best class of accuracy – H6
The part is made from B95-1060.
Mechanical properties of B95-1060 alloy GOST 21488-97.

Table 1- Chemical Composition in % for B95-1060.

Fe Si Mn Cr Ti Al Cu Mg Zn
Max- Max- 0.3-0.9 Max Max 90.9- 3.8-4.9 1.2-1.8 Max
0.5 0.5 0.1 0.15 94.7 0.25

Table 2- Mechanical Properties of B95

Ϭuts,MPa Ϭy,MPa δ, % HB Heat Treatment
390 275 8-10 105 Hardening
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Table 3 – Geometry and Dimensions of the Part

Designation of Allocation of Shape of the Dimensions Class of
the Machined the surface surface (mm) Accuracy of
Surface dimension
tolerance

Surface 1 Outer Flat l=109 h14

Surface 2 Outer Curve R=19 H14
Surface 3 Outer Flat l=125 h14
Surface 4 Inner Cylindrical Ø 17.5 H6
Surface 5 Inner Cylindrical Ø 7.5 H7
Surface 6 Inner Cylindrical Ø 5.5 H7
Surface 7 Outer Cylindrical Ø 5.5 H7

Figure2 – Sketch with Surfaces to be machined

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1.2. Choose the type of blank for a part and justify the method of its
manufacture.

I have selected the process of forging for the development of work piece for the
following reasons:
1. Forging as compared to casting is used for parts which are used in critical operations
and require high strength. Due to forging we obtain small grain structure which gives us
the possibility of getting this strength.
2. The part in my task is housing part, as it can be understood this part is used as a
housing and need high strength to bear the loading during the operation, and hence it is a
critical part.
3. Due to complex shape we use closed die forging, since using open die we cannot get
such complex shape.
4. Cost of creation of dies is high, but in serial production this cost is distributed well
enough to get enough profit from the process and acquire the part according to strength
requirement.

Selection of the initial stock and of method of its manufacturing:-

Selection of the initial stock (forging) is determined by a number of factors. The
main factors are: the production volume, requirement to the mechanical properties of the
part, stock utilization factor.as a rule the working drawing of the part must contain
information concerning initial stock. The method chosen for the manufacturing of the
stock is by impressing die forging (die contains cavity of impression that is imparted to
work part. It contains better precision and complexity.

The necessary stages of the development of a technological process

Here we are expected to analyses the variant which have been obtained during
practice at plant. The main purpose of this stage to increase productivity and quality of
the production. For the purpose it is necessary to:
 Check selection of the rough and finishing datum surface to ensure principle of
coincidence of the processing and constructive datum surface;
 Validity of the chosen order of the machining operation and type of the machining;
 Estimate the level of the mechanization and automation of production;
 Using of advanced processes, tooling, and gaging equipment.
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Description of the production process

The part is made of B95 and the process is production is impressing die forging at
elevated temperature of about 870° C. Impressing die forging is used since at material is
B95 GOST
In the process of Forging, dimensions, allowances, draft angles, parting lines, flashes
should to considered and taken according to recommendations. All the descriptions are
mentioned below:

Impressing die forging: fillet radii calculation

In the process of impressing die forging fillet radii for forging between 1-4mm

Impressing die forging: draft angle calculation

In this propeller mount, there are two types of draft-namely outside draft and
inside draft. Outside draft angle value is between 3 ͦ and 5 ͦ and inside draft angle value is
between 5º and 7º. For my part, I take outside side draft angle as 7 ͦ.

1.3. Calculate allowance for each processing step, determine the dimensions
of the blank and develop its 3D model. Make detailed drawing model.

Selection of the initial stock is determined by a number of factors. The main

factors are: the production volume, requirement to mechanical properties of the part,
stock utilization factor. As a rule, the working drawing of the part must contain
information concerning initial stock. In the absence of such information student must
ground this selection. After the selection the stock it is necessary to calculate the
machining allowance by its summation for all operation of the surface, determining
overall dimension of the part.
Unilateral intermediate allowance is calculated according to equation:
2 Z=2[R z +h+( ρ̄a + ε̄ δ )]+ δ
Where, Z is a nominal intermediate allowance;
Rz = is a height of the microroughness (roughness coefficient for corresponding surface
finish class);
h = is thickness of the defect layer produced at previous operation;
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ρa = is a vector deviation of the related surfaces of the machined workpiece produced at

previous.
εδ = is an accuracy of the positioning during machining.
δ = is a tolerance during previous machining operation.
During machining of the surface of revolution allowance must be doubled:

Figure3 – Work piece Diagram with Allowances

As a result one should calculate stock utilization factor according to the equation:
Gp
η= Gs
164.5
So, η = 178.3 = 0.9226

Where GS and GP are the masses of the stock and that of the part correspondingly
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2. Defining of Operation-Routing Sequence and Technological Operations of

a Part Machining

2.1. Work out the route for manufacturing a part. Based on 3D model of the
part to select datum face for each operation.

Geometrical location of the work piece relatively cutting tools and reliability of its
clamping are ensured by scheme of location and clamping, such scheme must be worked
out for all operation.
Location of the datum surfaces must ensure convenient positioning, fixturing,
unfasten and removing of the part, application of the clamping loads and advance of the
cutting tools.
If there are no admissible datum surfaces in part design it is necessary to add such
special elements or surfaces which are used only during locating, fixturing and
machining. Number of repositioning should be minimized.
Selection of the datum surfaces for rough machining
During selection of the datum surfaces for rough machining (initial locating datum
surface) one should keep the following rules:
1. The non-machined surfaces must be used as datum only for the first operation.
2. The surfaces with sufficient dimension and with highest precision and surface finish
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parameters are more preferable as datum surfaces. Such surfaces mustn’t have parting
line, scale, and feeder head so on.
3. If there are some non-machined surfaces at part these surfaces must be used as datum
surfaces at the first operation.
4. If there aren’t non-machined surfaces at part the surfaces with least allowance must be
used as datum surface.

Selection of datum surfaces for finishing machining

The datum surfaces for finishing machining one should select keeping the following
rules:

1. During all operations one should ensure principle of constancy of datum surfaces so
only one set of datum surfaces for the highest accuracy;
2. The most important factor is coinciding of the machining and constructive datum
surfaces because in this case the given precision may be ensured
3. The locating datum surfaces must have the highest dimensional precision and surface
finish parameter; these surfaces mustn’t deform under influence of the cutting forces,
clamping and weight.

2.2. Develop a chart of sketches for locating the part during processing.

At this stage one should resolve two problems: selection of the method of
machining and selection of the order of the operations and steps.
Selection of the method is determined by the geometry of the part, by its overall
dimension, by the type of the initial stock, by precision and surface finish. Selection of
the order of the operation is determined by the fact, that every type of machining ensures
corresponding degree of accuracy and surface finish only when there was preliminary
machining.
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Figure4 - Operational Scheme of Part

Table:-4 Operations
Number of Operation Name Content of Operation Equipment Fixture
Operation
005 Milling To mill the flat face of CNC Workbench
length Milling
Machine
010 Drilling To drill the holes Drilling Drill
Machine
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2.3. Working out one of processing operations of the part machining in

details. Developing technological chart for CNC processing

In the operational sketch two of the main surfaces are machine by the CNC turning
machine so for that we need some value according to surface direction of the part means
how CNC machine working. Developments of technological chat (----) describe that
during that route CNC turning machine move fast and red thick line describe that
machine surface and during that time turning machine move slowly as shown in below
figure-5.

Figure 5 – Technological chart for CNC turning

In appointing the members consider cutting processing of regimes, type and size of
the tool, its cutting material of the material and the condition of the workpiece, the type
and condition of the equipment.
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Elements of the cutting mode is usually set in the manner described below.
- Cutting depth, t: roughing prescribed maximum possible t, equal to the entire
machining allowances or most of it; when finishing - depending on the
requirements of dimensional accuracy and surface roughness of the treated
surface.
- Cutting speed, v: calculated by the empirical formulas established for each type
of treatment.

- CAM machining
Computer-aided manufacturing (CAM) is the use of computer software to control
machine tools and related machinery in the manufacturing of work pieces. This is not
the only definition for CAM, but it is the most common; CAM may also refer to the use
of a computer to assist in all operations of a manufacturing plant, including planning,
management, transportation and storage. Its primary purpose is to create a faster
production process and components and tooling with more precise dimensions and
material consistency, which in some cases, uses only the required amount of raw
material (thus minimizing waste), while simultaneously reducing energy consumption.
CAM is now a system used in schools and lower educational purposes. CAM is a
subsequent computer-aided process after computer aided design (CAD) and sometimes
computer-aided engineering (CAE), as the model generated in CAD and verified in CAE
can be input into CAM software, which then controls the machine tool.
- Calculation of cutting parameter for CAM machining:

 Cutting depth (t):

Cutting depth can be calculated using the following formula;
t = 0.5 x D
Where, D = 17.5 mm is the drill diameter.
Hence t = 8.75 mm.

 Cutting speed (Vc):

Cutting speed can be calculated using the following formula;
Vc = ( π x D x n) / 1000
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Where, D=17.5 mm is the drill diameter and n=795 rpm is the rotational speed of the
main spindle.
Hence Vc =43.68 mm/min.
Cutting speed is 43.68 mm/min.

 Feed of main spindle (Vf):

Spindle feed can be calculated using the following formula;
Vf = (f x n)
Where f=0.2032 mm/rev is the feed per revolution and n=795 rpm is the rotational
speed of the main spindle.
Hence Vf = 161.54 mm/min.
Feed of main spindle is 161.54 mm/min.

 Drilling time (Tc):

Drilling time can be calculated using following formula;
Tc = (Id x i) / Vf
Where Id = 25 mm is the hole depth; i= 1 is the number of hole and V f = 161.54
mm/min is the feed of main spindle.
Hence Tc= 0.1547 min.
Drilling time is 9.282 second.
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Bibliography

1. Modeling of machining in CAM “ADEM” O.A Pavlenko.

2. Design Data
3. http://aloro.net/grades/su/gr-d16
4. http://www.daycounter.com/Calculators/GCode/Feed-Rate-Calculator.phtml
5. http://theminimachineshop.com/Technical/Machinerys%20Handbook.pdf