PROCESS PLANNING AND COST ESTIMATION (ME6005)

UNIT – I

INTRODUCTION TO PROCESS PLANNING

DESIGN MANUFACTURING
DEPARTMENT DEPARTMENT
Design for each The product is
product is developed. manufactured.

Process Process problems

Design improvement
modification
PLANNING INSPECTION
DEPARTMENT
Develops the process plan

Process planning:

 It is the systematic determination of the engineering processes and systems to manufacture a

product competitively and economically.
 It is an act of preparing detailed work instructions for the manufacture and assembly of
components into a finished product in discrete part manufacturing environment.

Process planning involves:

1. Selection of manufacturing processes and operation, production equipment, tooling and jigs
and fixtures.
2. Determination of manufacturing parameters
3. Specification of selection criteria for quality assurance to ensure product quality.

Importance of process planning:

 Establishes the link between engineering design and manufacturing department.

 Process plan determines how the product will be manufactured which determines the
production cost and profitability.
 Process planning facilitates the feedback from the shop floor to the design department
regarding the manufacturing process alternatives.

ME 6005- Process Planning & Cost Estimation 1

 THE DESIGN/MANUFACTURE INTERFACE

Market research
 Identifies the potential market gap for new product.
 Ideas for new product is generated

Marketing Customer Market

NO
Is there a market need?

YES
MODIFY
R&D
Product Idea
The product design specification
MODIFY
(PDS) is developed as per the
Product Specification
market research
MODIFY
Various designs are developed to
Concept Design
select a suitable design

Detail design stage MODIFY

Necessary information such as drawing,
bill of material etc. that is required for
manufacturing will be generated

NO
Is design is cost effective?

YES
AFTER SALES
DATA Prototype
CUSTOMER
A prototype of the product will be made
ORDER
based on the finalised product design

NO Prototype
ok?

After fixing the problems in YES

the prototype a trial batch is
Pilot & test run
manufactured

Process Planning
Process plan according to the selected design
DEMAND is prepared
DATA
Product manufactured

Sales
ME 6005- Process Planning & Cost Estimation 2
 Responsibility of Process Planning Engineer:

Responsibility of Process Planning

Engineer

Selecting proper Machining with allied

Drawing Interpretation
tooling based on
 Required machining capability
 Set up time
Selecting Machining Process  Practical lot size
 Quality of parts
 Cost of tooling
Sequencing the operation  Type of tooling

Gathering the fundamental details of

Deciding the inspection
product design
equipment
 Dimensional tolerances
 Type of finish
 Production rate
Determining production
 Production volume
tolerances
 Scrap loss
 Down time
 Design changes
Determining proper cutting
tool and cutting condition

Calculating overall time

using work measurement
techniques
Steps in Process Planning Activity:

1. Drawing interpretation:
 Analyse the finished part requirement as specified in the engineering design
(Engineering drawing or CAD model).
 The component drawing should be analysed in detail to identify its features,
dimensions, geometric tolerance, surface finish specification, material specification
and number of parts required.
 The part requirement defined will determine the corresponding process requirement
such as shape generation, inspection, testing, heat treatment, surface coating,
packaging etc.

ME 6005- Process Planning & Cost Estimation 3

 2. Material Evaluation and process selection:
 The factors that affect the choice of a material are function, appearance, reliability,
service life, environment, compatibility, productivity and cost.
 The process planner should evaluate the material specified along with design
engineers based on the availability of manufacturing processes.
 The sequence of operations required to process the material, to achieve the feature,
dimension and tolerance required is determined.
 Tolerance specifications are primary factors in determining the sequence of
operations.
3. Selection of machining, tooling and work holding devices:
 In this step machines, equipment, tools and work holding devices to accomplish the
required operations are selected.
 Machine selection generally means determining how the part would be processed on
each of the alternative machines so that the best machine can be selected.
 In this stage the firm has to decide whether to make or buy the component.
 Break even analysis is the most convenient method for selecting the optimum method
of manufacturing among various alternative method to manufacture the component.

Factors influencing the selection of

machines

Economic consideration Durability and

Dependability

Production rate and unit cost

of production Minimum set up and put
away time

Functional Versatility
Lower process rejection
Longer productive life of
machines

4. Selecting process parameters:

 In this step operation setup time and cycle time on each machine is calculated.
 For establishing the set up time detailed knowledge of equipment capability,
tooling and shop practice is required.
 For establishing the process time the sequence of operation is to be determined
this is known as outplannning.
 Once the processing time is calculated part loading , unloading, machine
indexing and other factors are determined to obtain the machine cycle time.

ME 6005- Process Planning & Cost Estimation 4

  With the calculated machine cycle time the allowance is added to obtain the
standard cycle time.
 With the calculated cycle time appropriate machine rate are applied to
calculate the expected standard cost for the given operation.

Loading time
Set up Processing
STANDARD TIME = + unloading Allowance
time time
time +
machine
indexing time
+ other factors

STANDARD COST = Standard Time X Machine Rate

5. Selecting quality assurance methods:

 In this step tools and techniques to be used for quality assurance are specified
clearly.
 The over use of QA method would increase the processing time and hence
increases the manufacturing costs.
 A proper balance is to be made between achieving product quality and
avoiding unnecessary checking.
6. Cost estimation:
 It is the process of determining the probable cost of the product before start of
its manufacture.
 The available cost and time data, the material, labour and overhead cost is
estimated. From this unit cost and profitability of the product can be
determined.
 The cost data will influence the process planner to various decisions on what
material to use, the manufacturing process, batch size and make or buy
decision.
7. Process planning documentation:
 Once the entire selection process is completed the process plan is to be
documented.
 The resulting process plan is documented as job routing or operation sheet.
 The process plan is to be documented in order to plan future parts with similar
design, to provide a record for future job quoting, cost estimating and standard
costing system. Documentation acts as a vehicle for communication. An
example of route sheet is given below.

Number Description Number Description

1 Part number and name 4 Standard set up and cycle time
(identification)
2 Description of process 5 Tooling requirement
3 Operation sequence

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 2 1 4
5
3

8. Communicate process knowledge:

 The final step in process planning is to communicate the manufacturing
knowledge to the shop floor.
 This communication is essential to ensure that the part will be processed
according to the most economically possible way determined through process
planning.

METHODS OF PROCESS PLANNING

Process
planning
Manual Computer Aided
Process process planning
planning (CAPP)

Traditional Retrieval
Approach CAPP

Workbook Generative
Approach CAPP

ME 6005- Process Planning & Cost Estimation 6

 Manual process planning:

1. Traditional Approach:
 The process plan is prepared manually.
 It involves examining and interpreting engineering drawing, making decision
on machining process selection, equipment selection and operation sequencing
done manually.
 The manual process planning is very much dependant on the skill judgement
and experience of the process planner.

Stages in manual
process planning

Stages I Stages II Stages III

 Interprets the  Refers the manual to decide  Resulting

part drawing.. the feed, speed, tool etc. process plan is
 List the  Operation time and set up documented.
sequence of time are calculated using
operation to be manual.
carried out.

2. Work book Approach:

 Uses a developed work book for preparing the route sheet.
 once the drawing interpretation is carried out suitable predetermined sequence of
operations are selected from the developed work book and the details are documented
in the route sheet.
Disadvantages of Manual approach
Advantages of Manual approach
 Very complex and time
 Suitable for small scale
consuming job.
industries.
 Requires skilled process planner.
 Highly flexible.
 Human error possible.
 Low investment cost.
 Increased paper work.
 Inconsistent process plan results in
reduced productivity.

Computer aided process planning (CAPP):

 In order to overcome the drawbacks in manual process planning the CAPP is used.
 The use of CAPP reduces the clerical work involved and also one can generate rational,
consistent and optimal plans.
 CAPP provides interface between CAD and CAM.

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 1. Retrieval or Variant CAPP system:
 The basic idea behind the retrieval CAPP is that similar parts will have similar
process plan.
 A process plan for a new part is created by recalling, identifying and retrieving an
existing plan for a similar part and making necessary modification for the new part.
 The retrieval CAPP system is based on the principles of group technology and part
classification and coding.
 In this system for each part family a standard process plan is prepared and stored in
computer files. A code number is generated based on the classification and these
codes are used to identify the part family and its associated process plan. This plan is
edited for the new part.
 Once a standard plan is created a variety of parts can be planned. The system is
understandable and the planner has control over the final plan.
 It is easy to learn and easy to use.
 The components to be planned are limited to the similar components previously
planned and it still requires skilled planners.
 Most commonly used retrieval CAPP are MultiCapp and MIPLAN.

2. Generative CAPP system:

 In generative CAPP system the computer generate each individual process plan
automatically without any reference to previous plans.
 The process plan is generated based on decision logics and pre coded algorithms.
 The plan is developed without any involvement of the process planner.
 The only role of the planner is to input the GT code and monitor the function.
 Process plan is generated rapidly.
 New component can be planned as easily as existing component. It can be interfaced
with automated manufacturing.
 It is complex and very difficult to develop.
 Commonly used Generative CAPP systems are APPAS, CMPP, EXCAP and
XPLAN.

Components of generative CAPP

Part Description: identifies series Subsystem to select and sequence

of component characteristics, individual operation: decision logic is
geometric feature, dimensions, used in associate with features of a
tolerance and surface condition component and algorithms are used to
calculate operation steps and sequence.

Subsystem to define machine Database of available machines and

parameter: looks up tables and tooling
analytical results for cutting parameters

Report generator: generates the report

ME 6005- Process Planning & Cost Estimation 8

 Benefits of CAPP:

 Process rationalization & Standardization

 Productivity improvement
 Product cost reduction
 Elimination of human error
 Reduction in time
 Reduced clerical effort and paper work
 Improved legibility
 Faster response to engineering
 Incorporation of other application programs.

Selection of process planning system:

 The general environment in which process planning is conducted.

 The organisation structure of the company.
 The technical expertise available to the company.
 The needs and objectives of the company regarding the generation of manufacturing
information and process plans.

DRAWING INTERPRETATION

 The first step in process planning is drawing interpretation.

 For the purpose of process planning orthographic projection are commonly used.
 The drawing is usually prepared by the design department. The drawing expresses certain
functional requirements of the component under consideration.
 The design and functional requirements of a component are translated into technical language
recognised by the production department and depicted in the technical drawing.
 In general information like material, number of parts, weight of the component, dimensions,
dimensional and geometric tolerances can be obtained from the design drawing.

Types of Drawing:

1. Detail drawing:
 It provides all the information required for the manufacture of the required
component.
 The information includes all dimensions, tolerances, surface finish specification and
material specification.

1.a.Single part drawing: 1.b.Collective Single part

drawing:
It contains the complete detailed
information to enable a single component They are used where one or
to be manufactured without reference to two dimensions of a
other sources. The drawing is fully component are variable and all
dimensioned including tolerances,
others being standard.
location of various features, heat
treatment required and surface finish

ME 6005- Process Planning & Cost Estimation 9

 2. Assembly drawing:
 Machines and mechanisms consists of numerous parts and a drawing which shows
the complete product with all its components in their correct physical relationship is
known as an assembly drawing.
 A drawing which gives a small part of the whole assembly is known as sub assembly
drawing.
2.a.Single part Assembly drawing: 2.b.Collective assembly drawing:

It contains information to build a single It is used where a range of products

sub assembly or assembly. It provides which are similar in appearance but
information like part list, dimension, different in size is manufactured and
weight, material, design characteristics assembled.
and operating details.

3. Combined detail and Assembly drawing:

 It shows the assembly with part list and the details of these parts in one drawing.
 It is more suited to limited production run assemblies.
 It reduces the actual number of drawing and also reduces the office time spent in
printing and scheduling.

Information on the drawing sheet required for process planning:

i. Dimensions:
 The drawing should provide complete dimensions of the component to ensure that the
design intent can be met of all stages of manufacture.
 The dimensions are classified as follows
Functional dimension: These dimensions influence the way in which part operates.
Non-functional dimension: These dimensions do not affect the way in which the
part operates but can influence the efficiency of the part.
Auxiliary dimensions: These dimensions are not related to the way the part operates
but they are required in order to manufacture the part.
ii. Material specifications:
 The material of the part is to be stated as a specification in the drawing.
iii. Special material treatment:
 To achieve the desired material properties of the parts they are to be treated. Those
details should be mentioned as a note in the part drawing.
iv. Tolerance, limits and fits:
 To ensure that an assembly will function correctly its components must fit together in
a predictable manner.
 Components cannot be manufactured to an exact size so the designer has to decide on
appropriate upper and lower limits for each dimension.
 Accurately tolerance dimensioned features usually take much time to manufacture
correctly and therefore can increase production cost. Good engineering practice finds
the optimum balance between required accuracy for the function of the component
and minimum cost of manufacture.

ME 6005- Process Planning & Cost Estimation 10

  Dimension tolerance: Dimension specified as 10 0.02 the part will be acceptable if
the dimension is manufactured to an actual size between 9.98 and 10.02 mm.
 General tolerance: General tolerance notes apply tolerance to all unspecified
dimension on a drawing. They can save time and makes the drawing less cluttered.
 Limits and Fits for shaft and holes:
Basic size: It is the size of shaft or hole that the design specifies before applying the
limit to it.
Shaft/Hole tolerance system: There are two system used for specifying shaft/hole
tolerance.
1.Basic hole system: starts with the basic hole size and adjusts shaft size to fit.
2.Basic shaft system: starts with the basic shaft size and adjusts hole size to fit.
Because holes are usually made with standard tools such as drill and reamers etc. the
basic hole system tends to be preferred and therefore they are commonly used.
 Fit: The fit represents the tightness or looseness resulting from the application of
tolerance to matting parts that is shaft and holes.
 Fits are generally classified as one of the following:
Clearance fit: Assemble/dissemble by hand. Creates running and sliding assemblies
ranging from loose low cost to free running high temperature change application and
accurate minimal play location.
Transition fit: Assembly usually requires press tooling or mechanical assistance of
some kind. Creates close accuracy with little or no interference.
Interference fit: Parts need to be forced or shrunk fitted together. Creates permanent
assemblies that retain and locate themselves.
v. Geometric tolerances:
 A geometric tolerance limits the permissible variation of form, attitude or location of
a feature of the component.
 The various types of geometric tolerances are: Straightness, flatness, roundness,
cylindricity, parallelism, squareness, angularity, concentricity, symmetry and position
tolerance.
vi. Surface finish:
 Surface finish is the depth of irregularities of a surface resulting from the
manufacturing process used to produce it.
 Three basic types of surface irregularities that can occur are:
1.Form error: the form error is for longer wavelength deviation of a surface from
corresponding nominal surface. Form error results from large scale problems in the
manufacturing process such as errors in a machine tool ways, guides or spindles,
inaccurate alignment of workpiece.
2.Roughness: It include the finest irregularities of a surface. It results from a
particular production process or material condition.
3.Waviness: It includes the more widely spaced deviations of a surface from its
nominal shape. It is generally caused by machine vibration or heat.
 The surface texture is the combination of roughness and waviness.
 Surface roughness symbols and surface texture symbols are used for indicating
surface roughness and surface texture on components respectively.

ME 6005- Process Planning & Cost Estimation 11

 MATERIAL SELECTION AND EVALUATION

 Though the material selection for a component is the responsibility of design

engineers, the process planner should evaluate the material specified along with
design engineers, based on the availability of manufacturing processes.
 The material and process selection should be made taking into consideration the
product to be manufactured, the process and material availability in the organisation.
 Selection of material influences the selection of manufacturing process.

Properties Engineering Materials:

 Each material have their own properties and qualities. The properties of material provide a
basis for predicting its behaviour under various conditions.
 Both design and process planner should have a wide knowledge of materials and their
properties so that they can select a suitable material for the product.

Properties Qualities
Physical properties Colour, density, melting point, size, shape, surface finish,
damping capacity, specific gravity, porosity and
structure.
Chemical properties Corrosion resistance, atomic weight, equivalent weight,
molecular weight, acidity, alkalinity, atomic number and
chemical composition
Mechanical properties Strength, elasticity, plasticity, ductility, brittleness,
hardness, toughness, stiffness, resilience and creep.
Electrical properties Resistivity, conductivity, dielectric constant and
dielectric strength.
Magnetic properties Relative permeability, reluctivity, retentivity,
susceptibility
Thermal properties Specific heat, thermal capacity, thermal conductivity,
thermal stresses, thermal fatigue, thermal shocks and
latent heat.
Technological properties Malleability, machinability, weldability, castability and
formability.
Aesthetic properties Appearance, texture and ability to accept special finishes.
Economic properties Raw material and processing cost and availability
Other properties Optical, acoustical.

Metals and their Classification:

Metals/ Metal Alloys

Ferrous Non Ferrous

 Contains iron as their  Contains elements other than iron as chief
prime constituent. constituent.
 They have properties like light weight, higher
electrical and thermal conductivity, resistance to
corrosion and ease of fabrication.
 Eg: copper, aluminium, lead, magnesium, nickel, tin,
titanium and zinc

ME 6005- Process Planning & Cost Estimation 12

 Ferrous

Steel Cast iron

 Alloy of iron and carbon.  Contains iron, 2-4.5% carbon
 Carbon steel can be classified as and 3.5% silicon.
Low carbon steel : less than 0.25% carbon.  Types of cast iron:
Medium carbon steel : 0.25-0.60% carbon Grey cast iron: least expensive
High carbon steel : more than 0.60% & most common type
carbon White cast iron:very hard and
 In alloy steel alloying material such as brittle
chromium, nickel, molybdenum, vanadium, Malleable cast iron:good
tungsten and cobalt are added to achieve ductility and malleability
the required properties. properties
 Alloy steel can be divided into two main Spheroidal graphite cast
group: iron:ductility, tensile and yield
Low alloy steel : 3-4% alloying element strength.
High alloy steel : more than 5% alloying
element
 Stainless steel, tool steel, HSLA steels and
maraging steels are some of the alloy
steels.

Polymers:

 Polymers are widely used in many engineering application.

 They possess characteristics like low density, good thermal and electrical insulation
properties, high resistance to chemical attack, ease of fabrication and relative low cost.

Engineering Ceramics:

 Ceramic material are used in varied engineering applications including tools for grinding and
cutting, seals, bearings, magnets, other components for engines and pumps.
 The outstanding feature of ceramics includes ceramics are strong, hard and brittle, can be
used at high temperature, possess high melting temperature, good thermal and electrical
insulator and resistant to oxidation and corrosion.
 Eg- Alumina, silicon carbide, silicon nitride, sialons and partially stabilized zirconia.

Composites:

 It is a material composed of two or more different material with the properties of the resultant
material being superior to the properties of the individual materials that make up the
composites.
 Particle reinforced composites : consists of particles of one material dispersed in a matrix of a
second material. Eg. Sintered aluminium powder.
 Fibre reinforced composites : the dispersed phase is in the form of a fibre. Eg. Borosic
aluminium, glass polymer and graphite polymer.

ME 6005- Process Planning & Cost Estimation 13

 Material Selection process:

 The selection of appropriate material for the product under consideration is a complex task.
 The commonly used material selection are selection with computer aided database,
performance indices, decision matrices, selection with expert system, value analysis, failure
analysis and cost benefit analysis.
 The material selection process involve the following steps
1.Translation : Interpreting the design requirements in terms of function, constrains,
objectives and free variable.
2.Screening : Deriving attribute limits from the constrains and applying these to isolate a
subset of viable materials.
3.Ranking : Ordering the viable candidates by the value of material index, the criterion of
excellence that maximizes or minimizes some measures of performance.
4.Seeking supporting information : for the top ranked candidates, explore aspects of their
past history, their established uses, their behaviour in relevant environments, their availability
and more until a sufficiently detailed picture is built up, that a final choice can be made.

Material Evaluation method:

The material considered for selection is to be evaluated based on the following three
considerations.

1. Shape or geometry consideration:

 The shape or geometric consideration of a component influences the manufacturing
processes to be employed to manufacture the component.
 Some important shape or geometric consideration are relative size of the component,
complexity of shape, dimensional tolerance requirement, surface finish, allowance,
design for assembly and design for manufacturability.
2. Material property requirement:
 Mechanical property requirements include loading type involved, loading magnitude
involved, chance of impact and cyclic loading, wear resistance, permissible
temperature range and material deformation requirement.
 Physical property requirements include effect of processing on electrical, magnetic
and thermal property requirements, significance of weight and significance of
aesthetic requirement.
 Service requirement include range of operating temperature, rate of temperature
change, expected life span, most extreme working environment anticipated,
maintenance of the product, reliability, serviceability and recyclability.
3. Manufacturing Consideration:
 Use of standard components to take advantage of interchangeability.
 Ease of manufacture of the design.
 Quantity and rate of components to be made.
 Desired level of quality.
 QA and inspection requirement.
 Ease of assembly of the design

ME 6005- Process Planning & Cost Estimation 14

 PROCESS SELECTION

 Process is a method of shaping, joining or finishing a material.

 The right manufacturing process should be chosen in the design stage itself.
 The factors to be considered in the selection of manufacturing processes include material
form, component size & weight, economic consideration, dimensional and geometric
accuracy, surface finish specification, batch size and production rate.
 Identify the manufacturing process which can provide the required dimensional/geometric
accuracy and surface finish.
 For more choice on manufacturing process specify the maximum possible tolerances and
surface finish.
 Employ prototypes to verify and validate the potential manufacturing process under
consideration.
 Perform a comparison analysis of the potential manufacturing processes under consideration,
taking into account the variation in assembly costs for different processes.

Classification of manufacturing processes:

Primary process
 Casting Secondary process
Shaping  Moulding  Machining
 Deformation  Heat treatment
 Powder method
 Rapid prototyping

Adhesives
Joining
process Welding

Fastener
s

Polish

Shaping
process Coating

Paint/print

ME 6005- Process Planning & Cost Estimation 15

 Steps in process selection:

1. Drawing interpretation:
 From the drawing the design requirements are expressed as constrains on material,
shape, size, tolerance, roughness and other process related parameters.
 The drawing interpretation can be presented under three different analysis and
outputs.
1.Geometry analysis : The selection of manufacturing processes depend on the
geometry and shape of the component.
2.Manufacturing information : The manufacturing information derived from
drawing interpretation are dimensional and geometric tolerances, limits and fits,
surface finish requirements, tolerances specification, tool references, gauge reference
and special material treatment.
3.Material Evaluation : the final information interpreted form the drawing is the
material of the product.
2. Identification of critical processing factor:
 The combined output from the first stage of drawing interpretation should be
analysed and correlated to identify the critical processing factors.
 The correlation of the potential manufacturing processes from the geometry analysis
and the material evaluation will provide the opportunity to reduce the number of
potential manufacturing processes under consideration.
3. Comparison of potential manufacturing processes:
 In this stage the identified potential manufacturing processes are compared using the
correlated data from the second stage.
 The process selection tables will help in the decision making of selection of
appropriate manufacturing processes using all the information gathered in previous
stages.
 When more than one process satisfies all the requirements, then economic data can be
used for decision making. If required, a detailed cost comparison can be carried out
between manufacturing processes to help the decision making.
4. Identification of suitable processes:
 In this stage using the data from the second stage and a detailed economic analysis,
most appropriate manufacturing process should be selected.
 If the manufacture of part involves only one process, then the process selection is
complete.
 Usually the component requires many processes that is primary and secondary
processes. In such case the critical processing factor should be reconsidered and stage
3 should be repeated until all the required processes are selected.

PRODUCTION EQUIPEMENT AND TOOLING SELECTION

 Once the process planner has selected the manufacturing process the next step is to select the
appropriate equipment to carry put the selected process.
 The important factors to be considered while selecting the production equipment include
component size, component weight, physical size of machine, construction of machine, power
& torque of machine, number and types of tools available.
 Once the equipment is selected then the appropriate tool has to be identified.

ME 6005- Process Planning & Cost Estimation 16

  Factors to be considered while selecting the appropriate tool include availability of tool,
workpiece material, type of cut, part geometry, tool material, machine data, tool
characteristics, tool holding requirement & quality requirement.
 The tooling generally in manufacturing refers to cutting tool, work holding devices and jigs
and fixture.

Factors in equipment selection:

1. Technical factor:
 The technical factor ensures that the selected machine tool capable of manufacturing
the component to the required specification.
 The following technical factors are to be considered:
Physical size : The machine tool to be selected should be of sufficient size so as to
carry out the required processing and also to cope with the dimension of the
component. It should be robust enough to cope with the weight of the component.
Machine Accuracy : This refers to the capability of the machine under consideration
to manufacture the part with the required dimension and geometric tolerance
specification.
Surface finish : This refers to capability of the machine tool under consideration to
be able to manufacture parts to the required specification.
Cutting force : Feed, sped and depth of cut influence the magnitude of the cutting
force. The machine tool under consideration should be capable of providing the
calculated cutting force for the operation identified.
Machine power : The power rating of the machine should be sufficient enough to
provide the power required to carry out the required operations.
Power required for each operation = cutting force x cutting speed.
2. Operational factor:
 The operational factor focus on availability of machine tools consideration and how
can be used cost effectively to full fill the master production schedule(MPS).
 The important factors to be considered are as follows
Batch size : The economic batch quantity (EBQ) calculated for each process has to
be taken into consideration for machine tool selection. The break-even analysis can
be used for comparing potential machine tool under consideration for the calculated
batch size and the most economical machine tool will be short listed.
Capacity : It is the production rate of the machine. The machine under consideration
should be capable of achieving the specified output per unit time.
Availability : It refers to the proportion of time a machine is actually available to
perform work out of the time it should be available. The availability is related to the
overall efficiency and reliability.

Steps in machine selection:

1. First cut selection:

 Based on the preselected manufacturing processes, the machine types are identified
and specified. Eg. If turning operation is preselected already then the type of machine
to be selected is lathe.
 In this stage only one factor that is physical size of the machine in relation to the
component is considered for selection.

ME 6005- Process Planning & Cost Estimation 17

 2. Power/Force analysis:
 The selected machine in the stage should be verified with the specified power/force
requirement.
 The selected machine should be sufficient enough to meet the power requirement for
all operations. Those machines that cannot meet the requirement should be excluded
for further consideration.
3. Capability analysis:
 The factors such as dimensional and geometric accuracy and the surface finish
requirements considered for further short listing the machines selected.
4. Operational analysis:
 At the end of third stage if there are more than one machine then the machine with the
lowest machining time for most operation will be selected.
 In this stage the machine limitations and the economics of machine are calculated and
compared to finalize the single machine selection.

Factors in tooling selection:

Factors in tooling selection

1.Constrain on tool 2.Operating requirements 3.Factors affecting tooling

selection: for tool selection: performance:
 Manufacturing practice  Work piece material  Cutting tool materials
 Manufacturing process  Operation  Cutting tool geometry
 Machine tool  Part geometry  Cutting fluids
characteristics
 Tooling data
 Capability
 Process time
 Cutting tool
availability

Constrains on tool selection:

1. Manufacturing practice:
 The type of manufacturing practice will limit the selection of tooling.
 The manufacturing practice with respect to how the tool is actually fed into the
workpiece can be categorised as
Continuous cutting: the tool is continuously fed. Eg. Turning, milling and drilling.
Intermittent cutting: the tool is not continuously fed. Eg. Shaping and planning
2. Manufacturing process:
 Since the manufacturing process has already been selected the selection of tool is
simple. Eg. If the process selected is turning then the selection is limited to single
point cutting tool.

ME 6005- Process Planning & Cost Estimation 18

 3. Machine tool characteristics:
 The various tool characteristics that should be considered are availability of work
holding device, machine tool structure, power output, range of speed available, range
of feed available and availability of machine.
4. Capability:
 Dimensional and geometric accuracy required and surface finish specification are the
factors to be considered.
5. Machining time:
 The machining time influences the power, feed and speed requirements for both
machine and tooling this factor should be considered for tool selection.
6. Cutting tool availability:
 The availability of the tool should be checked before selecting the tool.

Operating requirement for tool selection:

1. Work piece material: Different work piece material during cutting results in different chip
formation and heat generation. This in turn will determine the cutting tool geometry and the
cutting tool material.
2. Operation: Each operation will have specific tool requirements.
3. Part geometry: The processing of specific part geometry requires the cutting with specific
geometric feature.
4. Tooling data: The manufacture tooling data book or catalogue can be used to select the
suitable tool for specified operation.

Factors affecting tooling performance:

1. Cutting tool material:

 Variety of materials are used to manufacture different cutting tool, the choice of
cutting tool material for the required operation has influence in the tool performance.
 The commonly used tool materials are high speed steel, carbide, cast ferrous alloy
and ceramics.
2. Cutting tool geometry:
 The cutting tool geometry such as tool angles, rake angles, cutting edge angles, tool
nose radius affect the tool performance.
 The work piece material influences the cutting tool geometry.
3. Use of cutting fluids:
 The cutting fluids acts as
Cooling medium: cools both the tool and work piece, by which the temperature is
reduced, which in turn will maintain the hardness and prevent any work piece
distortion.
Lubricating medium: reduces the friction between the tool and the work piece and
also maintain the wear resistance of the tool.
 Cutting fluids enhance the performance of cutting tool employed.

The steps in tool selection:

1. Evaluation of process and machine selection:

 In this stage, based on the preselected manufacturing processes and machine tools
already, the ranges of tools that can be employed are limited.

ME 6005- Process Planning & Cost Estimation 19

 2. Analysis of machining operation:
 From the short listed tools, the specific tool types to carry out certain operation in
each selected machines are to be analysed. This analysis helps to identify the specific
tool type for specific operation.
3. Analysis of work piece characteristics:
 The work piece material that are to analysed for the selection include work piece
material, work piece geometry, dimensional and geometric accuracy requirements
and surface finish. This analysis will help to further refine the tool type and geometry
to suit the operation.
4. Tooling analysis:
 From the general tooling specification generated at stage 3, a tooling list can be
prepared using the tooling data available. The tooling list provides the list of tools
available for the operation required.
5. Selection of tooling:
 In this stage the following selection process is used
 For single piece tooling, a suitable tool holder is selected. Then the tool
geometry and tool material can be defined.
 For insert type tooling select clamping system, select tool holder type and
size, select insert shapes and size, determine tool edge radius, select insert
type and select tool material.

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