Manufacturing Process - Gearbox

Master Thesis Erasmus Mundus Master of Mechanical Engineering
Setup of the Manufacturing Process and Economic Study of the Gear Box for Industrial Vehicle
Report
Author: Sarawut WONGTHIANCHAI Adviser: IRENE BUJ CORRAL
Escola Tcnica Superior dEnginyeria Industrial de Barcelona
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Acknowledgments
No any accomplishment of any significance is achieved solely by the effort of one person and that is certainly true of this project. I am deeply indebted to Prof. Irene Buj Corral, my advisor, who has been a true mentor and guide, and to the member of my project committee, Prof. Joan Vivancos Calvet for the assistance he has provided. I am also indebted to Prof. Ana Barjau Condomines and Prof. Jean- Claude BOYER ( INSA DE LYON ) as well as the European Commission who have provided me the greatest opportunity of my life, the chance to study master degree in INSA DE LYON and ETSEIB, UPC. I would like to thanks every professors in INSA DE LYON and ETSEIB for the everything you gave me during these 2 years. Thank you to my Erasmus Mundus colleague for the friendship and pleasure. Finally, I must acknowledge my fiance for without her love, patience, encouragement and support, this project would never have been completed. To all, a sincere thank you
Sarawut WONGTHIANCHAI
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Table of Contents
Page Acknowledgments... List of Figures. List of Tables.. Abstract... Introduction of the Project..... Objectives of the Project .... Gear Box Overview..... 1. Marketing study.. 1.1. Introduction 1.2. Objective 1.3. Estimation Method. 1.4. Assumptions... 1.5. Estimation For Year 2008, main targets are in Spain. 1.6. Estimation For Year 2009 - 2012, main targets are expanded to Europe. 1.7. Conclusion. 2. Manufacturing Process of Shaft 1... 2.1. The Raw Material.. 2.2. The Process and Calculation of Phase10... 2.3. The Process and Calculation of Phase20... 2.4. The Process and Calculation of Phase30... 2.5. The Process and Calculation of Phase40... 2.6. The Process and Calculation of Phase50... 2.7. The Process and Calculation of Phase60... 2.8. The Process and Calculation of Phase70... 2.9. The Process and Calculation of Phase80... 2.10. The Process and Calculation of Phase90. 2.11. The Process and Calculation of Phase100... 2.12. Calculation of Cycle Time for Shaft1.. 3. Manufacturing Process of Shaft 2... 3.1. The Raw Material.. 3.2. The Process and Calculation of Phase10... 3.3. The Process and Calculation of Phase20... 3.4. The Process and Calculation of Phase30... 3.5. The Process and Calculation of Phase40... 3.6. The Process and Calculation of Phase50... 1 6 9 12 13 14 15 16 16 16 16 17 17 18 20 21 21 21 21 25 26 30 33 35 36 36 36 39 43 43 43 43 46 47 50
Page 3 Page 3.7. The Process and Calculation of Phase60... 3.8. The Process and Calculation of Phase70... 3.9. The Process and Calculation of Phase80... 3.10. The Process and Calculation of Phase90. 3.11. The Process and Calculation of Phase100... 3.12. Calculation of Cycle Time for Shaft1.. 4. Manufacturing Process of Casing... 4.1. The Raw Material.. 4.2. The Process and Calculation of Phase20... 4.3. The Process and Calculation of Phase30... 4.4. The Process and Calculation of Phase40... 4.5. Calculation of Cycle Time for Casing... 5. Manufacturing Process of Sliding part 5.1. The Raw Material... 5.2. The Process and Calculation of Phase10... 5.3. The Process and Calculation of Phase20 5.4. The Process and Calculation of Phase30.... 5.5. Calculation of Cycle Time for Sliding part. 6. Manufacturing Process of Clutch Fork. 6.1. The Raw Material... 6.2. The Process and Calculation of Phase20 6.3. The Process and Calculation of Phase30 6.4. The Process and Calculation of Phase40 6.5. The Process and Calculation of Phase50 6.6. Calculation of Cycle Time for Clutch Fork 7. Manufacturing Process of Pin... 7.1. The Raw Material.... 7.2. The Process and Calculation of Phase10. 7.3. The Process and Calculation of Phase20. 7.4. The Process and Calculation of Phase30. 7.5. The Process and Calculation of Phase40. 7.6. The Process and Calculation of Phase50. 7.7. Calculation of Cycle Time for Pin... 8. Manufacturing Process of Sealing plate 1-2.................................................. 8.1. The Raw Material. 8.2. The Process and Calculation of Phase10.. 8.3. The Process and Calculation of Phase20.. 8.4. Calculation of Cycle Time for Sealing plate 1-2.. 9. Manufacturing Process of Transmission Plate 2. 9.1. The Raw Material.. 9.2. The Process and Calculation of Phase20.. 9.3. The Process and Calculation of Phase30... 51 53 54 54 54 56 58 58 58 62 65 69 70 70 70 71 73 74 75 75 75 77 78 79 79 80 80 80 80 82 83 85 85 86 86 86 89 93 94 94 94 96
Page 4 Page 9.4. The Process and Calculation of Phase40... 98 9.5. The Process and Calculation of Phase50... 99 9.6. The Process and Calculation of Phase60... 102 9.7. Calculation of Cycle Time for Transmission Plate 2. 103 10. Manufacturing Process of Washer 2. 10.1. The Raw Material... 10.2. The Process and Calculation of Phase10 10.3. The Process and Calculation of Phase20 10.4. Calculation of Cycle Time for Washer 2 11. Manufacturing Process of Gear1.. 11.1. The Raw Material... 11.2. The Process and Calculation of Phase20 11.3. The Process and Calculation of Phase30 11.4. The Process and Calculation of Phase40 11.5. The Process and Calculation of Phase50 11.6. The Process and Calculation of Phase60 11.7. Calculation of Cycle Time for Gear1. 12. Manufacturing Process of Gear2.. 12.1. The Raw Material... 12.2. The Process and Calculation of Phase20 12.3. The Process and Calculation of Phase30 12.4. The Process and Calculation of Phase40 12.5. The Process and Calculation of Phase50 12.6. The Process and Calculation of Phase60 12.7. Calculation of Cycle Time for Gear2. 13. Choosing the proper machine....................................................................... 13.1. CNC Lathe Machine.. 13.2. CNC Milling Machine... 13.3. Manual Grinding Machine 13.4. Broaching Machine 13.5. Hobbing Machine.. 13.6. Manual Disc Saw Machine 13.7. Manual Sensitive Press.. 14. Calculation of the Machines Amount Required 15. Calculation of the Workers Amount Required. 16. Economic Study 16.1. The calculation of Hour Cost. 16.2. The calculation of The Price of the cost of the Product. 16.3. The calculation of Inversion Cost.. 16.4. The calculation of the Selling Price of the Product 16.5. The Situation of the Company in the Next 5 years 16.6. The calculation of Cash Flow 104 104 104 104 108 109 109 109 111 113 113 115 116 117 117 117 119 121 121 122 123 124 124 125 128 129 130 132 133 134 135 137 137 140 142 142 143 144
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Page 16.7. The calculation of the Period of Pay Back. 16.8. The calculation of Net Present Value (NPV). 16.9. The calculation of Internal Rate of Return (IRR) 17. Production Plant Layout and the Companys Location 17.1. Production Plant Layout. 17.2. The Companys Location... 18. Waste Management and Security Policy for Workers..................... 18.1. Waste Management 18.2. The Security Policy for Workers 19. Conclusions.. References... 144 145 146 147 147 148 151 151 153 154 155
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List of Figures
Figure 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Operation of Phase10 of Shaft1... Operation of Phase20 Step1 of Shaft1.... Operation of Phase20 Step2 of Shaft1 Operation of Phase30 Step1 of Shaft1 Operation of Phase30 Step2 of Shaft1 Operation of Phase40 Step1 of Shaft1 Operation of Phase40 Step2 of Shaft1 Operation of Phase40 Step3 of Shaft1 Operation of Phase40 Step4 of Shaft1 Operation of Phase40 Step5 of Shaft1 Operation of Phase50 Step1 of Shaft1 Operation of Phase60 Step1 of Shaft1 Operation of Phase60 Step2 of Shaft1 Operation of Phase60 Step3 of Shaft1 Operation of Phase70 of Shaft1.. Operation of Phase90 of Shaft1.. Operation of Phase100 Step1 of Shaft1... Operation of Phase100 Step2 of Shaft1.. Operation of Phase10 of Shaft2.. Operation of Phase20 Step1 of Shaft2 Operation of Phase20 Step2 of Shaft2 Operation of Phase20 Step3 of Shaft2 Operation of Phase20 Step4 of Shaft2 Operation of Phase30 Step1 of Shaft2 Operation of Phase30 Step2 of Shaft2 Operation of Phase40 Step1 of Shaft2 Operation of Phase40 Step2 of Shaft2 Operation of Phase40 Step3 of Shaft2 Operation of Phase40 Step4 of Shaft2 Operation of Phase50 Step1 of Shaft2 Operation of Phase60 Step1 of Shaft2. Operation of Phase60 Step2 of Shaft2 Operation of Phase70 Step1 of Shaft2. Operation of Phase70 Step2 of Shaft2 Operation of Phase90 of Shaft2... Operation of Phase100 Step1 of Shaft2.. Operation of Phase100 Step2 of Shaft2.. Operation of Phase20 Step1 of Casing Operation of Phase20 Step2 of Casing.... Operation of Phase20 Step3 of Casing Operation of Phase20 Step4 of Casing Operation of Phase20 Step5 of Casing Operation of Phase30 Step1 of Casing Drawing for tools movement path calculation of Phase30 Step1 of Casing. Operation of Phase30 Step2 of Casing Page 21 22 24 25 26 26 27 28 29 29 30 33 34 35 36 36 37 39 43 44 44 45 45 46 46 47 48 49 50 51 52 52 53 53 54 55 55 58 59 60 60 61 62 63 63
Page 7 Figure 4.9 4.10 4.11 4.12 4.13 4.14 5.1 5.2 5.3 5.4 6.1 6.2 6.3 6.4 6.5 7.1 7.2 7.3 7.4 7.5 7.6 7.7 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 10.1 10.2 10.3 10.4 10.5 10.6 11.1 Operation of Phase30 Step3 of Casing Operation of Phase40 Step1 of Casing Operation of Phase40 Step2 of Casing Operation of Phase40 Step3 of Casing Operation of Phase40 Step4 of Casing Operation of Phase40 Step5 of Casing Operation of Phase10 of Sliding part... Operation of Phase20 Step1 of Sliding part..................... Operation of Phase20 Step2 of Sliding part..................... Operation of Phase30 Step1 of Sliding part..................... Operation of Phase20 Step1 of Clutch Fork..... Operation of Phase20 Step2 of Clutch Fork. Operation of Phase20 Step3 of Clutch Fork. Operation of Phase30 Step1 of Clutch Fork. Operation of Phase30 Step1 of Clutch Fork. Operation of Phase10 of Pin.. Operation of Phase20 Step1 of Pin Operation of Phase20 Step2 of Pin Operation of Phase30 Step1 of Pin Operation of Phase30 Step2 of Pin Operation of Phase40 Step1 of Pin Operation of Phase40 Step2 of Pin Operation of Phase10 Step1 of Sealing plate 1-2.. Operation of Phase10 Step2 of Sealing plate 1-2.. Operation of Phase10 Step3 of Sealing plate 1-2.. Operation of Phase10 Step4 of Sealing plate 1-2.. Operation of Phase20 Step1 of Sealing plate 1-2.. Operation of Phase20 Step2 of Sealing plate 1-2.. Operation of Phase20 Step3 of Sealing plate 1-2.. Drawing for cutting volume calculation of Phase20 Step3 of Sealing plate 1-2 Operation of Phase20 Step4 of Sealing plate 1-2.. Operation of Phase20 Step1 of Transmission Plate 2 Operation of Phase20 Step2 of Transmission Plate 2 Operation of Phase20 Step3 of Transmission Plate 2 Operation of Phase30 Step1 of Transmission Plate 2 Operation of Phase30 Step2 of Transmission Plate 2 Operation of Phase30 Step3 of Transmission Plate 2 Operation of Phase40 Step1 of Transmission Plate 2 Operation of Phase50 Step1 of Transmission Plate 2 The cutting surface of part in Broaching Process.. Operation of Phase10 of Washer2. Operation of Phase20 Step1 of Washer2... Operation of Phase20 Step2 of Washer2... Operation of Phase20 Step3 of Washer2... Operation of Phase20 Step4 of Washer2... Operation of Phase20 Step5 of Washer2... Operation of Phase20 Step1 of Gear1... Page 64 65 66 66 67 67 70 71 72 73 75 76 76 77 78 80 81 81 82 83 84 84 86 87 87 88 89 90 90 91 91 94 95 95 96 97 97 98 99 101 104 105 105 106 106 107 109
Page 8 Figure 11.2 11.3 11.4 11.5 11.6 12.1 12.2 12.3 12.4 12.5 12.6 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 16.1 17.1 17.2 17.3 17.4 17.5 Operation of Phase20 Step2 of Gear1... Operation of Phase20 Step3 of Gear1... Operation of Phase30 Step1 of Gear1... Operation of Phase30 Step2 of Gear1... Operation of Phase40 Step1 of Gear1... Operation of Phase20 Step1 of Gear2... Operation of Phase20 Step2 of Gear2... Operation of Phase20 Step3 of Gear2... Operation of Phase30 Step1 of Gear2... Operation of Phase30 Step2 of Gear2... Operation of Phase40 Step1 of Gear2... CNC Lathe Machine Model: SL-10HE. CNC Milling Machine Model: CNC Supra Vertical Knee-Type. 8 CNC Rotary Table Manual Grinding Machine Model: PMT/300/125 Broaching Machine Model: Slotting CNC-200S. Hobbing Machine Model: LC-200... Manual Disc Saw Machine Model: YY-131-004. Manual Sensitive Press Machine Model: 10 T. Diagram of the Period of Pay Back.. Plant Layout.. Map of Spain. Map of Barcelona. El Prat de Llobregat Industrial Area, Barcelona... Vila de Begur Street in el Prat de Llobregat Area. Page 110 110 111 112 113 117 118 118 119 120 121 124 126 127 128 130 131 132 133 145 148 149 149 150 150
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List of Tables
Table 1.1 1.2 1.3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 5.1 5.2 5.3 5.4 6.1 6.2 6.3 6.4 7.1 7.2 7.3 7.4 7.5 8.1 8.2 8.3 Number of company in Spain... Number of Company in 4 European Country, year 2004. Total expected production from year 2008-2012. Calculation data of Phase10 of Shaft1...................................... Class of surface rugosity... Calculation data of Phase20 of Shaft1.. Calculation data of Phase30 of Shaft1.. Calculation data of Phase40 of Shaft1.. Tool size data for gear shape tool. Number of tool data for gear shape tool... Cutting speed and advance of teeth for different materials.. Calculation data of Phase50 of Shaft1.. Data of external groove at section A-A of Shaft1. Calculation data of Phase60 of Shaft1.. Cutting speed (Vc) for grinding process... Calculation data of Phase100 of Shaft1 Cycle Time for Shaft1... Proper Cutting Speed Calculation data of Phase10 of Shaft2.. Calculation data of Phase20 of Shaft2.. Calculation data of Phase30 of Shaft2.. Calculation data of Phase40 of Shaft2.. Calculation data of Phase50 of Shaft2.. Calculation data of Phase60 of Shaft2.. Calculation data of Phase100 of Shaft2 Cycle Time for Shaft2.. Calculation data of Phase20 of Casing. Calculation data of Phase30 of Casing. Calculation data of Phase40 of Casing. Cycle Time for Casing.. Calculation Data of Phase10 of Sliding part............................. Calculation Data of Phase20 of Sliding part............................. Calculation Data of Phase30 of Sliding part............................. Cycle Time for Sliding part...................................................... Calculation data of Phase20 of Clutch Fork. Calculation data of Phase30 of Clutch Fork. Calculation data of Phase40 of Clutch Fork. Cycle Time for Clutch Fork. Calculation data of Phase10 of Pin... Calculation data of Phase20 of Pin... Calculation data of Phase30 of Pin... Calculation data of Phase40 of Pin... Cycle Time for Pin Calculation data of Phase10 of Sealing plate1-2.. Calculation data of Phase20 of Sealing plate1-2.. Cycle time for Sealing plate1-2 Page 17 19 20 21 23 25 26 30 32 32 33 33 34 35 37 39 41 42 43 46 47 50 51 53 56 56 62 64 68 69 70 73 74 74 77 78 79 79 80 82 83 84 85 88 92 93
Page 10 Table 9.1 9.2 9.3 9.4 9.5 10.1 10.2 10.3 11.1 11.2 11.3 11.4 11.5 11.6 12.1 12.2 12.3 12.4 12.5 12.6 13.1 13.2 13.3 13.4 13.5 13.6 14.1 15.1 15.2 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 16.11 16.12 16.13 16.14 16.15 Calculation data of Phase20 of Transmission Plate2 Calculation data of Phase30 of Transmission Plate2 Calculation data of Phase40 of Transmission Plate2 Calculation data of Phase50 of Transmission Plate2 Cycle time for Transmission Plate2.. Calculation data of Phase10 of Washer2.. Calculation data of Phase20 of Washer2.. Cycle time for Washer2 Calculation data of Phase20 of Gear1.. Calculation data of Phase30 of Gear1.. Calculation data of Phase40 of Gear1.. Data for external gear of Gear1 Calculation data of Phase50 of Gear1.. Cycle time for Gear1 Calculation data of Phase20. Calculation data of Phase30. Calculation data of Phase40. Data for external gear of Gear1... Calculation data of Phase50. Cycle time for Gear2... The Maximum machine power and rotation speed of turning operation.. The Maximum machine power and rotation speed of milling operation.. The Maximum machine power and rotation speed of grinding operation The Maximum machine power of broaching operation.. The Maximum machine power of gear machining operation The Maximum machine power of saw operation... The amount of Machines. The amount of workers ( Operator of Machine )... The amount of workers and salary rate for all positions. The Amortization Cost Show the details of investment cost of each machines and its amount Total Electric Power Cost per Year The Constants to be used in equation54. Total Salary Cost per year.. Total General Cost.. Hour Cost Steel Price Raw Material Cost for each part. The Price of the Cost of the Product... Inversion Cost for the first 3 months.. The Selling Price of the Product. The Situation of the Company in the Next 5 years. Cash Flow The Period of Pay Back.. Page 96 98 99 102 103 104 107 108 111 112 113 114 115 116 119 120 121 122 122 123 124 125 128 129 130 132 134 136 136 137 138 138 139 139 139 140 141 141 142 142 143 143 144 144
Page 11 Table 16.16 16.17 17.1 18.1 The results of the calculation of NPV The calculation of IRR The estimation of the required area for production plant... The list of the waste management company in Spain and Europe. Page 145 146 147 151
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Abstract
The concept of the project is to setup the manufacturing process and the economic study as well as the production plant layout and waste management of the gear box for industrial vehicle. The gear box contains 21 main parts and 11 parts will be explained in this project, including: Shaft1, Shaft2, Casing, Sliding part, Clutch fork, Pin, Sealing plate1-2, Transmission Plate2, Washer2, Gear1 and Gear2. Firstly we have to do the marketing study in order to estimate the amount of the production we expect to sell in the first and the following years. The marketing study is done by analyzing the data from Spain and European database in industrial section together with the assumption based on reality. The results from this part are the expected production per year which can let us make the decision for the machine type and it will be used in economic study as well. Then the proper manufacturing process and specific tools type for each part will be decided and written on the Phase Document and the Summary of the Operation. These 2 documents are in the form that suitable to be used in reality effectively. Not only the manufacturing procedure, we also indicate the proper cutting condition and the calculations of cycle time, cutting force, machine power and the quality verification for each part. The data obtained by the calculation will be used to choose the specific model of machines, the amounts of machines and workers required to achieve the expected production. After we have the clear image of the production line, we shall advance to the economic study. The economic study is a good and reliable tool to indicate the profitability of the business. Every possible cost of the company will be taken into account and be presented as Hour Cost . As well as the economic indicators such as Cash Flow, Period of Pay back, Net Present Value ( NPV ) and Internal Rate of Return ( IRR ) will be presented to be sure that the investment of this business will be profitable. The final tasks are the production plant layout and the waste management. The production plant layout will be designed sketchily as well as the specific suitable location. The waste management is the explanation the way to deal with the chips and chemical waste to be responsible for the social and environment.
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Introduction of the Project

The Manufacturing Process in general is not a very complicate task but its difficult to define the best solution for one process. There are many alternative methods to achieve the same result, but each one has dissimilarity itself and the toughness is to indicate the best solution. The good decision will be depended on both theory and experience and this decision will effect to the profit of the company in long-term. The aim of this project is to define the setting-up the manufacturing process and do the economic study of the gear box for industrial vehicle. Imagine that the we want to manufacture the gear box which is already designed. Its always strongly necessary to study it before investing the production plant in order to know the profitability of the business. All the necessary data are prepared in this project and the remainder of this document is organized as follows: Chapter1: The Marketing Study to estimate the productions expected to produce. Chapter2 to Chapter12: Manufacturing Process and the Calculation of Shaft 1, Shaft2 , Casing, Sliding part, Clutch Fork, Pin, Sealing plate 1-2, Transmission Plate 2, Washer 2, Gear1, Gear2. Chapter13: Choosing the proper specific model of each machine from the manufacturers catalog as well as its price to be used in the economic study . Chapter14: Calculation of the Machines Amount Required to achieve the expected production quantities. Chapter15: Calculation of the Workers Amount Required both direct and indirect workers to achieve the expected production quantities. Chapter16: Economic Study to indicate the profitability of the investment. Chapter17: Production Plant Layout and the Companys Location. Chapter18: Waste Management policy to show the responsibility for the Social and Environment. Chapter19: Conclusions of the project.
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Objectives of the Project

The main idea of this project is to be a tool for making the right decision to invest in manufacturing of the gear box for industrial vehicle as well as to prepare the manufacturing process for each part to be able to use in reality. At the end of the project, we expect to have the entire of important task to set-up the manufacturing process and the key point to indicate the profitable of this business. The objectives of the project are defined as follows: - To define the operations as well as the quality verifications that are necessary to manufacture a number of gear boxes per year according to the marketing study. - To prepare the Documents: Phase of Manufacturing Cycle which will be composed of the clearly process explanation, drawings for each step with the verification points, raw material details, specific tools type and measuring tool. - To prepare the Documents: Summary of Operations which will be composed of the brief process explanation of every phase for each part. - To select the specific type of machines according to the data from calculation part. - To calculate the number of machines and direct workers according to the cycle time obtained in the calculation part. - To carry out the economic study of the project to indicate the its profitability by obtaining these indicators: Hour Cost, Price of the cost of the product, Inversion Cost, Selling Price of the product, Cash Flow, Period of Payback, NPV and IRR. - To propose the production plant layout and the location for the company. - To propose the waste management and the security policy After getting all the above information, the investor will be confident enough to progress this business effectively as well as the risk of ruin.
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Gear Box Overview

Gear Box is the Transmissions provide a speed-power conversion known as gear reduction (in speed) to a higher torque (rotational force) using gear sets. In motor vehicles, the transmission provides different speed-power ratios known as "gears" or "speeds", some of which may be in the reverse direction. Tractors and large trucks especially may have a dozen or more forward "gears" which vary from a crawling speed at high torque to high speed at low torque where the only torque needed with a load coasting along at a given speed are that small additional energy (force) needed to overcome ongoing friction and other road losses such as climbing a grade. When the torque needed to surmount a grade is insufficient at a higher rotational speed, the gearbox is shifted into a lower gear to provide more power, as was needed when initially accelerating said vehicle to the desired road speed. Gearing has much in common with the mechanic and mechanical factors present in pulley systems. One trades distance (numbers of rotations) for increased force. Early transmissions included the right-angle drives and other gearing in windmills, horse-powered devices, and steam engines, in support of pumping, milling, and hoisting. Most modern gearboxes either reduce an unsuitable high speed and low torque of the prime mover output shaft to a more usable lower speed with higher torque, or do the opposite and provide a mechanical advantage (i.e increase in torque) to allow higher forces to be generated. Some of the simplest gearboxes merely change the physical direction in which power is transmitted. Many typical automobile transmissions include the ability to select one of several different gear ratios. In this case, most of the gear ratios (simply called "gears") are used to slow down the output speed of the engine and increase torque. However, the highest gears may be "overdrive" types that increase the output speed. Gear boxes have found use in a wide variety of different often stationary applications. Transmissions are also used in agricultural, industrial, construction, mining and vehicle equipment. In addition to ordinary transmission equipped with gears, such equipment makes extensive use of the hydrostatic drive and electrical adjustable speed drives. The simplest transmissions, often called gear boxes to reflect their simplicity (although complex systems are also called gear boxes in the vernacular), provide gear reduction (or, more rarely, an increase in speed), sometimes in conjunction with a right-angle change in direction of the shaft (typically in helicopters). These are often used on PTO-powered agricultural equipment, since the axial PTO shaft is at odds with the usual need for the driven shaft, which is either vertical (as with rotary mowers), or horizontally extending from one side of the implement to another (as with manure spreaders, flails mowers, and forage wagons). More complex equipment, such as silage choppers and snow blowers, have drives with outputs in more than one direction. Regardless of where they are used, these simple transmissions all share an important feature: the gear ratio can not be changed during use. It is fixed at the time the transmission is constructed.
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1. Marketing Study for Gear Box of Industrial Vehicle in Spain

1.1. Introduction : We are studying to setup the manufacturing process to fabricate the Gear Box for Industrial Vehicle. The Gear Box contains of 21 main mechanical parts which required the different process to fabricate and of course different machines. At the beginning phase of the project, its necessary to decide the way of fabrication, in this case means the type of machine we will employ. There are 2 main machine types, CNC and Manual Machine. The CNC type has better capacity and precision but higher investment cost. In the other hand, the Manual type requires lower budget but lower capacity and the precisions are depended on the man skill which can be vary a lot. In order to make a decision for machine type, we will point out to the marketing point of view. We will estimate the selling amount of our company by analyzing the numbers of Industrial Vehicles in the target area. In the first year, our target area is mainly in Spain and for the following 5 years we will expand to Europe. This analysis will be shown in the following part of this study.
1.2. Objective : To estimate the expected production per year in order to make a decision for the main category before designing the fabrication line and its operation, including : Type and number of machine.
1.3. Estimation Method : Because of our product is Gear Box which mainly use for industrial vehicle. In order to estimate the amount of productions per year, we have to point out to two ways, the quantity of industrial vehicles existed in the industrial company and the total selling amount of new industrial vehicle per year. In reality, its very difficult to know the exact number of existed industrial vehicle in Spain or in Europe. We propose the estimation by knowing the amount of industrial company in Spain and Europe which are the possible data to be obtained. With the number of company, we add the assumptions base on reality and norm of each area to get finally the estimation amounts of industrial vehicles existed in Spain and Europe. We can also estimate the total selling amount of new industrial vehicle per year by utilizing the amounts of industrial vehicles existed. Finally, with these two data, we can proceed this study in the following part
Page 17 1.4. Assumptions : In Spain: The company with under 20 employees has 1 Industrial Vehicle. The company with 20 or more employees has 3 Industrial Vehicles. The selling amount of New Industrial Vehicle is equal to 30% of the total amounts of Industrial Vehicle existed in Spain. 10% of the total amounts of Industrial Vehicle existed in Spain have to change the new gear box every year. Market share of our company in Gear Box for Industrial Vehicle in Spain is 10%
In France, UK, German and Switzerland: Each company in France, UK, German and Switzerland (with 20 or more employees ) has 3 Industrial Vehicle. The selling amount of New Industrial Vehicle is equal to 30% of the total amounts of Industrial Vehicle existed in France, UK, German and Switzerland. 10% of the total amounts of Industrial Vehicle existed in France, UK, German and Switzerland have to change the new gear box every year. Market share of our company in Gear Box for Industrial Vehicle in Spain is 5%
1.5. Estimation For Year 2008, main targets are in Spain Data :
Year 2001 2002 2003 2004 2005
Number of company in Spain with under 20 with 20 or more employees employees 124047 23076 120104 23424 119728 22941 120806 22375 119218 22869
Table1.1: Number of company in Spain [15]
Variables: Ntot = Number of Industrial Vehicles existed in Spain (unit) Nsell = The selling amount of New Industrial Vehicle in Spain (unit) Mgear = The amounts of Industrial Gear Box be sold in the Spanish Market (unit/year) Pexpect = The expected production (unit/year)
Page 18 Calculation : In this calculation, we use the data in year 2005. We begin with the calculation of the number of Industrial Vehicles existed in Spain (Ntot). According to table1, the number of company in Spain with under 20 employees are 119218 companies and the number of company in Spain with 20 or more employees are 22869 companies. From the previous assumption, we can calculate The number of Industrial Vehicles existed in Spain (Ntot) by the following equation, Ntot = (119218 * 1) + (22869 * 3) = 187825 units
With the number of Industrial Vehicles existed in Spain (Ntot), we can calculate the estimation of selling amount of New Industrial Vehicle (Nsell) by the following equation, Nsell = Ntot * 0.3 = 187825 * 0.3 = 56347.5 units Now we already got the two important parameters Ntot and Nsell to calculate the amounts of Industrial Gear Box be sold in the Spanish Market per year (Mgear) by the following relation, Mgear = ( 10% * Ntot ) + ( Nsell ) = ( 0.1 * 187825 ) + ( 56347.5 ) Mgear = 75130 units/year Finally, we can estimate the expected production of our company for the year 2008 (only in Spain) by considering that our market share is 10%, the calculation is shown below,
Pexpect = 10% * Mgear = 0.1 * 75130 = 7513 units/year
1.6. Estimation For Year 2009 - 2012, main targets are expanded to Europe As we have calculated in the previous part, in the first selling year ( year 2008 ), we only point to the market in Spain. In the following years (year 2009, 2010, 2011, 2012) , we consider to open European market in order to increase the sell volume of our company. At the beginning, we will consider the market in the European country which is big enough to get its market share, including France, United Kingdom, German, Switzerland. Their data are shown in the following table.
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Country France German United Kingdom Swizerland Total Enterprise 20414 37680 79664 37129 174887
Table1.2: Number of Company in 4 European Country, year 2004 [16]
* Scope of coverage: Taking to account only the enterprises with 20 or more employees
Variables: Ntot = Number of Industrial Vehicles existed in France, UK, German and Switzerland (unit) Nsell = The selling amount of New Industrial Vehicle in France, UK, German and Switzerland (unit) Mgear = The amounts of Industrial Gear Box be sold in the Market of France, UK, German and Switzerland (unit/year) Pexpect = The expected production (unit/year)
Calculation: In this calculation, we use the data of France, UK, German and Switzerland in year 2004. We begin with the calculation of the number of Industrial Vehicles existed in France, UK, German and Switzerland (Ntot). According to table2, the total number of company in the 4 European country is 174887 companies. From the previous assumption, we can calculate The number of Industrial Vehicles existed (Ntot) by the following equation, Ntot = 174887 * 3 = 524661 units
With the number of Industrial Vehicles existed in France, UK, German and Switzerland (Ntot), we can calculate the estimation of selling amount of New Industrial Vehicle (Nsell) by the following equation, Nsell = Ntot * 0.3 = 524661 * 0.3 = 157398.3 units
Now we already got the two important parameters Ntot and Nsell to calculate the amounts of Industrial Gear Box be sold in the Market of France, UK, German and Switzerland (Mgear) by the following relation, Mgear = ( 10% * Ntot ) + ( Nsell ) = ( 0.1 * 524661 ) + ( 157398.3 ) Mgear = 209864 units/year
Page 20 Finally, we can estimate the expected production of our company for the year 2009 - 2012 ( in France, UK, German and Switzerland ) by considering that our market share is 5%, the calculation is shown below, Pexpect = 5% * Mgear = 0.05 * 209864 = 10493 units/year
We expect that the selling amount for France, UK, German and Switzerland will increase 25% of Pexpect every year continuously. So The selling amount from year 2009 2012 are : For year 2009 For year 2009 For year 2009 For year 2009 = 0.25 * Pexpect = 0.25 * 10493 = = 0.50 * Pexpect = 0.50 * 10493 = = 0.75 * Pexpect = 0.75 * 10493 = = 1 * Pexpect = 1 * 10493 = 2623.25 5246.5 7869.75 10493 units/year units/year units/year units/year
The total expected production are shown in the following table :
Year 2008 2009 2010 2011 2012
In Spain (units/year) 7513 7513 7513 7513 7513
In Europe (units/year) 0 2623.25 5246.5 7869.75 10493
Total (units/year) 7513 10136.25 12759.5 15382.75 18006
Table1.3: Total expected production from year 2008-2012
1.7. Conclusion : As we can see in Table3, the expected productions are not too large in year 2008 and it could be possible to employ Manual Machine. However if we observe the following year, the amount of expected productions are increasing year by year. In this case, it seems to be unsuitable to employ Manual Machine due to its low capacity and flexibility. Due to this reason, it would be better to choose CNC Machine for the main process and Manual Machine for the support function.
Page 21
2. Manufacturing Process of Shaft 1

2.1. The raw material: In order to machine this part, we use cylindrical bar steel 16 Mn Cr 5 with diameter 73 mm because we have to add 1.5 mm. to the final shape ( Maximum diameter of part is 70 mm.) in radial direction to be machined in Finishing Operation. 2.2. Phase 10: The cylindrical bars usually come with the long length shape. To be suitable for the Lathe Machine, the bars have to be cut by Manual Disc Saw Machine. The total distance of the final shape is 172.75 mm., we have to add 1.5 mm. for the both end of bar to be machine in Finishing Operation. So we have to cut the bar to have the length 175.75 mm. with the tolerance +1, -0 mm. The calculation can be done by the same method as milling machine in the following step. In this case we consider that the diameter of disc (d) is 210 mm. with the thickness (b) 2 mm. The number of teeth (zt) is 60 and the advance of teeth (az) is 0.015 mm. We use the cutting speed (Vc) 40 m/min and the mechanical efficiency () is 0.75. We use the maximum width of part to calculate the maximum power, so the cutting width (p) is 73 mm. and the cutting length (L) is also 73 mm. The results of the calculations are shown in table2.1.
Figure2.1: Operation of Phase10
Step 1
d(mm) 210
Tool Data az(mm.) Zt(teeth) 0.015 60
n(rpm) 60.63
av(mm/turn) 0.9
Vam(mm/min) 54.567
p(mm) 73
b(mm) 2
Fc(N) 262800
Pc(kW) 0.239
Pm(kW) 0.319
L(mm) 73
tc(min) 1.338
Table2.1: Calculation data of Phase10
2.3. Phase 20: This process employ CNC Lathe Machine by fix the part with fixing plate with hard jaws. The part will be fixed at one end and will be machined at another end.
Page 22 Step1: We start machining the part by taking out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Figure2.2: Operation of Phase20 Step1
Calculation of Step1: In this operation, we fix cutting speed Vc = 150 m/min which is the proper value for the material of tool and part. We employ CNC Lathe, so the tangential speed at the surface of part is always fixed at 150 m/min. The rotation speed will be vary due to the changing of diameter, but in this calculation we use the average diameter of this step to calculate the rotation speed by the formula below[1]. n = ( 1000 * Vc ) / ( * d) Where: n = Average rotation speed of machine (rpm) Vc = Cutting speed (m/min) d = Average diameter of the process (mm.) The advance of the tool can be calculate by knowing tool radius and the average roughness of the machined surface. With the tool information, we know that the edge radius of tool rp = 0.031 mm. and the average roughness of this process is Ra = 1.6 m (see table1.1). The advance velocity a (mm/turn) is calculated by the formula below [1]. a = sqrt{(Ra * rp)/25} Where: a = Advance velocity of tool (mm/turn) Ra = Average roughness of the surface (m) rp = Radius of the edge of tool (mm.) (2) (1)
Page 23
Class of rugosity N12 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2 N1 Ra (m) 50 25 12.5 6.3 3.2 1.6 0.8 0.4 0.2 0.1 0.05 0.025
Table2.2: Class of surface rugosity [1]
The cutting force required for this process (Fc) is needed to be calculated in order to calculate the machine power in the following step. By knowing that the cutting depth of this step (p) is equal to 1.5 mm and the value of t and k from table1.2, we can obtain Fc by utilizing the following formula [1]. Fc = k * t * S Where: k = constant depending on the type of material k = 3 for elastic material k = 5 for less or non elastic material (ex. Casting ) t = Resistant of traction stress of material (N/mm2) S = Cutting surface perpendicular to the cutting velocity (mm2) S = a * p ; a = advance velocity (mm/turn) p = Cutting depth (mm.) The cutting power (Pc) and the machine power (Pm) will be calculated in order to choose the proper machine. The formulas are shown below[1]. Pc = (Fc * Vc)/60000 Pm = Pc/ Where: Pc = Cutting power required to cut material (kW) Pm = Machine power (kW) = Efficiency of lathe machine = 0.7 0.8 We also have to calculate the cutting time tc. In order to calculate it, we have to find the cutting length and cutting velocity. Cutting length (L) is all paths that tool have to pass and cut the material. In this step, cutting length is 36.5 mm. ( from the surface to the center of the bar). The calculation process can be done by the following formula[1]. tc = L/Va (6) (4) (5) (3)
Page 24 Va = a * n Where: L = Cutting length (mm.) Va = Cutting velocity (mm/min) a = advance velocity (mm/turn) n = rotation speed (rpm) Step2: This operation is to drill a hole for fixing with tail stock. The drilling tool has a special shape with angle 60 degree. In this case we use drill Garant 111050A with edge diameter 2 mm. (7)
Calculation of Step2: The material of drill is high speed steel, so the proper cutting speed Vc is equal to 25 * 0.8 m/min (For drill, we multiply the cutting speed of lathe or milling by 0.8). To calculate the rotation speed of tool, in this case the diameter of hole is not constant, so we use the average diameter to calculate (davg = (10 + 2)/2 = 6 mm.) The rotation speed can be calculated by the same formula as we have calculated in Step1. The advance speed of drill depends on the diameter of drill. The formula below shows how to calculate it [1]. a = d / 100 (8) Where: a = advance speed of drill (mm/turn) d = average diameter of drill (mm) Generally, normal drill has 2 cutting edges. To calculate the cutting force of drilling operation, we consider only one side and finally we multiply by 2 to have to whole cutting force for drill. The formula is shown below [1]. Fc = 2 * k * t * (a/2) * (d/2) Where: Fc = cutting force (N) k = constant depending on the type of material k = 3 for elastic material k = 5 for less or non elastic material (ex. Casting ) t = Resistant of traction stress of material (N/mm2) (9)
Page 25 a = advance speed of drill (mm/turn) d = average diameter of drill (mm) The cutting power required for cutting process (Pc) is the product of cutting force Fc and the average cutting velocity (0.8 * Vc)/2. If we divide Pc by drilling efficiency (drill), we will get the power required for the machine. The formulas are shown below [1]. Pc = Fc * (0.5 * 0.8 * Vc) /60000 Pm Pc / drill Where: Pc = cutting required to cut the material (kW) Pm = the power required for the machine drill = efficiency of drill = 0.7 0.8 The cutting time for this process (tc) can be calculated by utilizing the equations 6 and 7.
S(mm2) 0.067
(10) (11)
Step 1 2
rp(mm) 0.031
d(mm) 36.5 6
n (rpm) 1308 1061
p(mm) 1.5
Ra(mm) 1.6
a(mm/turn) 0.045 0.06
Step 1 2
Fc(N) 120 324
Pc(kW) 0.301 0.027
Pm (kW) 0.401 0.036
L (mm) 36.5 10.6
Va(mm/min) 58.267 63.662
tc(min) 0.626 0.167
2.4. Phase30: This Phase is almost the same process as in Phase20. We only change the machining surface to the other end of the raw part and following the operation in Step1 and Step 2 of Phase20.
Page 26
Step 1 2
rp(mm) 0.031
d(mm) 36.5 6
n (rpm) 1308 1061
p(mm) 1.5
Ra(mm) 1.6
a(mm/turn) 0.045 0.06 Va(mm/min) 58.267 63.662
S(mm2) 0.067
Step 1 2
Fc(N) 120 324
Pc(kW) 0.301 0.027
Pm (kW) 0.401 0.036
L (mm) 36.5 10.6
tc(min) 0.626 0.167
2.5. Phase40: This process employ CNC Lathe Machine by fix the part with fixing plate with hard jaws at one end. The part will be fixed by pressing tail stock at the 2 ends. It will be driven by the jaws at one end. The advantage of this fixing system is that we can machine the profile of the part in only one phase (without changing of fixing position) Step1: This step is to do rough machining. We will machine the part to be similar to the final profile but adding 1.5 mm. in radius and axial direction for finishing operation. The tool we employ is Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B, the same tool as Phase20 Step1.
Page 27 Calculation of Step1: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 but we use the cutting speed (Vc) for rough machining (see table1.2). The advance speed for rough machining is 0.5-0.8 mm/turn [1], so its not necessary to define the surface roughness (Ra). The only different in this step is the way to calculate L. This step is the rough machining by utilizing CNC Lathe machine and fix cycle. We use the cutting depth of each pass (p) 3 mm. By considering the manner of fix cycle path, we can calculate the total cutting length (L) by the equation below. L = (5*89.75) + (1*37.75) + (5*23.5) + (2*78) + (5*33) + (1*29) = 954 mm. Step2: This step is to machine finishing surface. The part will have almost the same shape as the final part after this step. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, both right and left hand.
Calculation of Step2: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). According to the drawing, the sign of rugosity class is N7 which is equal to the average roughness Ra = 1.6 m. (see table1.1) and the edge radius of this tool (rp) is 0.031 mm. With these 2 values, we can find the advance velocity. In this step, we leave the material 0.15 mm. in radius direction at diameter 16 h5 mm. and 25 k6 mm. because they require high precision and need to be done by Grinding process. The cutting length in this step can be done in the similar way as rough machining. But in this process, we machine only 1 pass with cutting depth (p) 1.5 mm.
Page 28 Step3: This step is to make a round shape groove at the shaft surface. We use the grooving tool from Kyocera, the tool insert is GMM6020-30R and the tool holder is KGML2525M-6T30 [3]. In this case the length of tool insert should be longer than 14 mm. to avoid crash with the diameter 70 mm. of the part. The length of tool insert GMM6020-30R is 20 mm., so we dont have the risk of crash. In this process, its not necessary to define the average roughness (Ra). So we can choose the advance speed (a) equal to 0.1 mm., its the suitable value for the finishing surface [1]. Because the shape of the tool in this process is curve shape, we propose to use the average cutting depth to calculate in this process. The average cutting depth is equal to : (maximum depth + minimum depth) / 2 = (6 + 0) / 2 = 3 mm.
Calculation of Step3: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7 and use Vc for finishing surface with carbide tool (see table1.3). Step4: The objective of this step is to make a groove and chamfer at the external surface of the part. In this step we use Kyocera tool, tool insert KCG2094L and tool holder KKCL 1212M-2-150F [3]. The width of tool is 2.4 mm. but the width of groove profile is 7 mm. So the tool has to work 3 times in order to have 7 mm. groove, 1st is 2.4 mm., 2nd is 2.4 mm. and 3rd is2.2 mm. After that the tool will move out with the angle 30 degree from the part o make a chamfer. In this process, its not necessary to define the average roughness (Ra). So we can choose the advance speed (a) equal to 0.1 mm., its the suitable value for the finishing surface [1]. The cutting length of this process can be considered that the lengths for each cutting pass are equivalent. The total cutting length is the summation of the 3 vertical cutting pass and 1 inclination for chamfer. The equation below shows the calculation of total cutting length. L = (3 * ( (42 - 38) / 2) ) + (3.2 / cos30) = 6 + 3.695 = 9.695 mm.
Page 29
Calculation of Step4: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7 and use Vc for finishing surface with carbide tool (see table1.3). Step5: The objective of this step is to make a groove at the external surface of the part. In this step we use Kyocera tool, tool insert TGF32R130 and tool holder KTGFRL1010K-16F [3]. The width of this tool is exactly 1.3 mm., so we need only 1 cutting pass for this step. In this process, its not necessary to define the average roughness (Ra). So we can choose the advance speed (a) equal to 0.1 mm., its the suitable value for the finishing surface [1].
Calculation of Step5: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7 and use Vc for finishing surface with carbide tool (see table1.2).
Page 30
Step 1 2 3 4 5 Step 1 2 3 4 5
rp(mm) 0.031 0.031
d(mm) 44.057 41.143 39 40 24.6 Pc(kW) 6.75 0.361 1.62 1.296 0.702
n (rpm) 1084 1393 1469 1432 2329
p(mm) 3 1.5 3 2.4 1.3
Ra(mm) 1.6
a(mm/turn) 0.5 0.045 0.1 0.1 0.1
S(mm2) 1.5 0.067 0.3 0.24 0.13 tc(min) 1.761 3.583 0.02 0.068 0.003
Fc(N) 2700 120 540 432 234
Pm (kW) 9 0.481 2.16 1.728 0.936
L (mm) 954 222.3 3 9.695 0.7
Va(mm/min) 541.87 62.03 146.912 143.239 232.91
2.6. Phase50: This phase we move the part to CNC Milling Machine. The part will be fixed by the Index Plate with soft jaws which is suitable for cylindrical part and its possible to rotate the part. Step1: This step is to make external grooves of section C-C. The grooves have gear shape which need a special tool to machine. The tool we use in this process should has the shape according to DIN 5480.
Calculation of Step1: We have to start the calculation by finding the gear module of the part. The module (m) will be necessary for the next step. It can be calculated by the following formula [1]. m = dp / zp (12)
Page 31 Where: m = gear module dp = pitch diameter (mm.) zp = number of teeth The next step is to choose the number of teeth of milling tool from catalog (see table1.7). For ex. We choose tool with 22 teeth, we get number of tool (Nm) equal to 4.Then we shall find the tool size by the following equation [1]. Size = m / Nm (13)
Where: Size = tool size (see table1.6) m = gear module Nm = Number of tool With the Size obtained from equation13, we can get the external diameter of tool from table1.6. This external diameter let us be able to calculate the rotation speed of tool. The formula is shown below [1]. The cutting Vc is chosen from table1.2. n = (1000 * Vc) / (pi * d) Where: n = rotation speed tool Vc = Cutting speed d = external diameter of tool The next step is to calculate the advance speed (av) of milling tool. The formula is shown below [1]. av = az * z or Vam = az * z * n (15) (16) (14)
Where: av = advance speed of tool (mm/turn) z = number of teeth (teeth/turn) az = the distance between tools teeth (mm/tooth), choose from table1.8 Vam = advance speed of tool in mm/min n = rotation speed tool The cutting force required for this process (Fc) is needed to be calculated in order to calculate the machine power in the following step. We choose cutting depth of each pass p = 2 mm. and the width of tool b = (3.65+1.5)/2 = 2.575 mm. (the avg of tool profile), the value of t and k are from table1.2, we can obtain Fc by utilizing the following formula [1]. Fc = k * t * p * b Where: k = k k t = constant depending on the type of material = 3 for elastic material = 5 for less or non elastic material (ex. Casting ) Resistant of traction stress of material (N/mm2) (17)
Page 32 p = cutting depth of each pass (mm) b = average width of the cutting profile (mm) The cutting power (Pc) and the machine power (Pm) will be calculated in order to choose the proper machine. The formulas are shown below[1]. Pc = (Fc * Vam) / 60000000 Pm = Pc / mill Where: Pc = Cutting power required to cut material (kW) Pm = Machine power (kW) = Efficiency of milling machine = 0.6 0.75 We also have to calculate the cutting time tc. In order to calculate it, we have to find the cutting length and cutting velocity. Cutting length (L) is all paths that tool have to pass and cut the material. In this step, cutting length 0f each pass is 32 mm. and the tool will repeat 28 passes. So, the total cutting length is equal to 32 * 28 = 896 mm. The calculation process can be done by the following formula[1]. tc = L / Vam Where: tc = cutting time (min) L = total cutting length (mm) Vam = advance speed of tool in mm/min (20) (18) (19)
Tool Size OD (mm.) ID (mm.)
0.5 40 16
0.75 40 16
1 50 16
1.25 50 16
1.5 63 22
1.75 63 22
2 63 22
2.25 63 22
2.5 63 22
2.75 80 27
3 40 16
3.25 40 16
3.5 50 16
3.75 50 16
4 63 22
4.25 63 22
4.5 63 22
4.75 63 22
Table2.6: Tool size data for gear shape tool [4]
Number of tool Number of teeth
1 12 to 13
2 14 to 16
3 17 to 20
4 21 to 25
5 26 to 34
6 35 to 54
7 55 - 134
8 more than 135
Table2.7: Number of tool data for gear shape tool [4]
Page 33
Cutting Speed (m/min) 20 to 25 9 to 12 20 to 25 25 to 50 15 to 25 10 to 18 8 to 12 30 to 45 15 to 22 Advance of teeth, az (mm) 0.005 - 0.015 0.005 - 0.01 0.005 - 0.01 0.005 - 0.025 0.005 - 0.015 0.005 - 0.010 0.015 - 0.025 0.005 - 0.03 0.005 - 0.01
Material Soft Cast Iron 200B Hard Cast Iron 200B Ductile Cast Iron Steel 50 N/mm^2 Steel 600-700 N/mm^2 Steel 700-1100 N/mm^2 Stainless Steel Soft Brass Hard Brass and Bronze
Table2.8: Cutting speed and advance of teeth for different materials [4]
Step 1
Zp 28
Dp 58
m 2.07
Nm 4
Size 0.52
d(mm) 40
n(rpm) 1194
av(mm/turn) 0.375
Vam(mm/min) 447.623
p(mm) 2
b(mm) 2.575
Fc(N) 9270
Pc(kW) 0.069
Pm(kW) 0.099
V(mm3/min) 2305.26
L(mm) 896
tc(min) 2.002
2.7. Phase60: We still use the CNC milling Machine in this phase and the part will be fixed by the Index Plate with soft jaws. Step1: The purpose of this process is to drill 3 holes with 5 mm. diameter and deep 10 mm at section A-A. The 3 holes should be 120 degree between each other. We choose the drill Garant drill 113260 diameter 5 mm. [4] which is suitable for this material. This step is to prepare the hole for the next step which will be done by Mandrel Drill in order to have diameter 8 H7 mm. Because normal drill can make only a hole with the precision IT 9-10 but Mandrel Drill can reach IT 8-9.
Page 34 Calculation of Step1: The calculation of this step can be done by follow the method and formula in Phase20 Step2. We use the diameter 5 mm. and the depth 30 mm. The total cutting length is the summation of the depth of the 3 holes. Step2: In this step, we will increase the hole diameter to 8 H7 mm. by utilizing Mandrel Drill. We choose the drilling tool Garant Mandrel Drill 163500 diameter 8 mm.[4]. The process is similar to the previous step.
Calculation of Step2; The calculation of this step can be done by follow the method and formula in Phase20 Step2. We use the diameter 8 mm. and the depth 30 mm. The total cutting length is the summation of the depth of the 3 holes Step3: This step is to make external grooves of section A-A. The grooves have gear shape which need a special tool to machine. The tool we use in this process should has the shape according to the data in table1.10.
Table2.10: Data of external groove at section A-A
Page 35
Calculation of Step3: Every calculation of this step is similar to Phase50 Step1. We can use the formula 12,13,14,15,16,17,18,19 and 20 to calculate it with the data in table1.6, 1.7, 1.8. In this case, we choose the number of tools teeth (z) equal to 25 and the average width of tools profile (b) is (5.84 + 4.38) / 2 = 5.11 mm.
Step 1 2 3
Zp
Dp
Nm
Size
12
41.2
3.43
0.86
d(mm) 5 8 40
Tool Data az(mm.) Zt(teeth)
0.015
25
n(rpm) 1273 795.8 1194
av(mm/turn) 0.05 0.08 0.375
Vam(mm/min) 63.662 63.662 447.623
Step 1 2 3
p(mm)
b(mm)
5.11
Fc(N) 225 576 18396
Pc(kW) 0.038 0.046 0.137
Pm(kW) 0.054 0.066 0.196
V(mm3/min)
4574.71
L(mm) 30 30 306
tc(min) 0.471 0.471 0.684
2.8. Phase70: This phase is the manual operation to protect the small slot groove from carburizing operation. We shall paint the slot by anti-carburizing paint because the width and the depth of the slot are quite small, their distances can be changed if we let them pass the carburizing process.
Page 36
2.9. Phase80: We will do the Heat Treatment for this part by Carburizing Process. We will heat the part to 900 930 C in the carburizing oven which has more concentration of carbon than in the part. The time required for Carburizing Process is 720 min/lot ( 1 lot contains 20 parts). Then we have to do Quenching process which required 180 min/lot and finally Tempering process which required 30 min/lot. The total time required for this phase is 930 min/lot or 46.5 min/part ( This operation will be done by the external company ). 2.10. Phase90: The part after heat treatment process could be bent and need to be straightened. This operation will solve this problem by straightening the part with sensitive press machine.
2.11. Phase100: We shall move the part to the Manual Grinding Machine which is the last operation. The part will be fixed with axial fix at the ends of shaft by Driving Point with soft jaws.
Page 37 Step1: The purpose of this step is to grind the part at the diameter 16.3 mm. to be 16 h5 mm. The tool we employ in this step is A46K5V [1], the external diameter of grinder (d) is 150 mm. and its thickness is 30 mm. In this kind of machine, the part can rotate with a constant tangential speed (Vat) and move in axial direction with constant speed (Val) while the tool will rotate with high rotation speed (n) and can move in the radius direction toward the part with constant speed (Vaf). In general, Vat is between 10 15 m/min [1] , Val is (1/4 to 1/3) * the thickness of grinder [1] and Vaf is between 0.1 - 0.2 mm. in radius direction [1]. For the Grinding Operation, the cutting speed (Vc)depends on the type of Binder material. The values of Vc are shown in Table1.12. By the way, the maximum rotation speed is limited by the capability of the machine, so we fix the maximum rotation speed at 1800 rpm.
Binder Ceramic Organic Metallic Magnesium Silicate Shellac Rubber
Cutting Speed Vc (m/s) 30 50 80 (with carbon fiber) >80 (depends of the machine) 20 30 30 30
Table2.12: Cutting speed (Vc) for grinding process [1]
Calculation of Step1: The rotation speed of the machine can be calculated by using the value Vc from table 1.12 and the diameter of tool. The formula is shown below. n = (Vc * 60000) / (pi * d) Where: n = rotation speed of grinder (rpm) Vc = cutting speed from table1.12 (m/s) d = external diameter of grinder (mm) (21)
Page 38 By the way, the maximum rotation speed of tool is fixed by the capability of machine. So we fix the maximum rotation velocity at 1800 rpm. The Cutting Force (Fc) has to be calculated in order to find the machine power in the following steps. The formula is shown below. Fc = t * k * Val * p (22) Where: k = constant depending on the type of material k = 3 for elastic material k = 5 for less or non elastic material (ex. Casting ) t = Resistant of traction stress of material (N/mm^2) Val = Speed of tool in axial direction = 0.25 * b = 0.5 mm/turn b = The thickness of tool, in this case is 2 mm. p = the cutting depth of each pas (mm) = 0.01 0.02 mm [1] The cutting power (Pc) and the machine power (Pm) will be calculated in order to choose the proper machine. The formulas are shown below[1]. Pc = (Fc * Vc) / 1000 Pm = Pc / Where: Pc = Cutting power required to cut material (kW) Pm = Machine power (kW) Vc = Cutting speed, in this case is 30 m/s = Efficiency of grinding machine = 0.7 0.8 The idea to calculate the cutting time (tc) is to multiply the number of cutting pass (Ncut) with the time required for each pass (tpass). The number of cutting pass is to divide the total cutting distance by the cutting depth of each pass. The time required for each pass depends on the rotation speed of the part. The formulas are shown below [1]. Ncut = L / p tpass = L / ( np * Val ) tc = Ncut * tpass (25) (26) (27) (23) (24)
Where: Ncut = number of cutting pass required L = total cutting length (mm), in this case is equal to 0.15 mm. p = cutting depth of each pass (mm) np = Rotation speed of part (rpm) = (Vat * 1000) / (dp * pi) dp = Diameter of part at the position that will be grinded (mm) Vat = rotation speed with a constant tangential speed (m/min) tpass = time required for each cutting pass (min) tc = total cutting time foe the process (min)
Page 39
Step2: We change the machining position to diameter 25.3 and follow the same process as Step1.
Calculation of Step2: The calculations can be done by use the same equations 21,22,23,24,25,26 and 27 in Shaft1 Phase100.
Step 1 2
d(mm) 150 150
n (rpm) 1800 1800 Fc(N) 13.5 13.5
np (rpm) 298.416 190.986
p(mm) 0.015 0.015
Vat(m/min) 15 15 L (mm) 23.5 23.9 Ncut 10 10
Val(mm/turn) 0.5 0.5 tpass(min) 0.157 0.250
Vaf(mm/turn) 0.01 0.01 tc(min) 1.575 2.503
S(mm2) 0.03 0.03
Pc(kW) 0.405 0.405
Pm (kW) 0.54 0.54
2.12. Calculation of Cycle Time for Shaft1: The Cycle Time is the total time used for machining 1 part. It includes with Machining time (tm) , Tool changing time (tch) , Phase changing time (tph) , Machine preparation time (tpre) , Time for taking out the finished part (thmp) , Time for unmachine phase (tun) : Cycle Time = tm + tch + tph + tpre + thmp + tun (48)
Machine time (tm) is the time required during the machining operation, from tool moving into the part, do the machining operation and move out from the part, then it changes the tool and repeat the operations. The estimate time for tool moving into the part is 2 s, tool moving out from the part is 3 s and the machining operations are in the previous calculations.
Page 40
Tool changing time (tch) is calculated by considering that the life time of tool (tedge) is 7200 s (2 hr) for cutting tool and 3600 s (1 hr) for drilling. We assume that the time for changing the new tool (tchtool) when its worn out is 120 s for cutting tool and 90 s for drilling. The formulas are shown below. tch = tchtool / n n = tedge / tc Where: tch = Tool changing time for each part (s/part) tchtool = Time for changing the new tool (s) n = Number of part able to be machined by 1 tool (part) tedge = Life time of tool (s) tc = Machining time for each operation (s) Phase changing time (tph) is the time required for changing phase, because we need time to change the fixing position or fixing type as well. We estimate that the Phase changing time (tph) is 120 s for each changing. Machine preparation time (tpre) is needed when we change the machine. Its for setting up the machine and the part before start the operation. W estimate that the Machine preparation time (tpre) for CNC controlled machine per batch is 3600 s and 300 s for manual machine. 1 batch of part is the part manufactured in 1 month, so it is the annual production divide by 11 months. According to the Marketing Study, the annual production is 7513 part/year. So 1 batch = 7513 / 11 = 683 parts/batch. In reality, we have to setup the machine only 1 time per 1 batch of parts, so the Machine preparation time (tpre) per 1 part is 3600 / 683 = 5.27 s/part ( for CNC Machine) and 300 / 683 = 0.439 s/part. Time for taking out the finished part (thmp) is required when the worker stop the machine and take the finished part out. We estimate that we required 15 s for thmp. Time for un-machine phase (tun) is for the phase that we dont employ any machine, for example phase 70, 80, 90 of shaft1. We define the Time for un-machine phase (tun) by considering the theory and the reality of each task. The results of the calculation of cycle time are shown in table2.14. (49) (50)
Page 41
tm (s) 80.27 2 37.56 3 2 10.02 3 57.58 2 37.56 3 2 10.02 3 57.58 2 105.6 3 2 215 3 2 1.225 3 2 4.061 3 2 0.18 3 351.1 2 120.1 3 125.1 2 28.27 3 2 28.27 3 2 41.02 3 112.6 tch (s) tph (s) tpre (s) 0.439 95.707 5.271 thmp (s) 15 tun (s)
Phase 10 20
30
40
50
60
Step Task 1 Cut the part Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Point drilling Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Point drilling Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Rough machining Tool move out from the part 2 Tool moves into part Finish surface machining Tool move out from the part 3 Tool moves into part Curve groove machining Tool move out from the part 4 Tool moves into part External groove width 7 mm. Tool move out from the part 5 Tool moves into part External groove width 1.3 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Groove section C-C Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill 3 holes dia. 5 mm. Tool move out from the part 2 Tool moves into part Drill 3 holes dia. 8 H7 mm. Tool move out from the part 3 Tool moves into part Groove section A-A Tool move out from the part Total Time (s)
0.628
0.25 0.878
0 120
5.2709 78.729
15 15
0.628
0.25 0.878
120 0 193.458 120
15 15
1.761
3.583
0.02
0.068
0.003 5.435
120 0 491.515 5.271
15 15
2.002 2.002
5.271 147.393 120
15 15
0.707
0.707
1.414
120
15 15
Page 42
Cycle Time (s) 1 Anti-carburizing paint. 1 Carburizing and quenching 1 Straightening of the shaft 1 Grinding of Dia 16 h5 2 Grinding of Dia 25 k6 Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s) 248.979 60 2790 90 94.5 150.2 244.7 1029 0.439 0 10.61 0.439 260.106 360 11.42 4455.888 0 15 15 105 0 2940
70 80 90 100
Table2.14: Cycle Time for Shaft1
Rough Machining Carbon Steel 12 10 8 20 12 40 HSS 25 20 15 30 18 60-200 Tungsten Carbide 200 150 100 300 200 75-300
Finish Machining Carbon Steel 20 15 12 32 20 100 HSS 30 25 20 40 25 100-700 Tungsten Carbide 300 180 130 400 300 200-2000
Steel
400 N/mm^2 600 N/mm^2 800 N/mm^2 Brass Bronze Aluminum
Table2.15: Proper Cutting Speed [1]
Page 43
3. Manufacturing Process of Shaft 2

3.1. The raw material: In order to machine this part, we use cylindrical bar steel 16 Mn Cr 5 with diameter 58 mm because we have to add 1.5 mm. to the final shape ( Maximum diameter of part is 55 mm.) in radial direction to be machined in Finishing Operation.
3.2. Phase 10: The cylindrical bars usually come with the long length shape. To be suitable for the Lathe Machine, the bars have to be cut by Manual Saw Machine. The total distance of the final shape is 137.5 mm., we have to add 1.5 mm. for the both end of bar to be machine in Finishing Operation. So we have to cut the bar to have the length 140.5 mm. with the tolerance +1,-0 mm. The calculation of this phase can be done in the same way as Shaft1 ( by using the method of milling machine ) and the results are shown in table3.1.
Step 1
d(mm) 210
n(rpm) 60.63
av(mm/turn) 0.9
Vam(mm/min) 54.567
p(mm) 58
b(mm) 2
Fc(N) 208800
Pc(kW) 0.19
Pm(kW) 0.253
L(mm) 58
tc(min) 1.063
3.3. Phase 20: This process employ CNC Lathe Machine by fix the part with fixing plate with hard jaws. The part will be fixed at one end and will be machined at another end. Step1: We start machining the part by taking out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Page 44
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (58 + 0) / 2 = 29 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7. Step2: This operation is to drill a hole for fixing with tail stock. The drilling tool has a special shape with angle 60 degree. In this case we use drill Garant 111050A with edge diameter 2 mm.
Calculation of Step2: The calculation in this step is exactly the same as the one of Shaft1 Phase20 Step1. We can calculate by utilizing the equations 6,7,8,9,10 and 11. Step3: This step is to drill a hole diameter 6.8 mm. deep 23 mm. in order to tap thread M8 x 1.25 in the next step. We choose the drilling tool Garant drill 113260 diameter 6.8 mm. maximum cutting length 34 mm. (more than 23 mm.) and total length 74 mm. The material of drill is suitable for steel with t = 600 N/mm2 Calculation of Step3: The calculation in this step can be done by using equations 6,7,8,9,10 and 11. The diameter of drill is 6.8 mm. and the cutting velocity is 25 m/min.
Page 45
Step4: In this step, we shall make an internal thread M8 x 1.25 by tapping. The suitable cutting speed (Vc) for internal tapping is 8 m/min and the advance speed (a) equal to pitch (1.25 in this case). The tool employed in this step is Garant Tap 130180 M8 x 1.25 which is suitable for Steel 16Mn Cr5.
Calculation 0f Step4: The rotation speed can be found by using equation 1. The advance speed is fix at pitch mm/turn. With these data, we can find the total cutting time (tc) by the following equation. Va = n * a tc = L / Va Where: L = total cutting length (mm) or depth of internal thread Va = advance speed of tool (mm/min) a = advance speed of tool (mm/turn) n = rotation speed of tool (rpm) (28) (29)
Page 46
Step 1 2 3 4 rp(mm) 0.031 d(mm) 29 6 6.8 8 n (rpm) 1646 1061 936.2 318.3 p(mm) 1.5 Ra(mm) 1.6 a(mm/turn) 0.045 0.06 0.068 1.25 Va(mm/min) 73.335 63.662 63.662 397.887 S(mm2) 0.067
Step 1 2 3 4
Fc(N) 120 324 416
Pc(kW) 0.301 0.027 0.035
Pm (kW) 0.401 0.036 0.046
L (mm) 29 10.6 23 21
tc(min) 0.395 0.167 0.361 0.053
3.4. Phase30: This Phase is almost the same process as in Shaft1 Phase20. We only change the machining surface to the another end of the raw part and following the operation in Step1 and Step 2 of Phase20 of Shaft1.
Page 47
Step 1 2 rp(mm) 0.031 d(mm) 29 6 n (rpm) 1646 1061 p(mm) 1.5 Ra(mm) 1.6 a(mm/turn) 0.045 0.06 Va(mm/min) 73.335 63.662 S(mm2) 0.067
Step 1 2
Fc(N) 120 324
Pc(kW) 0.301 0.027
Pm (kW) 0.401 0.036
L (mm) 29 10.6
tc(min) 0.395 0.167
3.5. Phase40: This process employ CNC Lathe Machine by fix the part with fixing plate with hard jaws at one end. The part will be fixed by pressing tail stock at the 2 ends. It will be driven by the jaws at one end. The advantage of this fixing system is that we can machine the profile of the part in only one phase (without changing of fixing position)
Step1: This step is to do rough machining. We will machine the part to be similar to the final profile but adding 1.5 mm. in radius and axial direction for finishing operation. The tool we employ is Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B, the same tool as Phase20 Step1.
Calculation of Step1: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 of Shaft1 but we use the cutting speed (Vc) for rough machining (see table1.2). The advance speed for rough machining is 0.5-0.8 mm/turn [1], so its not necessary to define the surface roughness (Ra). The only different in this step is the way to calculate L.
Page 48 This step is the rough machining by utilizing CNC Lathe machine and fix cycle. We use the cutting depth of each pass (p) 3 mm. By considering the manner of fix cycle path, we can calculate the total cutting length (L) by the equation below. L = (3 * 84) + (2 * 41.5) + (2 * 27) + (3 * 45) + (1 * 30) = 554 Step2: This step is to machine finishing surface. The part will have almost the same shape as the final part after this step. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, both right and left hand.
Calculation of Step2: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). According to the drawing, the sign of rugosity class is N7 which is equal to the average roughness Ra = 1.6 m. (see table1.1) and the edge radius of this tool (rp) is 0.031 mm. With these 2 values, we can find the advance velocity. In this step, we leave the material 0.15 mm. in radius direction at diameter 25 h5 mm. and 40 k6 mm. because they require high precision and need to be done by Grinding process. The cutting length in this step can be done in the similar way as rough machining. But in this process, we machine only 1 pass with cutting depth (p) 1.5 mm. Step3: This step is to make a shape groove width 2.25 at the shaft surface. We use the grooving tool from Stellram, the tool insert is G217018500 and the tool holder is GR360121202 [2]. The width of this tool is 1.99 mm. while the width of groove is 2.25 mm. , so its necessary to do the operation 2 times. The total cutting length will be L = 2 * (0.715) = 1.43 mm.
Page 49 In this process, its not necessary to define the average roughness (Ra). So we can choose the advance speed (a) equal to 0.1 mm., its the suitable value for the finishing surface [1].
Calculation of Step3: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7 and use Vc for finishing surface with carbide tool (see table1.2). Step4: The objective of this step is to make external thread M35 x 1.5 by turning operation. The tool we employ in this step is 11ER1.5ISO for insert part and ERNM1010H11 for holder part. This process will be done by CNC Milling Machine with fix cycle for thread. Refer to Computer Assisted Manufacturing , Joan Vivancos Calvet , the depth of thread M35 x 1.5 (pt) is 1.54 mm. and the number of pass for rough machining (np) is 6 passes. We shall leave the layer of material for finishing (pf) 0.2 mm. These 3 values will be used in the following calculation part. In this process, its not necessary to define the average roughness (Ra). So we can choose the advance speed (a) equal to 1.5 mm/turn with rotation speed 200 rpm which are suitable for this operation [1]. This operation has 6 times of rough machining and 1 time for finishing. So the total cutting length is L = 7 * 12.25 = 85.75 mm.
Page 50
Calculation of Step4: First of all, we have to find the cutting depth of each pass. The equation is shown below. p = (pt pf) / np Where: p = cutting depth of each pass (mm) pt = the depth of thread (mm) pf = layer of material left for finishing (mm) np = number of pass for rough machining The cutting force (Fc), cutting power (Pc), machine power (Pm), advance velocity (Va) and cutting time (tc) can be calculated by equations 3,4,5,6 and 7.
Step 1 2 3 4 rp(mm) 0.031 0.031 d(mm) 41.833 38.933 34.285 35 Pc(kW) 6.75 0.361 1.075 1.806 n (rpm) 1141 1472 1671 200 Pm (kW) 9 0.481 1.433 2.408 p(mm) 3 1.5 1.99 0.223 Ra(mm) 1.6 a(mm/turn) 0.5 0.045 0.1 1.5 tc(min) 0.971 2.471 0.009 0.286 S(mm2) 1.5 0.067 0.199 0.335
(30)
Step 1 2 3 4
L (mm) 554 162 1.43 85.75
Va(mm/min) 570.675 65.55 167.116 300
3.6. Phase50: This phase we move the part to CNC Milling Machine. The part will be fixed by Index Plate with soft jaws which is suitable for cylindrical part and its possible to rotate the part.
Page 51 Step1: This step is to make external grooves of section C-C. The grooves have gear shape which need a special tool to machine. The tool we use in this process should has the shape according to DIN 5462.
Calculation of Step1: In this step, we choose the number of tools teeth equal to 22 teeth, diameter primitive (dp) is 34 mm and the number of gears teeth is 8. All the calculation process can use the same formula as Shaft1 Phase50, equations 12, 13,14,15,16,17,18,19 and 20.
Step 1
Zp 8
Dp 34
m 4.25
Nm 4
Size 1.06
d(mm) 50
n(rpm) 954.9
av(mm/turn) 0.22
Vam(mm/min) 210.085
Step 1
p(mm) 2
b(mm) 7.25
Fc(N) 26100
Pc(kW) 0.091
Pm(kW) 0.131
V(mm3/min) 3046.226
L(mm) 240
tc(min) 1.142
3.7. Phase60: We still use the CNC milling Machine in this phase and the part will be fixed by the Index plate with soft jaws. Step1: The purpose of this process is to make external grooves of section B-B. The grooves have gear shape which need a special tool to machine. The tool we use in this process should have the shape according to DIN 5480.
Page 52
Calculation of Step1: In this step, we choose the number of tools teeth equal to 25 teeth, diameter primitive (dp) is 40 mm and the number of gears teeth is 20. All the calculation process can use the same formula as Shaft1 Phase50, equations 12,13,14,15,16,17,18, 19 and 20. We choose cutting depth of each pass p = 2 mm. and the width of tool b = (8+6.5)/2 = 7.25 mm. (the average of tool profile).
Step2: The purpose of this process is to make external grooves of section A-A. The tool for this process is Garant Milling 191080 , diameter 3 mm. , cutting length
Calculation of Step2: The calculations of this step will start with tool rotation speed. We can use equation 14 of shaft 1 with tool diameter 3 mm. Because of very small diameter, the rotation speed from calculation is too high and it could damage the machine. We have to set the maximum rotation speed of tool to prevent this problem. In this case, we set at 5500 rpm. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20. In this operation, the cutting depth (p) is 2.5 mm, the cutting width (b) is 3 mm. ( equal to the tool diameter) and the cutting length (L) is 18.98 mm.
Page 53
Step 1 2
Zp 20
Dp 40
m 2
Nm 4
Size 0.5
d(mm) 40 3
Tool Data az(mm.) Zt(teeth) 0.015 25 0.025 2
n(rpm) 1194 5500
av(mm/turn) 0.375 0.05
Vam(mm/min) 447.623 275
Step 1 2
p(mm) 2 2.5
b(mm) 3.3 3
Fc(N) 11880 13500
Pc(kW) 0.089 0.062
Pm(kW) 0.127 0.088
V(mm3/min) 2954.314 2062.5
L(mm) 670 18.98
tc(min) 1.497 0.069
3.8. Phase70: This phase is the manual operation to protect the external and internal thread from carburizing operation. We shall paint the external thread by anti-carburizing paint and fill the hole of internal thread with bolt M8 x 1.25.
Page 54
3.9. Phase80: We will do the Heat Treatment for this part by Carburizing Process. We will heat the part to 900 930 C in the carburizing oven which has more concentration of carbon than in the part. The time required for Carburizing Process is 720 min/lot ( 1 lot contains 20 parts). Then we have to do Quenching process which required 180 min/lot and finally Tempering process which required 30 min/lot. The total time required for this phase is 930 min/lot or 46.5 min/part ( This operation will be done by the external company) . 3.10. Phase90: The part after heat treatment process could be bent and need to be straightened. This operation will solve this problem by straightening the part with press machine.
3.11. Phase100: We shall move the part to the Manual Grinding Machine which is the last operation. The part will be fixed with axial fix at the ends of shaft with Driving Point. Step1: The purpose of this step is to grind the part at the diameter 25.3 mm. to be 25 h5 mm. The tool we employ in this step is A46K5V [1], the external diameter of grinder (d) is 150 mm. and its thickness is 30 mm. In this kind of machine, the part can rotate with a constant tangential speed (Vat) and move in axial direction with constant speed (Val) while the tool will rotate with high rotation speed (n) and can move in the radius direction toward the part with constant speed (Vaf). In general, Vat is between 10 15 m/min [1] , Val is (1/4 to 1/3) * the thickness of grinder [1] and Vaf is between 0.1 - 0.2 mm. in radius direction [1]. For the Grinding Operation, the cutting speed (Vc)depends on the type of Binder material. The values of Vc are shown in Table1.12. By the way, the maximum
Page 55 rotation speed is limited by the capability of the machine, so we fix the maximum rotation speed at 1800 rpm.
Calculation of Step1: The calculations can be done by use the same equations 21,22,23,24,25,26 and 27 in Shaft1 Phase100. We only change the diameter of the part according to shaft2.
Step2: We change the machining position to diameter 40.3 and follow the same process as Step1.
Calculation of Step2: The calculations can be done by use the same equations 21,22,23,24,25,26 and 27 in Shaft1 Phase100. We only change the diameter of the part according to shaft2.
Page 56
Step 1 2 d(mm) 150 150 n (rpm) 1800 1800 Fc(N) 13.5 13.5 np (rpm) 191 119.4 Pc(kW) 0.405 0.405 p(mm) 0.015 0.015 Vat(m/min) 15 15 L (mm) 27 15 Val(mm/turn) 0.5 0.5 tpass(min) 0.283 0.251 Vaf(mm/turn) 0.01 0.01 tc(min) 2.827 2.513 S(mm2) 0.03 0.03
Pm (kW) 0.54 0.54
Ncut 10 10
3.12. Calculation of Cycle Time for Shaft2:
Phase 10 20
30
40
Step Task 1 Cut the part Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Point drilling Tool move out from the part 3 Tool moves into part Drill a hole dia. 6.8 mm. Tool move out from the part 4 Tool moves into part Tap M8 x 1.25 Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Point drilling Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Rough machining Tool move out from the part 2 Tool moves into part Finish surface machining Tool move out from the part 3 Tool moves into part Grooving width Tool move out from the part 4 Tool moves into part Tap M35 x 1.5 Tool move out from the part Total Time (s)
tm (s) 63.77 2 37.56 3 2 10.02 3 2 21.68 3 2 3.167 3 92.42 2 23.73 3 2 10.02 3 43.75 2 58.25 3 2 148.3 3 2 0.513 3 2 17.15 3 244.2
tch (s)
tph (s)
tpre (s) 0.439 79.213 5.271
thmp (s) 15
tun (s)
0.628
0.25
15
0.542
15
0.079 1.499
5.271 144.194 120
15 45
0.396
0.251 0.646
120 0 179.393 120
15 15
0.971
2.471
0.05
0.429 3.921
120
15 15
Page 57
Cycle Time (s) 1 Tool moves into part Groove section C-C Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Grooving section B-B Tool move out from the part 2 Tool moves into part Grooving section A-A Tool move out from the part Total Time (s) Cycle Time (s) 1 Anti-carburizing paint. 1 Carburizing and quenching 1 Straightening of the shaft 1 Grinding of Dia 16 h5 2 Grinding of Dia 25 k6 Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s) 383.115 5.271 1.142 1.142 15 15
50
2 68.52 3 73.52 2 89.81 3 2 4.141 3 103.9
60
5.271 94.933 120
2.245
0.104 2.349
120 0 241.297
15 15
0 120 2790 90
70 80 90 100
169.6 150.8 320.4 942
0.439 0 9.557 0.439 335.882 360 11.42 4458.027 0 15 15 135 0 3000
Table3.8: Cycle Time for Shaft2
Page 58
4. Manufacturing Process of Casing

4.1. The raw material: The raw part of this process is UNE 38212L-212 (Aluminum casting) from casting. The casting part has the shape similar to the final shape. The shape of raw part from casting is not exactly same as the final shape because there are several limitations for casting. It need to be machined in the following steps. We use the raw part from casting process because the shape of casing is too difficult to be machined and it will have high cost. 4.2. Phase20: We fix the raw part horizontally with fixing clamp of CNC Milling Machine. Our machine is vertical milling machine, so the tool is rotating while the part can move in 3 axis. Step1: The purpose of this step is to make flat machining at the joining surface with the cutting depth 1.5 mm. We use milling tool Garant 181000 diameter 30 mm and thickness 30 mm. We choose tools diameter 30 mm. because the tools diameter has to cover the maximum thickness of the joining surface which is 15.25 mm.
Page 59 Calculation of Step1: Because the part is casting aluminum and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 181000 has external diameter 30 mm. and number of teeth is 6. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 1.5 mm, the cutting width (b) is 15.25 mm. ( equal to the thickness of part because its less than the diameter of tool ). The cutting length (L) is the summation of the contour of the joining surface which is L = 848 mm.
Step2: In this step, we will drill 14 holes of diameter 5 mm and deep 25 mm. These holes are for preparing to tap M6 in the following step. We use the drilling tool Garant 113260 diameter 5 mm.
Calculation of Step2: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 5 mm. and the cutting velocity is 25 m/min. because the material of part is Aluminum casting. The depth of each hole is 25 mm. so the total cutting length (L) is 350 mm.
Step3: In this step, we shall make an internal thread M6 x 1 by tapping and deep 18 mm. for 14 holes. The suitable cutting speed (Vc) for internal tapping is 8 m/min and the advance speed (a) equal to pitch (1 in this case).The tool employed in this step is Tap Garant 131130 M 6 x 1.
Page 60
Calculation of Step3: The calculation in this process can be done by using the equation 28 and 29 of Shaft2. Step4: We will drill 2 holes in this step. The holes are 6 mm. diameter (+0.25, +0.1 tolerance) and deep 15 mm. We use drilling tool Garant 113260 diameter 6 mm.
Calculation of Step4: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 6 mm. and the cutting velocity is 80 m/min. because
Page 61 the material of part is Aluminum casting. The depth of each hole is 15 mm. so the total cutting length (L) is 30 mm. Step5: In this step, we will mill flat surface (1mm. depth) and increase the diameter of the 3 holes to be 32 H7 mm. We use milling tool Garant 191200 diameter 10 mm. , number of teeth 3 and cutting length 22 mm. We choose this tool because the tools diameter has to cover the maximum thickness of the 3 holes which is 5 mm. and the cutting length has to be longer than maximum depth of holes which are 20 mm.
Calculation of Step5: Because the part is casting aluminum and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 191200 has external diameter 10 mm. and number of teeth is 3. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 0.5 mm, the cutting width (b) is 20 mm. ( we use the depth of hole because its the maximum cutting width of this step ). The cutting length (L) is the summation of the movement of tool which is L = 697.43 mm.
Page 62
Step 1 2 3 4 5
d(mm) 30 5 6 6 10
0.025
n(rpm) 1592 4074 424.4 3395 4775
av(mm/turn) 0.15 0.05 1 0.06 0.075
Vam(mm/min) 238.732 203.718 424.413 203.718 358.099
p(mm) 1.5
b(mm) 15.25
0.5
20
Step 1 2 3 4 5
Fc(N) 28594 156.3 225 12500
Pc(kW) 0.1138 0.1563 0.225 0.0746
Pm(kW) 0.1625 0.2232 0.3214 0.1066
V(mm3/min) 5461.004
3580.986
L(mm) 848 350 252 30 697.43
tc(min) 3.552 1.718 0.594 0.147 1.948
4.3. Phase30: In this Phase, we will machine at the other side of part, so we have to turn the part up side down and fix the raw part horizontally with fixing clamp of CNC Milling Machine. Step1: In this step, we will make flat surface 1.5 mm. depth around and above the external diameter 83 mm. We use milling tool Garant 191200 diameter 10 mm. , number of teeth 3 and cutting length 22 mm. In this step, its possible to use another tool because the part surface to be machined is quite big. But we choose this tool because we already use it in the previous step, this let us reduce time to change tool and for the tool cost as well.
Page 63
Calculation of Step1: We could follow the calculation process in Phase20 Step5 because almost every condition is similar. We choose the cutting depth (p) 1.5 mm and the cutting width (b) is 10 mm. (b equal to the tools diameter because the minimum width of part 24.5 mm. is more than the width of tool 10 mm.). The cutting length in this step is the summation of the movement of tool. We use the true scale drawing to define the tools movement ( See Figure3.1). We found the cutting length (L) is : (pi * 93) + (pi * 113) + (pi * 133) + (4 * (21+10)) + (pi * 76) = 1427.8 mm.
Figure4.7: Drawing for tools movement path calculation
Step2: In this step, we will do fine machining at the same hole to get internal diameter 70 H11 mm. and external diameter 80 g6 mm. We use milling tool Garant 191200 diameter 10 mm. , number of teeth 3 and cutting length 22 mm. the same tool as in step1 to avoid tool changing.
Page 64 Calculation of Step2: We could follow the calculation process in Phase20 Step5 because almost every condition is similar. We choose the cutting depth (p) 1.5 mm and the cutting width (b) is 7.5 mm. The cutting length in this case is the summation of tools movement. Tool moves in circular shape with diameter 60 and 90 mm. (we consider at the center of tool) so the cutting length is 471.24 mm. Step3: We will Drill 4 holes diameter 14 mm. through the part in this step. We choose drilling tool Garant 113260 diameter 14 mm. , cutting length 54 mm.
Calculation of Step3: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 14 mm. and the cutting velocity is 80 m/min. because the material of part is Aluminum casting. The depth of each hole is 12.5 mm. so the total cutting length (L) is 50 mm.
Step 1 2 3
d(mm) 10 10 14
n(rpm) 4775 4775 1455
av(mm/turn) 0.075 0.075 0.14
Vam(mm/min) 358.099 358.099 203.718
p(mm) 1.5 1.5
b(mm) 10 7.5
Step 1 2 3
Fc(N) 2625 1969 171.5
Pc(kW) 0.016 0.012 0.172
Pm(kW) 0.022 0.017 0.245
V(mm3/min) 5371.479 4028.609
L(mm) 1427.8 471.24 50
tc(min) 3.987 1.316 0.245
Page 65 4.4. Phase40: In this phase, we fix the raw part vertically with fixing clamp of CNC Milling Machine which can rotate 90 degree. Step1: We will drill a hole diameter 13 mm. trough the part in this step. We choose drilling tool Garant 113260 diameter 13 mm. , cutting length 51 mm.
Calculation of Step1: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 13 mm. and the cutting velocity is 80 m/min. because the material of part is Aluminum casting. The cutting length (L) equal to the depth of hole, its 39.12 mm. Step2: In this step, we will drill at the same hole with diameter 14 H7 mm. deep 12 mm. We choose drilling tool Garant 113260 diameter 14 mm. , cutting length 54 mm.
Page 66
Calculation of Step2: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 14 mm. and the cutting velocity is 80 m/min. because the material of part is Aluminum casting. The cutting length is 12 mm. Step3: We will do back boring to have diameter 22 mm. in this step. We choose tool from Sandvik, the insert is CoroCut T-Max 4G and the tool holder is Q-Cut 151.3 . The operation in this step is quite complicate and its possible to be done since casting process if we increase diameter 22 mm. to be higher and avoid sharp edge.
Page 67
Calculation of Step3: In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. Step4: We turn the part 90 degree and drill a hole diameter 8.5 mm. through the part. We choose drilling tool Garant 113260 diameter 8.5 mm.
Calculation of Step4: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 8.5 mm. and the cutting velocity is 80 m/min. because the material of part is Aluminum casting. The cutting length is 5 mm. Step5: In this step, we will Tap M10 x 1.5 through the hole we drilled in the previous step. We use the tool Tap M10x1.5 Garant 131130. The suitable cutting speed (Vc) for internal tapping is 8 m/min and the advance speed (a) equal to pitch (1.5 in this case)
Page 68 Calculation of Step5: The calculation in this process can be done by using the equation 28 and 29 of Shaft2.
Step 1 2 3
d(mm) 13 14 12
0.025
n(rpm) 1567 1455 3979
av(mm/turn) 0.13 0.14 0.075
Vam(mm/min) 203.718 203.718 298.416
p(mm)
b(mm)
4.5
Step 1 2 3
Fc(N) 147.9 171.5 2363
Pc(kW) 0.148 0.172 0.012
Pm(kW) 0.211 0.245 0.017
V(mm3/min)
4028.609
L(mm) 39.118 12 28.274
tc(min) 0.192 0.059 0.095
Page 69 4.5. Calculation of Cycle Time for Casing:

Phase 20 Step 1 Task Tool moves into part Mill flat surface Tool move out from the part 2 Tool moves into part Drill 14 holes dia. 5 mm. Tool move out from the part 3 Tool moves into part Tap M6 deep 18 mm. 14 holes Tool move out from the part 4 Tool moves into part Drill 2 holes dia. 6 mm. Tool move out from the part 5 Tool moves into part Fine machining of 3 holes Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Mill flat surface Fine machining at hole 70 2 mm. Tool move out from the part 3 Tool moves into part Drill 4 holes dia. 14 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill a hole dia. 13 mm. Tool move out from the part 2 Tool moves into part Drill dia.14 H7 mm deep 12 mm Tool move out from the part 3 Tool moves into part Back boring dia. 22 mm. Tool move out from the part 4 Tool moves into part Drill a hole dia. 8.5 mm. Tool move out from the part 5 Tool moves into part Tap M10 x 1.5 Tool move out from the part Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s) tm (s) 2 213.1 3 2 103.1 3 2 35.63 3 2 8.836 3 2 1.948 3 387.6 2 239.2 78.96 3 2 14.73 3 342.9 2 11.52 3 2 3.534 3 2 5.685 3 2 1.473 3 2 3.77 3 50.98 781.5 tch (s) tph (s) tpre (s) 5.271 thmp (s) tun (s)
3.552
2.577
0.891
0.221
0.032 7.273
30
5.271 415.162 120
15 15
3.987
1.316
0.368 5.671
40
120 0 483.578 120
15 15
0.288
0.088
0.095
0.037
0.094 0.602 13.55
120 0 186.585 240 5.271 1085.325
15 15 45
0 0
Table4.4: Cycle Time for casing
Page 70
5. Manufacturing Process of Sliding part

5.1. The raw material: In order to machine this part, we use the rectangular block of Bronze UNE C3112 and it will be cut to the proper dimension in Phase10. Its also possible to manufacture this part by Sintering Process instead of machining. Sintering is easier in this case but to employ it, we have to invest more machine for manufacture only 1 type of part. So we decide to do by machining. 5.2. Phase 10: The raw rectangular block of UNE C-3112 will be place at the Manual Saw Machine. It will be cut to have the dimension 19.5 x 23 x 32.5 mm. The calculation of this phase can be done in the same way as Shaft1 ( by using the method of milling machine ) and the results are shown in table5.1.
Step 1
d(mm) 210
n(rpm) 60.63
av(mm/turn) 0.9
Vam(mm/min) 54.567
p(mm) 32.5
b(mm) 2
Fc(N) 81250
Pc(kW) 0.074
Pm(kW) 0.099
L(mm) 62
tc(min) 1.136
Table5.1: Calculation Data of Phase10
Page 71 5.3. Phase20: We will use CNC Milling Machine in this phase. We fix the part at both sides horizontally with fixing clamp. Step1: In the first step, we will make flat surface with 1.5 mm. depth. We use milling tool Garant 181000 diameter 30 and long 30 mm. We choose tools diameter 30 mm. because the tools diameter has to cover the maximum thickness of the part which is 19.5 mm.
Calculation of Step1: Because the part is bronze and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 181000 has external diameter 30 mm. and number of teeth is 6. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 1.5 mm for each cutting pass, the cutting width (b) is 19.5 mm. We can define the advance of teeth from table1.9. The suitable advance of teeth az = 0.005-0.025 mm.
Page 72 Step2: This step is the finishing operation (pocket operation). The part will have the same geometry as the final shape. We employ milling tool Garant 191200 , diameter 5 mm , cutting length 13 mm , number of teeth is 3. The diameter of milling tool must be not too big in order to have high precision.
Calculation of Step2: Because the part is bronze and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 191200 has external diameter 5 mm. and number of teeth is 3. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18 and 19 of Shaft1. In this operation, the cutting depth (p) is 3 mm for each cutting pass, the cutting width (b) is 5 mm. This process is quite difficult to define the cutting length (L). In order to calculate the cutting time, we propose to calculate by the following equation. tc = Vc / V Where: tc = total cutting time (min) Vc = Material volume to be cut (mm3) V = Volume cutting speed (mm3/min) The equation 31 base on the assumption that the movement of part is the shortest path. This assumption is possible in reality because we use Numerical control machine. (31)
Page 73
Step 1 2
d(mm) 30 5
n(rpm) 848.8 5093
av(mm/turn) 0.15 0.075
Vam(mm/min) 127.324 381.972
p(mm) 1.5 3
b(mm) 19.5 5
Step 1 2
Fc(N) 36563 18750
Pc(kW) 0.078 0.119
Pm(kW) 0.111 0.171
V(mm^3/min) 3724.226 5729.578
Vc(mm3) 6240.493
L(mm) 32.5
tc(min) 0.255 1.089
5.4. Phase30: Now we change the machining surface to another face and fix the part at both sides horizontally with clamp.
Step1: This step is the finishing operation (pocket operation) of the other side of part. The part will have the same geometry as the final shape. We employ milling tool Garant 191200 , diameter 5 mm , cutting length 13 mm , number of teeth is 3. The diameter of milling tool must be not too big in order to have high precision.
Calculation of Step1: Because the part is bronze and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 191200 has external diameter 5 mm. and number of teeth is 3. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 31 of Shaft1. In this
Page 74 operation, the cutting depth (p) is 3 mm for each cutting pass, the cutting width (b) is 5 mm.
Step 1
d(mm) 5
Tool Data az(mm.) 0.025
Zt(teeth) 3
n(rpm) 5093
av(mm/turn) 0.075
Vam(mm/min) 381.972
p(mm) 3
b(mm) 5
Step 1
Fc(N) 18750
Pc(kW) 0.119
Pm(kW) 0.171
V(mm3/min) 5729.578
Vc(mm3) 2242.5
tc(min) 0.391
5.5. Calculation of Cycle Time for Sliding part:
Phase 10 20
30
Step Task 1 Cut raw part by Saw Machine Cycle Time (s) 1 Tool moves into part Mill flat surface Tool move out from the part 2 Tool moves into part Finish machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Finish machining Tool move out from the part Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s)
tm (s) 68.16 2 15.32 3 2 65.35 3 90.67 2 23.46 3 28.46 187.3
tch (s)
tpre (s) 0.439 83.599 120 5.271
tph (s)
thmp (s) 15
tun (s)
0.255
1.089 1.344
120 5.271 232.281 120
15 15
0.391 0.391 1.735
120 0 163.851 240 5.710 479.731
15 15 45
0 0
Table5.4: Cycle Time for Sliding part
Page 75
6. Manufacturing Process of Clutch Fork

6.1. The raw material: The raw material for Clutch Fork is from forging process. The dimension is similar to the final shape. We decide to get raw material from forging because this kind of shape is not suitable to be machined from steel block, we will loose too much material. Its possible to use casting process, but the part will have low flexion resistance which is the important mechanical property of the part.
6.2. Phase20: We fix the raw part horizontally with fixing clamp of CNC Milling Machine. Step1: In this step, we will take out some material at the clutch legs 2 positions with 0.43 mm. depth and 15 mm. length. We use milling tool Garant 191080 diameter 10 mm. , cutting length 22 mm. and number of teeth is 2. The cutting length of the tool (22 mm.) must longer than the length of clutch legs (15 mm.) because would like to machine only 1 pass.
Calculation of Step1: Because the part is Alloy Steel and the milling tool is tungsten carbide, so the cutting velocity should be from 150 m/min [1]. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 0.43 mm, the cutting width (b) is 15 mm. The cutting length (L) is 30 mm.
Page 76 We can define the advance of teeth from table1.9. The material we have to machine is Steel 600-700 N/mm2, so the suitable Advance of teeth az = 0.005-0.015 mm. Step2: In this step, we will drill a hole diameter 3.3 mm. and deep 4.5 mm. (+1, -0 mm. tolerance). This hole is to prepare for the next tapping process. We use the drill Garant 113260 diameter 3.3 mm.
Calculation of Step2: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 3.3 mm. and the cutting velocity is 20 m/min. because the material of part is Alloy Steel. The total cutting length (L) is 4.5 mm. Step3: In this step, we will tap M4 x 0.7 , deep 4 mm. (+1, -0 mm. tolerance) at the hole in Step2. We use tap Garant 131130 M4 x 0.7 , total length 63 mm. The suitable cutting speed (Vc) for internal tapping is 8 m/min and the advance speed (a) equal to pitch (0.7 in this case)
Page 77 Calculation of Step3: The calculation in this process can be done by using the equation 28 and 29 of Shaft2. The rotation speed can be found by using equation 1 and the advance speed is fix at pitch mm/turn.
Step 1 2 3
d(mm) 10 3.3 4
n(rpm) 4775 1543 636.6
av(mm/turn) 0.03 0.033 0.7
Vam(mm/min) 143.239 50.93 445.634
p(mm) 0.43
b(mm) 15
Step 1 2 3
Fc(N) 19350 163.4
Pc(kW) 0.046 0.163
Pm(kW) 0.066 0.233
V(mm3/min) 923.894
L(mm) 30 4.5 4
tc(min) 0.209 0.088 0.009
6.3. Phase30: The Clutch Forks shape is quite difficult to be fixed vertically. We have to design special shape fixing plate for it. We fix the raw part with the special shape fixing plate, then fix them vertically with the fixing clamp of CNC Milling Machine. Step1: In this step, we will drill 2 holes, diameter 8 H11 mm. and diameter 8 H8 mm through the part. We use the drill Garant 113260 diameter 8 mm.
Page 78 Calculation of Step1: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 8 mm. and the cutting velocity is 20 m/min. because the material of part is Alloy Steel. The total cutting length (L) is the summation of the depth of the 2 holes, so L is 15 mm.
Step 1
d(mm) 8
n(rpm) 636.6
av(mm/turn) 0.08
Vam(mm/min) 50.93
p(mm)
b(mm)
Step 1
Fc(N) 960
Pc(kW) 0.128
Pm(kW) 0.183
V(mm3/min)
L(mm) 15
tc(min) 0.295
6.4. Phase40: In this phase, we will do at the other side of part. We turn the part 180 degree and fix the raw part with the special shape fixing plate, then fix them vertically with the fixing clamp of CNC Milling Machine. Step1: In this step, we will drill a hole diameter 8 H8 mm. through the part. We use the drill Garant 113260 diameter 8 mm.
Calculation of Step1: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 8 mm. and the cutting velocity is 20 m/min. because the material of part is Alloy Steel. The total cutting length (L) is 7.5 mm.
Page 79
Step 1
d(mm) 8
n(rpm) 636.6
av(mm/turn) 0.08
Vam(mm/min) 50.93
p(mm)
b(mm)
Step 1
Fc(N) 960
Pc(kW) 0.128
Pm(kW) 0.183
V(mm3/min)
L(mm) 7.5
tc(min) 0.147
6.5. Phase50: This phase is the heat treatment process. We will do heat treatment at the external dia 50 mm. to have the hardness 46-48 HRC ( 1mm. depth). The part will be heated by Induction heating and the time required for the process is 30 min/lot ( 1 lot contains 20 parts) or 1.5 min/part ( This operation will be done by the external company). 6.6. Calculation of Cycle Time for Clutch Fork:
Phase 20
Step 1
30
40
80
Task Tool moves into part Mill at 2 clutch legs Tool move out from the part 2 Tool moves into part Drill a hole dia. 3.3 mm. Tool move out from the part 3 Tool moves into part Tap M4 deep 4 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill 2 holes dia. 8 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill 1 hole dia. 8 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Heat treatment Total Time (s) Total Cycle Time (s)
tm (s) 2 12.57 3 2 5.301 3 2 0.539 3 33.41 2 17.7 3 22.7 2 8.82 3 13.82
tch (s)
tph (s)
tpre (s) 5.271
thmp (s)
tun (s)
0.209
0.133
0.013 0.355
5.271 54.033 120
15 15
0.443 0.443
120 0 143.143 120
0.221 0.221
120 0 149.041 240 5.271 436.216
15 15
0 90 90
69.93
1.018
30
Table6.4: Cycle Time for Clutch Fork
Page 80
7. Manufacturing Process of Pin

7.1. The raw material: Cylindrical Bar Dia 12 f6 mm. In order to machine this part, we use cylindrical bar steel 37 Cr 4 with diameter 12 f6 mm. The cylindrical bar steel diameter 12 f6 mm is existed in the market, so we dont need to use cylindrical bar steel diameter 15 mm. and do finishing operation. 7.2. Phase 10: The cylindrical bars usually come with the long length shape. To be suitable for the Lathe Machine, the bars have to be cut by Manual Disc Saw Machine. The total distance of the final shape is 85 mm., we have to add 1.5 mm. for the both end of bar to be machine in Finishing Operation. So we have to cut the bar to have the length 88 mm. with the tolerance +1, -0 mm. The calculation of this phase can be done in the same way as Shaft1 ( by using the method of milling machine ) and the results are shown in table7.1.
Step 1
d(mm) 210
n(rpm) 60.63
av(mm/turn) 0.9
Vam(mm/min) 54.567
p(mm) 12
b(mm) 2
Fc(N) 43200
Pc(kW) 0.039
Pm(kW) 0.052
L(mm) 12
tc(min) 0.22
7.3. Phase20: We employ CNC Lathe Machine in this phase. We fix the raw part at one end by fixing plate with hard jaws of CNC Lathe Machine. Step1: We start machining the part by taking out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for
Page 81 machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the shaft, in this shaft d = (12+0)/2 = 6 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. Step2: This step is to machine finishing surface to have diameter 8 h7 mm. length 7.5 mm. at the end of part. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, right hand.
Calculation of Step2: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). The rotation speed we obtain from calculation will be very high because of the diameter of bar is very small. We should limit the maximum rotation speed in order to protect machine from damage. In this process, we limit at 3000 rpm. The cutting length (L) in this step is the summation of the movement of part, we find L = 7.5 mm.
Page 82
Step 1 2 rp(mm) 0.031 0.031 Step 1 2 d(mm) 6 10 n (rpm) 3000 3000 p(mm) 1.5 2 Ra(mm) 1.6 1.6 a(mm/turn) 0.045 0.045 S(mm2) 0.067 0.089 tc(min) 0.045 0.056 Fc(N) 120 160
Pc(kW) 0.301 0.401
Pm (kW) 0.401 0.535
L (mm) 6 7.5
Va(mm/min) 133.626 133.626
7.4. Phase30: We are still at CNC Lathe Machine. We fix the raw part at another end by fixing plate with soft jaws of CNC Lathe Machine. Step1: We take out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Calculation of Step1: Its exactly the same as Phase20 step1 of this part. Step2: This step is to machine finishing surface to have diameter 10 h7 mm. length 20.5 mm. at the end of part. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, right hand.
Page 83
Calculation of Step2: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). The rotation speed we obtain from calculation will be very high because of the diameter of bar is very small. We should limit the maximum rotation speed in order to protect machine from damage. In this process, we limit at 3000 rpm. The cutting length (L) in this step is the summation of the movement of part, we find L = 20.5 mm.
S(mm2) 0.067 0.045
Step 1 2
rp(mm) 0.031 0.031
d(mm) 6 11
n (rpm) 3000 3000
p(mm) 1.5 1
Ra(mm) 1.6 1.6
a(mm/turn) 0.045 0.045
Fc(N) 120 80.2
Step 1 2
Pc(kW) 0.301 0.2
Pm (kW) 0.401 0.267
L (mm) 6 20.5
Va(mm/min) 133.626 133.626
tc(min) 0.045 0.153
7.5. Phase40: In this phase, we move to CNC Milling Machine. We fix the part by Index plate with soft jaws. Step1: In this step, we will drill a 120 degree hole at diameter 10 h7 mm. end. We use drill Garant 112110 , 120 degree , diameter 5 mm.
Page 84
Calculation of Step1: The calculation of this step can be done by follow the method and formula in Phase20 Step2 of Shaft1. We use the diameter 5 mm. and the depth 1 mm. The total cutting length equal to the depth. Step2: In this step, we will drill a 120 degree hole at diameter 8 h7 mm. end. We use drill Garant 112110 , 120 degree , diameter 5 mm.
Calculation of Step2: The calculation of this step can be done by follow the method and formula in Phase20 Step2 of Shaft1. We use the diameter 5 mm. and the depth 1 mm. The total cutting length is equal to the depth.
Step 1 2
d(mm) 5 5
n(rpm) 1273 1273
av(mm/turn) 0.05 0.05
Vam(mm/min) 63.662 63.662
p(mm)
b(mm)
Step 1 2
Fc(N) 225 225
Pc(kW) 0.038 0.038
Pm(kW) 0.054 0.054
V(mm3/min)
L(mm) 1 1
tc(min) 0.016 0.016
Page 85 7.6. Phase50: This phase is the heat treatment process. We will do heat treatment at the external dia 50 mm. to have the hardness 46-48 HRC ( 1mm. depth). The part will be heated by Induction heating and the time required for the process is 30 min/lot ( 1 lot contains 20 parts) or 1.5 min/part ( This operation will be done by the external company). . 7.7. Calculation of Cycle Time for Pin:
Phase 10 20
30
40
50
Step Task 1 Cut the part Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Finish surface machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Finish surface machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill a hole at section B-B 2 Drill a hole at section A-A Tool move out from the part Total Time (s) Cycle Time (s) 1 Heat treatment Total Time (s) Total Cycle Time (s)
tm (s) 13.19 2 2.694 3 2 3.368 3 16.06 2 2.694 3 2 9.205 3 21.9 2 0.96 0.96 3 6.92
tch (s)
tph (s)
tpre (s) 0.439 28.634 5.271
thmp (s) 15
tun (s)
0.045
0.056 0.101
0 120
5.271 36.434
15 15
0.045
0.153 0.198
120 0 157.097 5.271
15 15
0.024 0.024 0.048 15 15
5.271 27.239
0 90 90
58.08
0.347
120 10.981 339.403
60
Table7.5: Cycle Time for Pin
Page 86
8. Manufacturing Process of Sealing Plate 1-2

8.1. The raw material: The raw part of this process is UNE 38212L-212 (Aluminum casting) from casting. The casting part has the shape similar to the final shape. The part has to be machined in several steps by Milling Machine.
8.2. Phase10: We fix the raw part horizontally with fixing clamp of CNC Milling Machine. Step1: The purpose of this step is to make flat machining at the part with the cutting depth 1.5 mm. We use milling tool Garant 181000 diameter 50 mm , thickness 30 mm. and number of teeth is 6. We choose tools diameter 50 mm. which is more than half of the maximum width of part (45 mm.) in order to machine only 2 passes.
Calculation of Step1: Because the part is casting aluminum and the milling tool is tungsten carbide, so the cutting velocity should be from 75-300 m/min [1]. The milling tool Garant 181000 has external diameter 50 mm. and number of teeth is 6. In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 1.5 mm, the cutting width (b) is 45 mm. ( equal to half of maximum width of part). The cutting length (L) is the summation of 2 passes which is L = 342.5 mm. We can define the advance of teeth from table1.9. The material we have to machine is Aluminum 100 N/mm2, so the suitable Advance of teeth az = 0.0050.025 mm.
Page 87 Step2: In this process, We will do circular pocket of diameter 48 mm. deep 21.5 mm. (trough the part). We employ milling tool Garant 191200 diameter 15 mm. , cutting length 26 mm. and number of teeth is 3.
Calculation of Step2: We will calculate this process by the formula 15,16,17,18,19 of Shaft1 and equation 31 0f Sliding part. The cutting depth of each pass is 3 mm. and cutting width b equal to the diameter of tool (15 mm.). Step3: In this process, We will do circular pocket diameter 58 mm.2 positions, deep 5 mm. with radius 2 mm. on the left and deep 1.4 mm. on the right. We employ milling tool Garant 191200 diameter 15 mm. , cutting length 26 mm. and number of teeth is 3.
Page 88 Calculation of Step3: We can proceed the calculation for this step by the same manner as Step2 of this part. The cutting depth is still 3 mm. and cutting width b equal to the diameter of tool (15 mm.). Step4: In this process, We will do circular pocket diameter 75 mm. and deep 2 mm. We employ milling tool Garant 191200 diameter 15 mm. , cutting length 26 mm. and number of teeth is 3.
Calculation of Step4: We can proceed the calculation for this step by the same manner as Step2. The cutting depth is 2 mm. and cutting width b equal to the diameter of tool (15 mm.).
Step 1 2 3 4
d(mm) 50 15 15 15
Tool Data az(mm.) Zt(teeth) 0.025 6 0.025 3 0.025 3 0.025 3
n(rpm) 954.9 3183 3183 3183
av(mm/turn) 0.15 0.075 0.075 0.075
Vam(mm/min) 143.239 238.732 238.732 238.732
p(mm) 1.5 3 3 2
b(mm) 45 15 15 15
Fc(N) 84375 56250 56250 37500
Step 1 2 3 4
Pc(kW) 0.201 0.224 0.224 0.149
Pm(kW) 0.288 0.32 0.32 0.213
V(mm3/min) 9668.663 10742.959 10742.959 7161.972
Vc(mm3) 38905.48 16909.308 8835.729
L(mm) 342.5
tc(min) 2.391 3.621 1.574 1.234
Page 89 8.3. Phase20: In this phase, we are still with CNC Milling Machine. We change the machining surface to the another face and fix the part at both sides horizontally. Step1: In this process, We will do circular pocket diameter 55 H11 mm. deep 12.5 mm. We employ milling tool Garant 191200 diameter 15 mm. , cutting length 26 mm. and number of teeth is 3.
Calculation of Step1: We can proceed the calculation for this step by the same manner as Step2 of this part. The cutting depth is 3 mm. and cutting width b equal to the diameter of tool (15 mm.). Step2: In this process, We will do Grooving diameter 58 mm. deep 2.15 mm. We employ milling tool Garant 185500 diameter 50 mm. , thick 2 mm. , number of teeth is 22. The diameter of tool (50 mm.) has to be smaller than the diameter of part (55 mm.) because tool will enter into the part at the center of hole until it arrives the machining position and then make a groove.
Page 90
Calculation of Step2: In order to find advance speed, cutting force, cutting power, machine power and cutting time, we can use equations 15,16,17,18,19 and 20 of Shaft1. In this operation, the cutting depth (p) is 1.5 mm, the cutting width (b) is 2 mm. ( equal to the thickness of tool ). The cutting length (L) is the perimeter of the movement of tool (circular shape). The diameter of the movement of tool is 8 mm, so the cutting length (L) is 25.13 mm. Step3: In this step, we will mill the space for the head of bolts, the depth is 7.5 mm. and the radius is 10 mm, 6 positions. We use milling tool Garant 191200 diameter 15 mm. , cutting length 22 mm. and number of teeth is 3.
Page 91 Calculation of Step3: We can proceed the calculation for this step by the same manner as Step2. The cutting depth is 3 mm. and cutting width b equal to the diameter of tool (15 mm.). In order to calculate the cutting volume (Vc), We use the true scale drawing to define the cutting volume (Vc) ( See Figure7.1). We found the cutting volume (Vc) is: Vc = ( 2 * ( 235.635 + 318 + 451.26 ) ) * 7.5 = 15073.425 mm^3
Figure8.8: Drawing for cutting volume calculation
Step4: In this step, we will drill 6 holes diameter 6 mm and deep 14 mm. We use the drilling tool Garant 113260 diameter 6 mm.
Page 92 Calculation of Step4: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 6 mm. and the cutting velocity is 70 m/min. because the material of part is Aluminum casting. The depth of each hole is 14 mm. so the total cutting length (L) is 84 mm.
Step 1 2 3 4
d(mm) 15 50 10 6
Tool Data az(mm.) Zt(teeth) 0.025 3 0.025 22 0.025 3
n(rpm) 3183 954.9 4775 2971
av(mm/turn) 0.075 0.55 0.075 0.06
Vam(mm/min) 238.732 525.211 358.099 178.254
p(mm) 3 1.5 3
b(mm) 15 2 10
Fc(N) 56250 3750 37500 225
Step 1 2 3 4
Pc(kW) 0.224 0.033 0.224 0.225
Pm(kW) 0.32 0.047 0.32 0.321
V(mm3/min) 10742.959 1575.634 10742.959
Vc(mm3) 29697.868 15073.425
L(mm) 25.133 84
tc(min) 2.764 0.048 1.403 0.471
Page 93 8.4. Calculation of Cycle Time for Sealing plate 1-2:
Phase 10
Step 1
20
Task Tool moves into part Mill flat surface Tool move out from the part 2 Tool moves into part Circular pocket Dia 48 mm. 3 Circular pocket Dia 58 mm. 4 Circular pocket Dia 75 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Circular pocket Dia 55 H11 mm Tool move out from the part 2 Tool moves into part Grooving of Dia 58 mm. Tool move out from the part 3 Tool moves into part Mill the space for head of bolts Tool move out from the part 4 Tool moves into part Drill 6 holes dia. 6 mm Tool move out from the part Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s)
tm (s) 2 143.5 3 2 217.3 94.44 74.02 3 539.2 2 165.9 3 2 2.871 3 2 84.19 3 2 28.27 3 301.2 840.4
tch (s)
tph (s)
tpre (s) 5.271
thmp (s)
tun (s)
2.391 3.621 1.574 1.234 8.82 15 15
5.271 568.308 120
2.764
0.048
1.403
0.707 4.922 13.74
120 0 441.118 120 5.271 1009.426
15 15 30
0 0
Table8.3: Cycle time for Sealing plate1-2
Page 94
9. Manufacturing Process of Transmission Plate 2

9.1. The raw material: The raw material for Transmission Plate is from forging process. The dimension is similar to the final shape. We decide to get raw material from forging because this kind of shape is not suitable to be machined from steel bar, we will loose too much material. 9.2. Phase20: We use CNC Lathe Machine for this phase. We fix the raw part at external diameter 45 mm. by fixing plate with hard jaws of CNC Lathe Machine. Step1: In the first step, we take out front material 1.5 mm. at the diameter 93 mm. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (93 + 29) / 2 = 61 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. Step2: In this step we will do the boring operation. We Bore to have a hole with diameter 47 mm. length 2.3 mm. and diameter 42 mm. length 10.8 mm. and diameter 32 through the part with chamfer 2 x 30 degree at diameter 32 mm. We use cutting tool WBGW1.21_ (kyocera) with the tool holder S10H-SWUBR06-06 [3].
Page 95
Calculation of Step2: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. The average diameter to calculate rotation speed is d = ( 47 + 42 + 32 ) / 3 = 40.33 mm. The edge radius of tool is rp = 0.2 mm [3]. The total cutting length (L) is the summation of tools movement, L = ( 1 * 45.5 ) + ( 2 * 13.1 ) + ( 1 * 2.3 ) = 74 mm. Step3: In this step, we will do the finishing of the external surface. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, right hand.
Calculation of Step3: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2).
Page 96 The cutting length (L) in this step is the movement of part, we find L = 7.5 mm.
S(mm2) 0.067 0.339 0.067 tc(min) 0.918 0.46 0.264
Step 1 2 3
rp(mm) 0.031 0.2 0.031 Step 1 2 3
d(mm) 61 40.333 90 Pc(kW) 0.2 1.222 0.241
n (rpm) 782.7 1421 636.6
p(mm) 1.5 3 1.5
Ra(mm) 1.6 1.6 1.6 L (mm) 32 74 7.5
a(mm/turn) 0.045 0.113 0.045
Fc(N) 80.2 407 80.2
Pm (kW) 0.267 1.629 0.321
Va(mm/min) 34.864 160.718 28.356
9.3. Phase30: In this phase, we will machine the other side of part. We fix the raw part at internal diameter 42 mm. with soft jaws of CNC Lathe Machine. Step1: In this step, we take out front material 1.5 mm. at the diameter 53 mm. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (48 + 32) / 2 = 40 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1.
Page 97
Step2: In this step we will do the boring operation. We Bore to have a hole with diameter 36 mm. length 11.9 mm. with chamfer 2 x 30 degree at diameter 32 mm. We use cutting tool WBGW1.21_ (kyocera) with the tool holder S10H-SWUBR06-06 [3].
Calculation of Step2: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. The average diameter to calculate rotation speed is d = 36 mm. The edge radius of tool is rp = 0.2 mm [3]. The total cutting length (L) is the summation of tools movement, L = 11.9 mm. Step3: In this step, we will do the finishing of the external surface. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, right hand.
Page 98
Calculation of Step3: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). The cutting length (L) in this step is the movement of part, we find L = 38 + 40 = 78 mm.
S(mm2) 0.067 0.226 0.067
Step 1 2 3
rp(mm) 0.031 0.2 0.031
d(mm) 40 36 61.667
n (rpm) 1194 1592 929.1
p(mm) 1.5 2 1.5
Ra(mm) 1.6 1.6 1.6
a(mm/turn) 0.045 0.113 0.045
Fc(N) 80.2 272 80.2
Step 1 2 3
Pc(kW) 0.2 0.815 0.241
Pm (kW) 0.267 1.086 0.321
L (mm) 8 11.9 78
Va(mm/min) 53.168 180.063 41.385
tc(min) 0.15 0.066 1.885
9.4. Phase40: We will use CNC Milling Machine in this phase. We fix the raw part by Index Plate with soft jaws of CNC Milling Machine. Step1: We will drill 4 holes around the flange of Transmission Plate with 8 mm. ( +0.2, -0.2 mm.) through the part and make chamfer 0.5 x 45 degree for every holes. We use drill Garant 113260 diameter 8 mm, cutting length 37 mm.
Page 99
Calculation of Step1: The calculation in this step can be done by using equations 6,7,8,9,10 and 11 of Shaft1. The diameter of drill is 8 mm. and the cutting velocity is 80 m/min. because the material of part is Aluminum casting. The depth of each hole is 7.5 mm. so the total cutting length (L) is 30 mm.
Step 1
d(mm) 8
n(rpm) 795.8
av(mm/turn) 0.08
Vam(mm/min) 63.662
p(mm)
b(mm)
Step 1
Fc(N) 384
Pc(kW) 0.064
Pm(kW) 0.091
V(mm3/min)
L(mm) 30
tc(min) 0.471
9.5. Phase50: In this phase, we will make the internal gear by Broaching Machine because the internal diameter is too small to do this operation by Milling Machine. We fix the part at the external diameter 45 mm. by fixing plate with soft jaws of Broaching Machine. Step1: This step is to make Internal Gear according to DIN 5462 32x36x6. This process will be done by Broaching Machine. The tool we use in this process is the tool for Gear shape32x36x6.
Page 100
Calculation of Step1: We will start the calculations with the tool data. The pitch of tool (p) can be calculated by the following formula[6]. p = 1.75 * sqrt(L) Where: p = pitch of tool (mm.) L = Total length to broach (mm.) Then we have to find the number of teeth (z) necessary for this process. The calculation can be done by the following formula [6]. z = ( (di df)/2 ) / r Where: z = number of teeth necessary for the process di = The initial diameter of the part before broaching (mm.) df = The final diameter of part after broaching (mm.) r = The progression of the height of tool teeth (mm.) In fact, the number of teeth (z) necessary for the process is not real number of tools teeth because its enough for the rough machining only. We have to add more teeth for finishing surface as well. The formula is shown below [6]. zt = z + za Where: zt = The total (real) number of teeth za = Number of teeth for finishing surface In this case, we use za = 5 Now we can calculate the Cutting power (Fc) for broaching process. The formula is shown below [6]. Fc = t * k * S* zw zw = L / p (35) (36) (34) (33) (32)
Where: k = constant depending on the type of material k = 3 for elastic material k = 5 for less or non elastic material (ex. Casting ) t = Resistant of traction stress of material (N/mm2) S = Cutting surface of the part (mm2) , see details in Figure8.9 zw = The number of teeth to be machined in each moment. p = pitch of tool (mm.) L = Total length to broach (mm.)
Page 101
Figure9.9: The cutting surface of part in Broaching Process
From Figure8.9, we define the cutting surface is the parts material to be cut at each moment, so the depth of the surface equal to the progression of the height of tool teeth (r). We found that : S = 8 * 6 * 0.03 = 1.44 mm2 After we get the cutting force, we can now calculate the cutting power (Pc) and the machine power (Pm) by the following equations [6]. Pc = ( Fc * a ) / 60000 Pm = Pc / Where: Pc = Cutting power (kW) Pm = Machine power (kW) Fc = Cutting force (N) a = Advance speed of tool (m/min) In this case we use a = 4 m/min = Machine efficiency = 0.7 0.8 The broaching process sometimes could not be done in one pass but in several passes. The number of broaching passes (nb) can be calculated by the following formula [6]. nb = ( p * zt ) / ( lmax (p * za) ) Where: nb = Number of broaching pass p = pitch of tool (mm.) zt = The total (real) number of teeth za = Number of teeth for finishing surface In this case, we use za = 5 lmax = Maximum broaching length (39) (37) (38)
Page 102 Finally, we can calculate the total cutting time (tc) for broaching operation by the following formula. tc = ( zt * p * nb ) / ( a * 60 ) Where: tc = Total cutting time for broaching process (min) nb = Number of broaching pass p = pitch of tool (mm.) zt = The total (real) number of teeth a = Advance speed of tool (m/min) In this case we use a = 4 m/min (40)
Step 1
L(mm) 19
p(mm) 7.628
z(teeth) 67
zt(teeth) 72
nb 1
tc(min) 2.288 Pm (kW) 0.461
zw(teeth) 3
Step 1
S(mm2) 1.44
Fc(N) 5184
Pc(kW) 0.346
9.6. Phase60: This phase is the heat treatment process. We will do heat treatment at the external dia 50 mm. to have the hardness 54-56 HRC ( 1mm. depth). The part will be heated by Induction heating and the time required for the process is 30 min/lot ( 1 lot contains 20 parts) or 1.5 min/part This operation will be done by the external company).
Page 103 9.7. Calculation of Cycle Time for Transmission Plate 2:
Phase 20
Step 1
30
40
50
60
Task Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Boring operation Tool move out from the part 3 Tool moves into part Finish surface machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Boring operation Tool move out from the part 3 Tool moves into part Finish surface machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Drill 4 holes dia. 8 mm. Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Make Internal Gear DIN 5480 Tool move out from the part Total Time (s) Cycle Time (s) 1 Heat treatment Total Time (s) Total Cycle Time (s)
tm (s) 2 55.07 3 2 27.63 3 2 15.87 3 113.6 2 9.028 3 2 3.965 3 2 113.1 3 141.1 2 28.26 3 33.26 2 27.65 3 32.65
tch (s)
tph (s)
tpre (s) 5.271
thmp (s)
tun (s)
0.918
0.46
0.264 1.643
0 120
5.271 135.48
15 15
0.15
0.066
1.885 2.101
120 0 278.179 5.271
15 15
0.707 0.707
5.271 54.237 5.271
15 15
0.461 0.461
5.271 53.38
15 15
0 90 90
320.6
4.911
120 15.813 611.276
60
Table9.5: Cycle time for Transmission Plate2
Page 104
10. Manufacturing Process of Washer 2

10.1. The raw material: In order to machine this part, we use cylindrical bar steel C 25 with diameter 45 mm because we have to add 1.5 mm. to the final shape ( Maximum diameter of part is 42 mm.) in radial direction to be machined in Finishing Operation. 10.2. Phase10: In the first phase, we will prepare the raw material to be suitable for the machine. We will cut the raw material ( Cylindrical Bar Dia 45 mm.) to be a short bar with the length 1000 mm. by Manual Disc Saw Machine (+1 , -0 mm tolerance). The calculation of this phase can be done in the same way as Shaft1 ( by using the method of milling machine ) and the results are shown in table10.1.
Step 1
d(mm) 210
n(rpm) 60.63
av(mm/turn) 0.9
Vam(mm/min) 54.567
p(mm) 45
b(mm) 2
Fc(N) 108000
Pc(kW) 0.098
Pm(kW) 0.131
L(mm) 45
tc(min) 0.825
10.3. Phase20: We will do the operation in this phase by CNC Lathe Machine. We fix the raw part with continuous feed fixing plate with hard jaws of CNC Lathe Machine. We leave 12 mm. to be machined for each washer. Step1: In this step, we take out front material 1.5 mm. to have the new distance 10.5 mm. from fixing plate. we use Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Page 105
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (45 + 0) / 2 = 22.5 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7. Step2: We will take out surface material 1.5 mm. in radious direction to have new diameter 42 h8 mm. in this step. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B, both right and left hand.
Calculation of Step2: In order to calculate rotation speed (n), advance speed (a), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,2,3,4,5,6 and 7. In this step, we use the average diameter to calculate the rotation speed as we have said in the calculation of phase20 step1 and we use Vc for finishing surface with carbide tool (see table1.2). The average diameter (d) in this case is (45 + 42)/2 = 43.5 mm. The cutting length (L) is 10.5 mm. Step3: In this step, we will drill a hole diameter 10 mm. and 10.5 mm depth. We use drill Garant 113260 diameter 10.5 mm. and cutting length 43 mm.
Page 106
Calculation of Step3: The calculation in this step can be done by using equations 6,7,8,9,10 and 11. The diameter of drill is 10 mm. , the cutting length is 10.5 mm. and the cutting velocity is 25 m/min. Step4: In this step, we will do the groove at the surface. The groove width 3.9 mm (+0.2, -0 mm. tolerance) deep 2.3 mm. and 2.05 mm. from the front surface. We use the cutting insert KCGP3156R (Kyocera) and the holder KKCR12-3C [3].
Calculation of Step4: In order to calculate rotation speed (n), cutting force (Fc), cutting power (Pc), machine power (Pm), cutting time (tc) and advance velocity (Va), all can be calculate by the equations 1,3,4,5,6 and 7 of Shaft1 and use Vc for finishing surface with carbide tool (see table1.3). Step5: This step is the final operation for each part. The objective is to cut the part to be small piece, width 8 mm. We use cutting insert tool KCGP3156R (Kyocera) and tool holder KKCR12-3C. After this process, we have to repeat Phase20 again in order to get more washers.
Page 107
Calculation of Step5: Although this step is the cutting process, we can use the same calculation process as in Phase20 Step1 of this part. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7.
S(mm2) 0.067 0.067 0.441 0.246 tc(min) 0.238 0.179 0.165 0.014 0.082
Step 1 2 3 4 5
rp(mm) 0.031 0.031 0.2 0.2 Step 1 2 3 4 5
d(mm) 22.5 43.5 10 39.7 21 Pc(kW) 0.2 0.241 0.05 1.588 0.738
n (rpm) 2122 1317 636.6 1443 2274
p(mm) 1.5 1.5 3.9 2.175
Ra(mm) 1.6 1.6 1.6 1.6 L (mm) 22.5 10.5 10.5 2.3 21
a(mm/turn) 0.045 0.045 0.1 0.113 0.113 Va(mm/min) 94.521 58.668 63.662 163.282 257.233
Fc(N) 80.2 80.2 600 529 295
Pm (kW) 0.267 0.321 0.067 2.118 0.984
Page 108 10.4. Calculation of Cycle Time for Washer 2:
Phase 10 20
Step Task 1 Cut the part Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Finishing of external surface Tool move out from the part 3 Tool moves into part Drill a hole dia. 10 mm. Tool move out from the part 4 Tool moves into part Surface Groove width 3.9 mm Tool move out from the part 5 Tool moves into part Cutting of part to be small piece Tool move out from the part Total Time (s) Cycle Time (s) Total Time (s) Total Cycle Time (s)
tm (s) 49.5 2 14.28 3 2 10.74 3 2 9.896 3 2 0.845 3 2 4.898 3 65.66 115.2
tch (s)
tph (s)
tpre (s) 0.439 64.939 5.271
thmp (s) 15
tun (s)
0.238
0.179
0.247
0.014
0.082 0.76 0.76
5.271 86.691 0 5.71 151.631
15 15 30
0 0
Table10.3: Cycle time for washer2
Page 109
11. Manufacturing Process of Gear 1

11.1. The raw material: The raw material for Gear1 is from forging process. The dimension is similar to the final shape. We decide to get raw material from forging because of better mechanical property and its faster than using raw part from steel bar. Its possible to use casting process, but the part will have low flexion resistance which is the important mechanical property of the part. 11.2. Phase20: We start the operation of this part with CNC Lathe Machine. We fix the raw part at external diameter (96.5 mm.) by fixing plate with hard jaws. Step1: We start machining the part by taking out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (96.5 + 53) / 2= 74.75 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7.
Page 110 Step2: In this step we will do the boring operation. We Bore to have a hole with diameter 62 mm. length 21 mm. and diameter 56 H7 mm. length 25.5 mm. We use cutting tool WBGW1.21_ (kyocera) with the tool holder S10H-SWUBR06-06 [3].
Calculation of Step2: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. The average diameter to calculate rotation speed is d = ( 62 + 56 ) / = 59 mm. The edge radius of tool is rp = 0.2 mm [3]. The total cutting length (L) is the summation of tools movement, L = 25.5 + ( 2 * 21 ) = 67.5 mm. Step3: In this step, we will make 3 chamfers, 2 mm. x 45 degree , 2 mm. x 30 degree and 3 mm. x 30 degree. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B.
Page 111 Calculation of Step3: We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1 in this process.
S(mm2) 0.067 0.339 0.067 tc(min) 0.764 0.614 0.315
Step 1 2 3
rp(mm) 0.031 0.2 0.031 Step 1 2 3
d(mm) 74.75 59 71.5
n (rpm) 638.7 971.1 801.3
p(mm) 1.5 3 1.5
Ra(mm) 1.6 1.6 1.6
a(mm/turn) 0.045 0.113 0.045
Fc(N) 120 611 120
Pc(kW) 0.301 1.527 0.301
Pm (kW) 0.401 2.036 0.401
L (mm) 21.75 67.5 11.25
Va(mm/min) 28.451 109.869 35.693
11.3. Phase30: In this phase, we still use CNC Lathe Machine. We fix the raw part at internal dia 62 mm. with soft jaws and machine at the other side. Step1: We will take out front surface in this operation. We employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Page 112 Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (96.5 + 53) / 2= 74.75 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7. Step2: We will do Finishing of the external surface and make chamfer 2 x 45 degree and 2 x 30 degree in this step. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B.
Calculation of Step2: We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1 in this process.
S(mm2) 0.067 0.067
Step 1 2
rp(mm) 0.031 0.031
d(mm) 74.75 74.75
n (rpm) 638.7 766.5
p(mm) 1.5 1.5
Ra(mm) 1.6 1.6
a(mm/turn) 0.045 0.045
Fc(N) 120 120
Step 1 2
Pc(kW) 0.301 0.361
Pm (kW) 0.401 0.481
L (mm) 21.75 50.14
Va(mm/min) 28.451 34.141
tc(min) 0.764 1.469
Page 113 11.4. Phase40: In this step, we will move to Broaching Machine in order to make the internal gear. We have to use Broaching Machine because the inner diameter is too small to be machined by other machine. We fix the part at diameter 93.5 mm. by fixing plate with soft jaws. Step1: This step is to make Internal Gear according to DIN 5480 60 x 2. This process will be done by Broaching Machine. The tool we use in this process is the tool for Gear shape 60x2 DIN 5480.
Calculation of Step1: The calculation of this operation can be done by using the equations 32, 33, 34, 35, 36, 37, 38, 39 and 40 of Transmission plate Phase50 Step1.
Step 1
L(mm) 24
p(mm) 8.573
z(teeth) 67 S(mm2) 1.84
zt(teeth) 72 Fc(N) 9934
nb 1
tc(min) 2.572 Pm (kW) 0.883
zw(teeth) 3
Step 1
Pc(kW) 0.662
11.5. Phase50: We will move to Gear Machine in this phase in order to make the external gear.
Page 114 Step1: We fix the part with Gear Machine and make the external gear according to the data in table10.4.
Table11.4: Data for external gear of Gear1
Calculation of Step1: We will start calculation with the tool rotaion speed. The gear cutting tool has the following data ; module (m) 3, diameter (d) 80 mm and tools teeth (ztool) 12 teeth. The rotation speed can be calculated by the following formula [6]. nf = ( Vc * 1000 ) / ( pi * d ) np = nf / ztool Where: Vc = Cutting speed (m/min) , in this case Vc = 30 m/min nf = Tool rotation speed (rpm) d = Diameter of tool (mm.) , in this case d = 80 mm. np = Part rotation speed (rpm) ztool = Number of tools teeth, in this case ztool = 12 Now we will calculate the cutting force (Fc) in order to get the machine power in the following step. It can be calculated by he following formula. Fc = t * k * S Where: k = k k t = constant depending on the type of material = 3 for elastic material = 5 for less or non elastic material (ex. Casting ) Resistant of traction stress of material (N/mm2) (43) (41) (42)
Page 115 S = The cutting surface = p * b p = Cutting depth of each pass = 3 in this case b = The average width of teeth = (1.75 + 3.5) / 2 = 2.625 in this case With the Cutting force obtained in the previous step, we are able to calculate the cutting power (Pc) and machine power (Pm) by the following formulas. Pc = ( Fc * Vam ) / 60000000 Pm = Pc / Where: Pc = Cutting Power (kW) Pm = Machine Power (kW) Fc = Cutting Force (N) Vam = Tool advance speed (mm/min) We also have to calculate the cutting time tc. In order to calculate it, we have to find the Cutting length (Lt) and Number of Cutting Pass (np). The calculation process can be done by the following formula [6]. tc = Lt / Vam Lt = L + (r * cos) Where: tc = Cutting time (min) Lt = Total cutting length for 1 pass (mm.) Vam = Tool advance speed (mm/min) L = The thickness of gear (mm.) r = The outer radius of gear (mm.) = 56.93 degree in this case m = Gear module p = Cutting depth of each pass = 3 in this case (46) (47) (44) (45)
Step 1
m 3 Step 1
d(mm) 80
nf (rpm) 119.37
np (rpm) 9.947 Pc(kW) 0.01
b(mm) 2.625
p(mm) 3 L (mm) 45
az(mm/min) 0.03 l(mm) 21.83
S(mm2) 7.875 tc(min) 1.555
Fc(N) 14175
Vam(mm/min) 42.972
Pm (kW) 0.014
Lt(mm) 66.83
11.6. Phase60: We will do the Heat Treatment for this part by Carburizing Process all over the part withdepth 1 mm. (+0.1, -0.1 mm. tolerance) in order to reach the hardness 60-62 HRC. We will heat the part to 900 930 C in the carburizing oven which has more concentration of carbon than in the part. The time required for Carburizing
Page 116 Process is 720 min/lot ( 1 lot contains 20 parts). Then we have to do Quenching process which required 180 min/lot and finally Tempering process which required 30 min/lot. The total time required for this phase is 930 min/lot or 46.5 min/part ( This operation will be done by the external company).
11.7. Calculation of Cycle Time for Gear1:
Phase 20
Step 1
30
40
50
80
Task Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Boring operation Tool move out from the part 3 Tool moves into part Make chamfer Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Finish machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Make Internal Gear DIN 5480 Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Make External Gear Tool move out from the part Total Time (s) Cycle Time (s) 1 Carburizing and quenching Total Time (s) Total Cycle Time (s)
tm (s) 2 45.87 3 2 36.86 3 2 18.91 3 116.6 2 45.87 3 2 88.11 3 144 2 52.98 3 57.98 2 93.3 3 98.3
tch (s)
tph (s)
tpre (s) 5.271
thmp (s)
tun (s)
0.764
0.614
0.315 1.694
5.271 138.606 120
15 15
0.764
1.469 2.233
120 0 281.213 5.271
15 15
0.883 0.883
5.271 64.134 5.271
1.555 1.555
5.271 120.126
15 15
0 2790 2790
416.9
6.365
120 15.813 3394.079
45
Table11.6: Cycle time for Gear1
Page 117
12. Manufacturing Process of Gear 2

12.1. The raw material: The raw material for Gear2 is from forging process. The dimension is similar to the final shape. We decide to get raw material from forging because of better mechanical property and its faster than using raw part from steel bar. Its possible to use casting process, but the part will have low flexion resistance which is the important mechanical property of the part. 12.2. Phase20: We start the operation of this part with CNC Lathe Machine. We fix the raw part at external diameter (81.5 mm.) by fixing plate with hard jaws. Step1: We start machining the part by taking out front surface. In this operation, we employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (81.5 + 35) / 2 = 58.25 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7.
Page 118 Step2: In this step we will do the boring operation. We Bore to have a hole with diameter 44 mm. length 23 mm. and diameter 38 H7 mm. length 23.5 mm. We use cutting tool WBGW1.21_ (kyocera) with the tool holder S10H-SWUBR06-06 [3].
Calculation of Step2: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1. The average diameter to calculate rotation speed is d = (38 + 44) / 2 = 41 mm. The edge radius of tool is rp = 0.2 mm [3]. The total cutting length (L) is the summation of tools movement, L = 23.5 + ( 2 * 23 )= 69.5 mm. Step3: In this step, we will make 3 chamfers, 2 mm. x 45 degree , 2 mm. x 30 degree and 3 mm. x 30 degree. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B.
Page 119 Calculation of Step3: We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1 in this process.
S(mm2) 0.067 0.339 0.067 tc(min) 0.637 0.44 0.24
Step 1 2 3
rp(mm) 0.031 0.2 0.031 Step 1 2 3
d(mm) 58.25 41 54.5 Pc(kW) 0.301 1.527 0.301
n (rpm) 819.7 1397 1051
p(mm) 1.5 3 1.5
Ra(mm) 1.6 1.6 1.6
a(mm/turn) 0.045 0.113 0.045
Fc(N) 120 611 120
Pm (kW) 0.401 2.036 0.401
L (mm) 23.25 69.5 11.25
Va(mm/min) 36.51 158.104 46.827
12.3. Phase30: In this phase, we still use CNC Lathe Machine. We fix the raw part at internal dia 62 mm. with soft jaws and machine at the other side. Step1: We will take out front surface in this operation. We employ Stellram cutting tool SNMG120408E-3G with the holder MSKNR/L-124B [2]. The tool insert SNMG120408E-3G is square shape which is suitable for machining front surface and rough machining. The tool is Right hand tool because we fix the part with Lathe Machine on the left.
Page 120 Calculation of Step1: The calculation in this step is similar to the one of Shaft1 Phase20 Step1. The only difference is the average diameter of the machining position to calculate the rotation speed, in this case d = (81.5 + 35) / 2 = 58.25 mm. We can calculate by utilizing the equations 1,2,3,4,5,6 and 7. Step2: We will do Finishing of the external surface and make chamfer 2 x 45 degree and 2 x 30 degree in this step. We use Stellram tool insert DNMG150408E-3G and tool holder MDJNR/L-124B.
Calculation of Step2: We can calculate by utilizing the equations 1,2,3,4,5,6 and 7 of Shaft1 in this process.
S(mm2) 0.067 0.067
Step 1 2
rp(mm) 0.031 0.031
d(mm) 58.25 59.75
n (rpm) 819.7 958.9
p(mm) 1.5 1.5
Ra(mm) 1.6 1.6
a(mm/turn) 0.045 0.045
Fc(N) 120 120
Step 1 2
Pc(kW) 0.301 0.361
Pm (kW) 0.401 0.481
L (mm) 21.75 50.14
Va(mm/min) 36.51 42.713
tc(min) 0.596 1.174
Page 121 12.4. Phase40: In this step, we will move to Broaching Machine in order to make the internal gear. We have to use Broaching Machine because the inner diameter is too small to be machined by other machine. We fix the part at diameter 78.5 mm. by fixing plate with soft jaws. Step1: This step is to make Internal Gear according to DIN 5480 42 x 2. This process will be done by Broaching Machine. The tool we use in this process is the tool for Gear shape 42x2 DIN 5480.
Calculation of Step1: The calculation of this operation can be done by using the equations 32, 33, 34, 35, 36, 37, 38, 39 and 40 of Transmission plate Phase50 Step1.
Step 1
L(mm) 22
p(mm) 8.208
z(teeth) 67
zt(teeth) 72 Fc(N) 8424
nb 1
tc(min) 2.463 Pm (kW) 0.749
zw(teeth) 3
Step 1
S(mm2) 1.56
Pc(kW) 0.562
12.5. Phase50: We will move to Hobbing Machine in this phase in order to make the external gear.
Page 122 Step1: We fix the part with Hobbing Machine and make the external gear according to the data in table11.4.
Table12.4: Data for external gear of Gear1
Calculation of Step1: Every calculation can be done in the same way as Gear1 Phase50. We can use equations 41, 42, 43, 44, 45, 46 and 47 to calculate.
Step 1
m 3 Step 1
d(mm) 80
nf (rpm) 119.366
np (rpm) 9.947 Pc(kW) 0.018
b(mm) 4.64
p(mm) 3 L (mm) 45
az(mm/min) 0.03 l(mm) 21.83 Lt(mm) 66.83
S(mm2) 13.92 tc(min) 1.555
Fc(N) 25056
Vam(mm/min) 42.972
Pm (kW) 0.024
12.6. Phase60: We will do the Heat Treatment for this part by Carburizing Process all over the part withdepth 1 mm. (+0.1, -0.1 mm. tolerance) in order to reach the hardness 60-62 HRC. We will heat the part to 900 930 C in the carburizing oven which has more concentration of carbon than in the part. The time required for Carburizing Process is 720 min/lot ( 1 lot contains 20 parts). Then we have to do Quenching
Page 123 process which required 180 min/lot and finally Tempering process which required 30 min/lot. The total time required for this phase is 930 min/lot or 46.5 min/part ( This operation will be done by the external company).
12.7. Calculation of Cycle Time for Gear2:
Phase 20
Step 1
30
40
50
80
Task Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Boring operation Tool move out from the part 3 Tool moves into part Make chamfer Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Frontal machining Tool move out from the part 2 Tool moves into part Finish machining Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Make Internal Gear DIN 5480 Tool move out from the part Total Time (s) Cycle Time (s) 1 Tool moves into part Make External Gear Tool move out from the part Total Time (s) Cycle Time (s) 1 Carburizing and quenching Total Time (s) Total Cycle Time (s)
tm (s) 2 38.21 3 2 26.37 3 2 14.41 3 94 2 35.74 3 2 70.43 3 116.2 2 44.93 3 49.93 2 93.3 3 98.3
tch (s)
tph (s)
tpre (s) 5.271
thmp (s)
tun (s)
0.637
0.44
0.24 1.317
5.271 115.586 120
15 15
0.596
1.174 1.77
120 0 252.944 5.271
15 15
0.749 0.749
5.271 55.948 5.271
1.555 1.555
5.271 120.126
15 15
0 2790 2790
358.4
5.39
120 15.813 3334.603
45
Table12.6: Cycle time for Gear2
Page 124
13. Choosing the proper machine

13.1. CNC Lathe Machine In order to choose the specific machine for turning operation, we have to consider the data of every operation employed by CNC Lathe Machine. The data including maximum machine power (Pm) and maximum rotation speed (n) for each operation, the data are shown in table12.1.
Part Shaft 1 Shaft 2 Gear 1 Gear 2 Pin Transmission Plate Washer
Max. Rotation Speed (rpm) 2329.097 1671.162 971.115 1397.458 3000 1591.549 2273.642
Max. Power (kW) 9 9 2.036 2.036 0.535 1.629 2.118
Table13.1: The Maximum machine power and rotation speed of turning operation
As we see in table12.1, the maximum machine power is 9 kW and the maximum rotation speed is 3000 rpm, so we have to choose the machine which can support these requirements. According to the data above, we decide to choose CNC Lathe Machine from Haas Automation Model: SL-10HE , the machine details are shown below [8].
Figure13.1: CNC Lathe Machine Model: SL-10HE
Page 125 Supplier: Haas Automation Model: SL-10HE Price: 39,900 euros Details: CNC Lathe; 11" (279mm) x 14" (356mm) (maximum), 16.25" (413mm) swing, 15-hp (11.2kw), 100-6000 rpm, A2-5 spindle, 6.5" (165mm) chuck,12-station VDI30 turret,1MB, internal transformer, export packing, floppy drive, chip auger, macros, Visual Quick Code, rigid tapping, spindle orientation, tool presetter.
13.2. CNC Milling Machine With the same method, in order to choose the specific machine for milling operation, we have to consider the data of every operation employed by CNC Milling Machine. The data including maximum machine power (Pm) and maximum rotation speed (n) for each operation, the data are shown in table12.2.
Part Shaft 1 Shaft 2 Casing Sliding Part Clutch Fork Pin Sealing plate1,2 Transmission Plate
Max. Rotation Speed (rpm) 1273.24 5500 4774.648 5092.958 4774.648 1273 4774.648 795.775
Max. Power (kW) 0.196 0.131 0.321 0.171 0.233 0.054 0.321 0.091
Table13.2: The Maximum machine power and rotation speed of milling operation
As we see in table12.2, the maximum machine power is 0.321 kW and the maximum rotation speed is 5500 rpm, so we have to choose the machine which can support these requirements. According to the data above, we decide to choose CNC Milling Machine from CNC Masters Model: CNC Supra Vertical Knee-Type Milling Machine , the machine details are shown below [9].
Page 126
Figure13.2: CNC Milling Machine Model: CNC Supra Vertical Knee-Type
Supplier: CNC Masters Model: CNC Supra Vertical Knee-Type Price: 6,971 euros General data: - Super Strong Column and Base - High Precision Class 7 Spindle Bearings - X, Y, Z Zero-Backlash Ball Screws with Pre-Loaded Ball Nuts - X, Y, Size 34 Micro-Stepping Motors at 1500 in/oz of torque with Hand Wheels - Z, Size 34 Micro-Stepping Motor at 1200 in/oz of torque with Hand Wheel - 9" x 49" table - variable spindle speed computer controlled - Ground table t-slots - Hardened & ground ways - Hardened & ground table - Built-In Coolant Column Base (Computer Control Pump, Hose, and Flex Nozzle mounted next to quill--optional accessory) Built-In One-Shot Auto Lube
Tolerances: - Accuracy is +/- 0.003" in 12" (+/- 0.00025 per inch) - Repeatability is within 0.0005" - Resolution is 0.0002" of linear motion on the X, Y, and Z.
Page 127 Machine Specifications:

Table Size Table T-slot size Longitudinal X Travel Forward/Back Cross Y Travel Quill Z Travel Vertical Travel Knee Lift Up/Down Ram Travel Spindle taper Head swivel RH/LH Head tilting F/B Ram turret swivel Power Spindle motor Spindle speeds (rpm) Net weight Machine Height Machine Width (Front to Back) Machine Length 9" x 49" 5/8" x 3" 34" 11.5" 4.5" 16" 12" R8 90/90 45/45 360 220 VAC or 240 VAC with variable speed 3 hp ( 2.24 kW) variable speed up to 5600 with Variable Spindle Speed Computer Control including on/off 2600 lbs 86" (65" with head upside down) 70" 67"
Accessory: 8 CNC Rotary Table
Figure13.3: 8 CNC Rotary Table
Feature: 90:1 Gear Ratio ; 0.005 degree Resolution Horizontal and Vertical Mounting #3 Morse Taper Center Hole T-Slots, extra deep coolant channels Tailstock Available
Page 128 13.3. Manual Grinding Machine In order to choose the specific machine for grinding operation, we have to consider the data of every operation employed by Manual Grinding Machine which are only two operations of Shaft1 and Shaft2. The data including maximum machine power (Pm) and maximum rotation speed (n) for each operation, the data are shown in table12.3.
Part Shaft 1 Shaft 2 Max. Rotation Speed (rpm) 1800 1800 Max. Power (kW) 0.54 0.54
Table13.3: The Maximum machine power and rotation speed of grinding operation
As we see in table12.3, the maximum machine power is 0.54 kW and the maximum rotation speed is 1800 rpm, so we have to choose the machine which can support these requirements. According to the data above, we decide to choose Manual Grinding Machine from Precision Machine Tool. Model: PMT/300/125, the machine details are shown below [10].
Figure13.4: Manual Grinding Machine Model: PMT/300/125
Page 129 Supplier: Precision Machine Tool. Model: PMT/300/125 Price: 596.7 euros Specification:
13.4. Broaching Machine With the same method, in order to choose the specific machine for broaching operation, we have to consider the data of every operation employed by Broaching Machine. The data including with maximum machine power (Pm) for each operation, the data are shown in table12.4.
Part Gear 1 Gear 2 Transmission Plate
Max. Power (kW) 0.883 0.749 0.461
Table13.4: The Maximum machine power of broaching operation
As we see in table12.4, the maximum machine power is 0.883 kW, so we have to choose the machine which can support this requirement. According to the data above, we decide to choose Broaching Machine from APM Pavia Co., Ltd. Model: SLOTTING CNC-200S, the machine details are shown below [11].
Page 130
Figure13.5: Broaching Machine Model: Slotting CNC-200S
Supplier: APM Pavia Co., Ltd. Model: SLOTTING CNC-200S Price: 6,500 euros General data: - Gear driven - Brake motor - Automatic feed and index - Forced lubrication system - Ram can swivel 10" forward Specifications: - Max. stroke: 200mm. - Indexing ratio: 1:90. - Dividing number: 0 ~ 999. - Ram speed (spm): 27, 42, 67, 105. - Longitudinal travel: 510mm. - Transversal travel: 440mm. - Main drive motor: 3HP (2.238 kW).
13.5. Hobbing Machine In order to choose the specific machine for gear machining operation, we have to consider the data of every operation employed by Hobbing Machine. The data including maximum machine power (Pm) and maximum rotation speed (n) for each operation, the data are shown in table12.5.
Part Gear 1 Gear 2
Max. Rotation Speed (rpm) 119.4 119.4
Max. Power (kW) 0.014 0.024
Table13.5: The Maximum machine power of gear machining operation
Page 131 As we see in table12.5, the maximum machine power is 0.024 kW and the maximum rotation speed is 119.4 rpm, so we have to choose the machine which can support these requirements. According to the data above, we decide to choose Hobbing Machine from LIEBHERR Model: LC-120, the machine details are shown below [12].
Figure13.6: Hobbing Machine Model: LC-200
Supplier: LIEBHERR Model: LC-120 Price: 35,000 euros Details: Maximum Module [mm] Workpiece diameter [mm] Axial travel [mm] Shift travel [mm] Hob diameter [mm] Hob length [mm] Hob speed [1/min] 3 125 250 (400) 180 90 210 5500
Page 132 13.6. Manual Disc Saw Machine In order to choose the specific machine for saw operation, we have to consider the data of every operation employed by Saw Machine. The data including maximum machine power (Pm) and maximum rotation speed (n) for each operation, the data are shown in table12.6.
Part Shaft 1 Shaft 2 Sliding Part Pin Washer Max. Rotation Speed (rpm) 60.63 60.63 60.63 60.63 60.63 Max. Power (kW) 0.319 0.253 0.099 0.052 0.131
Table13.6: The Maximum machine power of saw operation
As we see in table12.6, the maximum machine power is 0.3187 kW and the maximum rotation speed is 60.63 rpm, so we have to choose the machine which can support these requirements According to the data above, we decide to choose Broaching Machine from Hangzhou Yangyang Machinery-Equipment Tools & Hardware Co., Ltd. Model: YY-131-004, the machine details are shown below [13].
Figure13.7: Manual Disc Saw Machine Model: YY-131-004
Supplier: Hangzhou Yangyang Machinery-Equipment Tools & Hardware Co., Ltd. Model: YY-131-004 Price: 800 euros Details: - Blade diameter: 210mm - Rated voltage: 120V/240V
Page 133 Rated input power: 1,300W No load speed: 4,500r/min Net weight: 12.5kg
13.7. Manual Sensitive Press We decide to choose Sensitive Machine from Eitel Presses Inc. Model:10T, the machine details are shown below [14].
Figure13.8: Manual Sensitive Press Machine Model: 10 T
Supplier: Eitel Presses Inc. Model: 10 T Price: 1,200 euros Details: Design: C-frame with hand-load, hand operated traveling carriage for unlimited straightening points. It can straighten parts up to 20 feet in length depending on part diameter. Control: Manual through the use of a hand lever connected to the control valve via mechanical linkages. Straightening Process: The operator hand loads the part into the straightening station and clamps the part in centers (or on rollers). The part is then rotated manually to measure the TIR using dial indicators and the high point is rotated up. The operator will then depress the hand lever, which brings the ram down to the part causing the part to flex. The depth of the stroke is adjusted using the fine stroke adjustment on the hand lever. After each stroke, the dial indicator will show how much the TIR of the part has changed so that the operator can increase the depth of stroke until the TIR is within customer specifications. This process is repeated at operator determined points along the work piece as necessary to achieve the specified straightness.
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14. Calculation of the Machines Amount Required

In order to know the number of the machine (Nm) required for this project, we have to analyze the data obtained in the previous chapter. We have to take into account the total cycle time of each machine and the expected production amount per year (from marketing study). We concept of this calculation is that we divide time required to machine parts per year by the operation time we have per year. The time required to machine parts per year is the multiplication of expected production amount per year (Pexpect) and the total cycle time of each machine (Ctot), its unit is h/year. The operation time we have per year is determined from the assumptions that we have 220 working days/year, 1 shift/day and 7.75 h/shift. The formula to proceed this calculation is shown below. Nmc = ( Pexpect * (Ctot / 3600) ) / ( 7.75 * 220 * 1 ) Where: Nmc = The calculation number of the machine Pexpect = The expected production amount per year = 7513 parts/year Ctot = The total cycle time of each machine (s) We also have to calculate the % of Work Load of the machine in order to manage each operation. If the % of Work Load is too low ( less than 40 % ), we may have to think about using the external sub-contract company instead of investing the new machine. If the % of Work Load is more than 90 %, we should add 1 more machine to avoid the over capacity situation. The % of Work Load can be found by the following equation. % of Work Load = ( Nmc / Nmr ) * 100 Where: Nmc = The calculation amount of the machine Nmr = The real amount of machine (50) (48)
The results of The number of the machine (Nm) by using equation 48 and 49 are shown in table14.1.
Machine CNC Lathe CNC Milling Grinding Broaching Hobbing Sensitive Press Disc Saw Oven
Total Cycle Time (s) 2952.634 3651.178 595.988 173.462 240.252 180 336.649 11160
Nm (calculation) 3.614 4.469 0.729 0.212 0.294 0.22 0.412 4.553
Nm (real) 5 5 1 1 1 1 1 6
% of Work Load 72.281 89.382 72.95 21.232 29.407 22.032 41.206 75.889
Table14.1: The amount of Machines
Page 135 According to the data in table13.1, there are 3 machines that have % of work load lower than 40 %. We could think about using the external sub-contract company to do these operations. However, in our case we also have to consider the increasing of production in the following year. With this reason, we can conclude that it would be worth enough to invest Broaching, Hobbing and sensitive Press Machine since the 1st year. However, in the case of Heat Treatment Process, it will be better to use the external sub-contract company to do, because this is the process which spends lots of time and it will increase the cost of product as well. Another reason is that heat treatment is usually the last process of the operation, this make it be easier to manage the process by the external company.
15. Calculation of the Workers Amount Required

We can calculate the amount of the Operator by analyzing the operation time done by human for each part. The operation time to be done by operator including; Phase changing time (tph) , Machine preparation time (tpre) , Time for taking out the finished part (thmp) , Time for verification (thmm) , Time for un-machine phase (tun) and some of Machining time from manual process (tm). Its clear that Phase changing time (tph) , Machine preparation time (tpre) , and Time for taking out the finished part (thmp) and Time for verification (thmm) have to be done by the operator, but not every Time for un-machine phase (tun) is done by operator. The process that we take tun into account for example to paint the anti-carburizing to the part. We also take into account the Machining time (tm) for Manual Machine. The concept to calculate the amount of workers (Nwc) is similar to the one of the machine amount calculation. The formula is shown below. Nwc = [ ( thuman / 3600 ) * Pexpect] / ( 7.75 * 220 * 1 ) (51)
Where: Nwc = The calculation amount of the workers thuman = The summation of operation time done by human for every part(s) = Sum( tph + tpre + thmp + thmm + tun + tm ) Pexpect = The expected production amount per year = 7513 parts/year
Page 136
Machine Shaft1 Shaft2 Casing Deslizamiento Gear1 Gear2 Clutch Fork Pin Tapa Sellado1,2 Transmission Plate2 Washer2 Total tph (s) 360 360 240 240 120 120 240 120 120 120 0 2040 tpre (s) 11.420 11.420 5.271 5.71 15.813 15.813 5.271 10.981 5.271 15.813 5.7101 108.492 thmp (s) 105 135 45 45 45 45 30 60 30 60 30 630 thmm (s) 30 30 30 30 30 30 30 30 30 30 30 330 tun (s) 150 210 0 0 0 0 0 0 0 0 0 360 tm (s) 474.9 594.2 0 68.16 58.863 50.679 0 13.19 0 33.111 49.5 1342.6 Nwc Nwr
5.889
Table15.1: The amount of workers ( Operator of Machine )
The amount of operator (Nwr) obtained in table15.1 are the workers who work with the machine only. In fact, we have to add 2 more workers for the assembly job. We also have to consider about the other positions such as Maintenance technician, Engineer, Manager and Officer ( including accounting, human resource, secretary etc.). The estimation of the amount and the salary rate are shown in table 15.2.
Position Operator of Machine Worker for Assembly Maintenance Technician Officer Engineer Manager Total
Amount 6 2 2 2 1 1 14
Salary Rate (euros/year) 16000 14000 17000 16000 21000 40000
Total Salary (euros/year) 96000 28000 34000 32000 21000 40000 251000
Table15.2: The amount of workers and salary rate for all positions
Page 137
16. Economic Study

16.1. Hour Cost Hour Cost is the important factor to calculate the product cost. It is the total cost of the company in one hour. It means that in every hour passed, company has to pay the money equal to Hour Cost. The Hour Cost is included with four factors, Amortization (A), Power (B), Salary (C), General (D). The formula to calculate Hour Cost is shown below. Hour Cost = ( A + B + C + D ) / Total Direct Working Hour Where: A B C D = = = = Amortization Cost (euros/year) Electric Power Cost (euros/year) Total Salary of employees (euros/year) General Cost, for ex. water, telephone, etc. (52)
Amortization Cost (A): Amortization Cost is the investment cost of company divide by the expected utilization year. For example, the machines are expected to be used for 5 years, after the 5th year it may be not in the good condition to produce a quality product, so the investment cost of the machines have to be divided by 5 in order to get the Amortization Cost for machines. The Amortization Cost we consider are 1.The Construction of Production Plant , 2.Construction of Office and 3.The Machines (see table16.2 for details of machine investment cost). The formula to calculate Amortization Cost is shown below. A = Sum(Pi/Ni) (53)
Where: Pi = Investment Cost (euros) Ni = The number of expected utilization year of each investment (year) The result of Amortization Cost are shown in the table below.
Total Cost (euros) Type of Investment Construction of Production Plant 1500000 Machines 278451.7 Total Amortization
Number of year 10 5
Amortization (euros/year) 150000 55690.34 205690.34
Table16.1: The Amortization Cost
Page 138
Amount Machine (unit) Lathe Machine 5 Milling Machine 5 Grinding Machine 1 Broaching Machine 1 Hobbing Machine 1 Sensitive Press 1 Disc Saw 1 Total Machine Cost Price (euros/units) 39900 6971 596.7 6500 35000 1200 800 Total Cost (euros) 199500 34855 596.7 6500 35000 1200 800 278451.7
Table16.2: Show the details of investment cost of each machines and its amount
Electric Power Cost (B): Electric Power Cost is the cost of electric consumption of the company. The details of Electric Power Cost are shown in table16.3. We estimate the electric consumption of the machines by using the average Machine Power (Pm) obtained in the calculation part multiply by the number of the machines. This estimation is based on the assumption that every machine are running during the working hour. The formula to calculate the Electric Power Cost (B) is shown below. The constant for this formula are shown in table16.4. B = Total Power * f * P * Nhf (54)
Where: Total Power = The summation of every consumption in the company (kW) f = Factor of utilization = 0.5 0.8 P = Electricity price rate (euros/kWhr), we use 0.083728 euros/kWhr [17] Nhf = Working hours per year (hr) = 220 * 7.75 * 1 = 1705 hr/year
Avg. Power per 1 Amount unit (kW) (unit) Type of Consumption Lathe Machine 3.765 5 Milling Machine 0.19 5 Grinding Machine 0.54 1 Broaching Machine 0.698 1 Hobbing Machine 0.019 1 Disc Saw 0.171 1 Computer 0.36 6 Air Conditioner 2 3 Heater 2 3 Other office equipment Total Electric Power Cost per Year
Table16.3: Total Electric Power Cost per Year
Total Power (kW) 18.825 0.9485 0.54 0.698 0.019 0.171 2.16 6 6 4
Power Cost, B (euros/year) 1881.17 94.783 53.962 69.751 1.899 17.064 215.847 599.576 599.576 399.717 3933.346
Page 139
Constant Electricity price rate ( P ) Working hour per year ( Nhf) factor
Value 0.084 1705 0.7
Unit euros/kWhr hr/year
Table16.4: The Constants to be used in equation54
Salary Cost (C): We define the salary for each positions by considering the difficulties of the job functions and the skill required for each position. The details of this task are shown in table16.5.
Position Operator of Machine Worker for Assembly Maintenance Technician Officer Engineer Manager Total
Amount 6 2 2 2 1 1 14
Salary Rate (euros/year) 16000 14000 17000 16000 21000 40000
Total Salary (euros/year) 96000 28000 34000 32000 21000 40000 251000
Table16.5: Total Salary Cost per year
General Cost (D): The General Cost is the estimation of the other possible cost for the company, for example Water, Telephone etc. The details are shown in table16.6.
Type of General Cost Water Telephone Office Materials Soap & Oil Transport Taxes Maintenance Total
Cost (euros/year) 1700 1700 1700 2000 4000 50000 8000 69100
Table16.6: Total General Cost
Page 140
The Total Direct Working Hour is the total working time of the workers who work directly with the product or we can say that its the working time of the workers who produce the product, including with the Operator of Machines and the Workers for Assembly line. In our case, we have 8 direct workers who work approximately 220 days/year and 7.75 hours/day ( we just consider 1 shift/day), so the Total Direct Working Hour is 220 * 7.75 * 8 = 13640 hours/year. Finally, we add the cost A, B, C and D from table16.1, 16.3, 16.5 and 16.6 together, then divide by Total Working Hour according to equation 52, Hour Cost will be obtained (see table16.7).
Amortization ( A ) Power ( B ) Salary ( C ) General ( D ) Total Cost Hour Cost
Cost 205690.34 3933.346 251000 69100 529723.69 38.836
Unit euros/year euros/year euros/year euros/year euros/year euros/hour
Table16.7: Hour Cost
16.2. The Price of the cost of the Product ( Pc ) In order to calculate the price of the cost of the product (Pc), we have to use Hour Cost obtained in 16.1, the production time to machine 1 part ( tprod, total cycle time ) and the cost of raw material. Because we decide to do Heat Treatment from the external company, so the tprod will not include the cycle time for the heat treatment process for each part. The price of the product are shown in table16.8. and the formula to calculate the price of the product is shown below. Pc = ( Hour Cost * tprod ) + Pmat + Ptool (56)
Where: tprod = total production time to machine 1 part exclude Heat Treatment Process which has to be done by external company (hr) Pmat = The cost of raw material for each part and include the hiring cost of heat treatment with the external company Ptool = The estimation cost of tool = 10 euros/part The cost of raw materials (Pmat) are different for each part depending on the preprocess of the raw parts. Some parts for example shaft1, we can use the round bar and buy it directly from the steel manufacturer. But for some parts for example casing, we have to hire the external company to do this casting part (its shown in Sub Contract Cost). We do the estimation of the price for casting and forging process, which are: Casing from casting process 22 euros/part, Tapasellado from casting process 7 euros/part, Gear1 and 2 from forging process 13 euros/part, Clutch Fork from forging process 2 euros/part, Transmission Plate from forging process 12 euros/part.
Page 141
In the calculation of Pmat, we take into account the cost for doing heat treatment by external company (its shown in Sub Contract Cost). The prices are different between carburizing and normal heat treatment. We estimate the price for carburizing is 21 euros/part and 7 euros/part for normal heat treatment. The price of some shape of steel is shown in table16.8 and the cost of raw materials (Pmat) are shown in table16.9.
Type of Steel Round Bar Dia. 73 mm. Round Bar Dia. 58 mm. Plate 20x1800 mm. Round Bar Dia. 12 mm. Round Bar Dia. 45 mm.
Cost 53.661 31.297 194.483 1.2646 17.483

Table16.8: Steel Price [18]
Unit euros/m euros/m euros/m2 euros/m euros/m
Part Shaft1 Shaft2 Casing Deslizamiento Gear1 Gear2 Clutch Fork Pin Sealing plate1,2 Transmission Plate2 Washer2
Raw Material Round Bar Dia. 73 mm. Round Bar Dia. 58 mm. From Casting Process Plate 20x1800 mm. From Forging Process From Forging Process From Forging Process Round Bar Dia. 12 mm. From Casting Process From Forging Process Round Bar Dia. 45 mm.
Material Used m, m2 per part 0.176 0.141 0.001
Price (euros/part) 9.431 4.397 0.145
Sub Contract Cost (euros/part) 21 21 22
Total Price (euros/part) 19.431 14.397 10 0.145 16 15 11 5.111 6 13 0.219
34 34 9 0.088 0.111 7 7 19 0.013 0.219
Table16.9: Raw Material Cost for each part
Page 142
Part Shaft1 Shaft2 Casing Deslizamiento Gear1 Gear2 Clutch Fork Pin Tapa Sellado1,2 Transmission Plate2 Washer2 Total
tprod (hr) 0.492 0.52 0.301 0.143 0.168 0.151 0.096 0.071 0.28 0.145 0.049 2.417
Pmat (euros) 30.431 25.397 22 0.145 34 34 9 7.111 7 19 0.219 188.303
Ptool (euros)
Price of Cost of the Product, Pc (euros)
10
292.173
Table16.10: The Price of the Cost of the Product
16.3. Inversion Cost ( Cinv ) In general, when the company start manufacturing the product, it usually suffer the Inversion Cost during the first 3 months. Inversion Cost is the cost that the company has to pay without obtaining any profit, because of some circumstance for example machine test run. In order to calculate the Inversion Cost, we have to take into account all of the cost in the first 3 months. The details of Inversion Cost are shown in Table16.11.
Calculation of Inversion Cost Type of Cost Cost (euros) Investment of Machines 278451.7 Construction of Production Plant 1500000 General Cost ( 3 months ) 17275 Salary ( 3 months ) 62750 Electricity Cost ( 3 months ) 983.336 Study of the Project 6000 Unexpected Cost 8000 Inversion Cost (Cinv) 1873460.036
Table16.11: Inversion Cost for the first 3 months
16.4. Selling Price of the Product (Pv) In order to define the selling price of the product (Pv), we have to consider the Price of Cost of the Product (Pc), the Inversion Cost (Cinv) and the expected production amount. In the calculation, we use the Bank Interest (i) 4 % and the expect profit 10 % of the Pc. The formula is shown below and the details of the calculation are shown in table16.12.
Page 143
Pv = Pc + [{Cinv*(i/100)}/(product per year)] + [Pc*(expected profit/100)] (57)
Where: Pv = Selling Price of the Product (euros) Pc = Price of Cost of the Product (euros) Cinv = The Inversion Cost (euros) product per year = 7513 part/year i = Bank Interest = 4 % expected profit = 10 %
Selling Price of Product ( Pv ) Price of Cost of the Product ( Pc ) 292.173 Inversion Cost (Cinv) 1873460.036 Bank Interest ( i ) 4 Number of Expected Production per Year 7513 Expected Profit ( % of Pc ) 10 Selling Price of Product ( Pv ) 331.364
Table16.12: The Selling Price of the Product
euros/part euros % part/year % euros/part
16.5. The Situation of the Company in the Next 5 years In this task, we shall do the estimation of the situation of the company in the next 5 years according to the marketing study. The estimation data in this step will be useful and necessary to calculate cash flow and the pay back period in the following steps. The estimation data are shown in table16.13.
Company's Situation in the next 5 years Expected Production per Year Direct Workers Lathe Machine Milling Machine Grinding Machine Broaching Machine Hobbing Machine Sensitive Press Disc Saw
2008 7513 8 5 5 1 1 1 1 1
2009 10137 10 6 6 2 1 1 1 2
2010 12760 12 7 7 2 1 1 1 2
2011 15383 14 8 8 3 1 1 1 3
2012 18006 16 9 9 3 1 1 1 3
Table16.13: The Situation of the Company in the Next 5 years
* Direct Worker are the operator of machine and the worker for assembly
Page 144
16.6. Cash Flow Cash Flow is the important factor to know if the business is profitable. The concept to calculate is that we make the summation of the income and expense of the company in each year. The data to calculate cash flow are shown in table16.14, the sign is for the expense and the sign + is for the income. In order to calculate the Tax ( 35 % of the Profit before Tax subtracted ), we have to deduct the Amortization Cost of Plant Construction and Investment of Machine. To know the Cash Flow, we shall add the Amortization Cost of Plant Construction and Investment of Machine to the Profit after Tax subtracted again. The details of the calculation are shown in table16.14.
Cash Flow Sale Volume Cutting Tool and Material's Cost Salary Electricity Cost General Cost Amortization of Machines Amortization of Plant Construction Profit before Tax subtracted Tax subtracted ( 35% ) Profit after Tax subtracted Amortization of Machines Amortization of Plant Construction Cash Flow Net
2008 2489540.4 -1489852.7 -251000 -3933.346 -69100 675654.4 -55690.34 -150000 469964.06 -164487.42 305476.64 55690.34 150000 511166.98
2009 3359040.5 -2010200.6 -283000 -4399.562 -69100 992340.4 -55690.34 -150000 786650.06 -275327.52 511322.54 55690.34 150000 717012.88
2010 4228209.2 -2530350 -315000 -4794.753 -69100 1308964.4 -55690.34 -150000 1103274 -386145.9 717128.12 55690.34 150000 922818.46
2011 5097378 -3050500 -347000 -5260.969 -69100 1625517 -55690.34 -150000 1419827 -496939.4 922887.5 55690.34 150000 1128578
2012 5966546.7 -3570649 -379000 -5656.16 -69100 1942141.3 -55690.34 -150000 1736450.9 -607757.8 1128693.1 55690.34 150000 1334383.5
Table16.14: Cash Flow
* We assume that the cutting tools cost is 10 euros/part.
16.7. Period of Pay Back Pay Back Period is the important factor to define the worthiness of the business. We define the Pay Back point by observing the position the accumulate cash flow become 0. The data are shown in table16.15 and the diagram is shown in figure16.1.
Year Cash Flow Accumulate Cash Flow Period of Pay Back
Calculation of the period of Pay Back 0 1 2 3 4 -1873460 511167 717012.9 922818.5 1128578 -1873460 -1362293 -645280 277538.3 1406116 2 Years and 273 days ( 2.75 years )
Table16.15: The Period of Pay Back
5 1334383 2740500
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Period of Pay Back

3000000 Accumulate Cash Flow (euros) 2000000 1000000 0 -1000000 -2000000 -3000000 Year
Figure16.1: Diagram of the Period of Pay Back
1 0 1 2 3 4 5 6
As we see in figure16.1, the Pay Back is only 2.75 years. It means that the company will cover the expense after run the business 2.75 years and will start gaining the profit.
16.8. Calculation of Net Present Value ( NPV ) The calculation of NPV with the bank interest i = 4 % can be done by the following formula. The results of the calculation are shown in table16.16. NPV = Sum[ Cash flowt / (1 + i)^t ] Where: Cash flowt = Cash flow net of the year t (year) i = Bank Interest = 4 % t = Year ( from 0 to 5 ) (58)
Year Cash Flow Bank Interest (4%) NPV Total NPV
0 -1873460 0.04 -1873460
Calculation of NPV 1 2 3 511167 717012.9 922818.5 0.04 0.04 0.04 491506.7 662918.7 820382.3 2162826.663
4 1128578 0.04 964713.1
5 1334383 0.04 1096766
Table16.16: The results of the calculation of NPV
Page 146 16.9. Calculation of Internal Rate of Return (IRR) IRR is the important factor to indicate that the investment of this business is better or worse than put the money into the Bank. We will compare the value IRR with the bank interest i, if IRR is more than i, it means that the investment in this business is better. The way to define IRR is to use the formula in equation 58, let NPV = 0 then use cash flow from year 0 to 5 and find the value i that make the equation true by excel table. The result of the calculation is shown in table16.17.
Calculation of IRR Cash Flow i ( when NPV = 0 ) NPV IRR
0 -1873460
1 511167
2 3 717012.9 922818.5 0.3275 -0.6121 0.3275
4 1128578
5 1334383
Table16.17: The calculation of IRR
As we see in table16.17, the value of I that make NPV near to 0 is 0.3275 or 32.75 %, so it means that IRR = 32.75 %. When comparing IRR and bank interest ( i = 4% ), its clear that IRR >> i. With this confirmation, we can conclude that the investment in this business is much more profitable than keep money in the bank.
Page 147
17. Production Plant Layout and the Companys Location

17.1. Production Plant Layout: We start the design of plant layout by considering the area required for each machine, room etc. With these data, we could estimate the total area we need and start designing the layout. Table17.1 show the area required for every items.
Dimension of Machines Width Length Height (m) (m) (m) 1.397 2.337 1.753 1.778 1.702 2.159 1.2 1.75 1.55 1 1.8 2 1.4 2.15 1.85 1.5 1 1.8 0.8 0.8 0.5 Area Required (m2) 16.324 15.131 2.1 1.8 3.01 1.5 0.64 101 30 30 30 39 36 400 706.505
Object Lathe Machine Milling Machine Grinding Machine Broaching Machine Hobbing Machine Sensitive Press Disc Saw Office Store of Raw Material Product and Waste Store Assembly Area Maintenance Shop and Spare Part Store Toilet and Lockers Room Passage and Space (estimation) Total Area
Amounts 5 5 1 1 1 1 1
Table17.1: The estimation of the required area for production plant
We propose the layout of the production plant as shown in figure17.1. It was designed by considering the order of the machine to be used for each part. For example, shaft1 and 2 after we prepare the material with Saw, it will be machined by Lathe then Milling, Sensitive Press and Grinder. This method make the production be done smoothly and profitably. So Shaft1 and 2 will be machined by production line1; Casing, Clutch Fork, Sliding Part, Sealing Plate will be done by production line 6 and 7 ; Gear 1 and 2 can be done by production line 3 and 4 ; Pin and Washer2 will be machined by production line 5. There are also possibilities to changed the production line if necessary. The distance between each machine and the wall are set at 2.5 m. in order to have enough space for workers. The raw material store is located near the entrance door in order to be easily to receive and keep the raw material and it also locate near begin of the production line. The assembly area is located at the end of the production line and next to the product store as well. The part will be kept in the store and be loaded into the truck at the product loading area afterward as well as the waste store. Concerning to the security reason, 10 Fire Extinguishers ( Type Dry Chemical Powder ) are set around the production plant, stores and offices. Fire Extinguishers ( Type Dry Chemical Powder ) is suitable for all fire type ( type A, B and C). Type A is
Page 148 the fire from normal fuel like wood, clothe, paper, plastic and rubber. Type B is the fire from fuel gas or oil. Type C is the fire occurred with the electronic devices. Because we expect to have 10 more machines within 5 years due to the growth of the business, so we have to arrange more area since the beginning of this project. The area required in this case is around 350 400 m2.
Office
Waste Store
Product Loading Area Product Store
Locker Room
Assembly Area
Toilet Bath Room
Line7
Line6 Spare Part Store
Work Shop Raw Mat. Store
Line1
Line2
Line3
Line4
Line5
Note:
Figure17.1: Plant Layout is Fire Extinguishers ( Type Dry Chemical Powder )
17.2. The Companys Location: Because we are planning to locate the company in Spain, the suitable province can be Barcelona. Barcelona situate on the north-east of Spain and easily to communicate with Europe. Barcelona has many transportations possibilities Airport, Seaport, Lorry and Train ( see figure17.2, 17.3) The suitable location in Barcelona for the company should be in el Prat de Llobregat industrial area because this area locate near the main transportation both airport and sea port as well as the main road and train ( see figure17.3 ). We found that Calle Vila de Begur would be one of the decent street to locate the company ( see figure17.4 )
Page 149
Figure17.2: Map of Spain
Figure17.3: Map of Barcelona
Page 150
Figure17.4: El Prat de Llobregat Industrial Area, Barcelona
Figure17.5: Vila de Begur Street in el Prat de Llobregat Area
Page 151
18. Waste Management and Security Policy for the Workers

18.1. Waste Management Concerning to the companys responsibility for the social and environment, the company should provide the activities to deal with the industrial waste. The industrial waste of the company can be divided in 2 group, metal chips and coolant of the cutting process. The metal chips from the cutting process and the metal waste from the preparation of raw materials can be recycled and be able to sell. The wastes have to be collected separately depended on the type of material. The liquid waste from the coolant contains of soap and oil. The waste will be kept in the waste store and will be treated by external company afterward. Because of the small scale of the company, it will be more profitable to do the waste treatment with the external company instead of invest the treatment system itself. There are some companies in Spain and Europe who are able to do the waste treatment. The list of the companies is shown in the table18.1.
Company Sita
Parent and website
Home Country Suez FR www.sitagroup.com
Operates in countries Belgium, Czech Republic, Denmark, Finland, France, Germany, Hungary, Ireland, Italy, Luxembourg, Netherlands, Poland, Portugal, Romania, Spain, Sweden, Switzerland, UK Czech Republic, Denmark, France, Germany, Hungary, Ireland, Italy, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland, UK. Austria, Belgium, Czech Republic, France, Germany, Greece, Hungary, Italy, Luxembourg, Netherlands, Poland, Portugal, Slovakia, Spain, Switzerland, Turkey, UK France, Portugal, Spain, UK Austria, Estonia, Czech Republic, Germany, Poland, Switzerland, Poland, Ukraine UK (Cleanaway Germany sold to Sulo Group). Belgium, UK Bosnia, Germany, Poland
Empl oyees 45800
Sales million 5500
Onyx
Veolia FR www.onyxenvironnement.com/
71000
6200
Remondis
Remondis DE www.remondis.com
17100
3300
FCC Sulo/Altvater
FCC www.fcc.es Sulo www.altvaterumweltservice.de Brambles www.cleanaway.com Severn Trent www.biffa.co.uk/ Alba www.albaonline.de
ES DE
55000 8000
2090 1200
Cleanaway Biffa Alba
Australia UK DE
9973 5441 5000
>1300 >1050 >700
Page 152
Cespa Van Gansewinkel CNIM Befesa AVR AGR Ragn-Sells Lassila & Tikanoja Shanks ASA Ferrovial http://www.cespa.es ING/De Graekt www.vangansewinkel.c om/ CNIM www.cnim.com Abengoa http://www.befesa.es/ CVC (finance capital) www.avr.nl munic KVR Ruhr www.agr.de Ragn-Sells www.ragnsells.se Lassila & Tikanoja www.lassilatikanoja.com/ Shanks Group www.shanks.co.uk EdF (France) 100% www.asa-group.com www.saubermacher.at ES NL Portugal, Spain Belgium, Czech Republic, France, Poland, Portugal Czech Republic, France, Italy, UK Portugal, Russia, Spain, UK, Ukraine Belgium, Ireland, Netherlands Finland, Germany, Poland, UK Denmark, Estonia, Norway, Poland, Sweden Estonia, Finland, Latvia, Russia 33000 3500 >685 >500
FR ES NL DE SV FI
2764 1316 2500 2750 2200 5409
554 359 522 >400 325 337
UK AT
Belgium, Netherlands, UK Austria, Bosnia, Croatia, Czech Republic, Hungary, Poland, Slovakia Albania, Austria, Croatia, Czech Republic, Greece, Hungary, Slovenia Austria, Croatia, Czech Republic, Germany, Hungary, Poland, Romania France, Portugal, Spain, UK Belgium, France, Portugal Austria, Belgium, Germany, Greece, Poland, Portugal, Slovakia, Spain, Switzerland Austria, Czech Republic, Croatia, Slovenia, Hungary. Belgium, Czech Republic, France, Germany, Netherlands, Poland, Portugal Belgium, Czech Republic, Ireland, Italy, Lithuania, Netherlands, Poland, Portugal, Slovenia, Switzerland
4131 2486
>800 198
Saubermacher
1209
128
Becker
www.jakob-becker.de/
DE
1800
Dragados www.urbaser.es Groupe Nicollin www.groupenicollin.co m/ www.lobbe.de Lobbe Urbaser
ES FR DE
30000 4600 2,500
1050 230
Rumpold Essent
www.rumpold.at Provinces 74%, Munic 26% Munic (54%) www.indaver.be
AT NL
812
414
Indaver
824
211
Table18.1: The list of the waste management company in Spain and Europe [19]
Page 153 18.2. The Security Policy for the Workers According to the Industry Standard for Security ISO18000 and for the security for the workers themselves, the company should provide the policy to minimize the accident. The security policy are as follows: - During the working time, the workers must wear the safety uniform, compose of Safety Helmet, Glove, Safety Shoes, Protective Glasses. - Its forbidden to have long hair without elastic band to gather hair together. - Its forbidden to wear decorations like necklace, earring, ring etc. during working time. - Its forbidden to smoke, eat, drink in the manufacturing plant. - The workers must follow the working procedure of each job strictly.
Page 154
19. Conclusions
As the results of the project conducted and documented in this report and the annex, the following major conclusions were reached: - The operations of each part as well as the quality verifications have been stated. - The Documents: Phase of Manufacturing Cycle were accomplished. Furthermore, the form of this document is suitable and efficient for the real work ( see annex A ). - The Documents: Summary of Operation were done correctly and will be used as a supporting document ( see annex B ). - The specific model of machines were chosen as well as the amount of machines and workers. - The economic study of the project was analyzed and the good significant is shown because all the key economic indicators are good. - The production plant layout, the location for the company and The waste management and security policy were proposed. We can conclude that the setting-up of the production plant will be profitable according to the accomplished objective explained above.
Page 155
References: [1] Tecnologias de Fabricacion Teoria y Problemas , Joan Vivancos , Cayetano Sierra , Rafael Ferre , Joan R. Goma , Irene Buj , Rosa Rodrguez , Lluis Costa [2] Stellram Tooling Catalog http://www.stellram.com/Company/Library/default.asp?ID=7 [3] Kyocera Cutting Tool http://americas.kyocera.com/KICC/ceratip/catalog.html#milling [4] Garant Tooling Catalog [5] [6] Fabricacio Assitida per Ordinador , Joan Vivancos Calvet Procesos Mecanizado Volumen Texto , Joan Vivancos , Argiles Garcia , , Pardo Diaz , Sierra Alcolea Procesos Mecanizado Volumen Figuras , Joan Vivancos , Argiles Garcia , , Pardo Diaz , Sierra Alcolea Haas Automation Web Site, http://www.haascnc.com/lang/LATHE/details_LATHE.asp?ID=44662 &intLanguageCode=1033#SL CNC Masters Web Site http://www.cncmasters.com/CNC%20Supra%20Knee%20Mill.htm http://www.microkinetics.com/rotary8.htm Precision Machine Tool. Web Site http://www.indiamart.com/precisionmachtools/grindingmachines.html#hydraulic-universal-cylindrical-grinding-machine APM Pavia Co., Ltd. , b2bchinasources Web Site
http://www.b2bchinasources.com/showroom.php?c=6318&f=5&p=0000007521 [12] LIEBHERR Web Site, http://www.liebherr.com/gt/en/24063_24353.asp
[7]
[8]
[9]
[10]
[11]
[13]
Hangzhou Yangyang Machinery-Equipment Tools & Hardware Co., Ltd. , Alibaba Web Site http://hzyymy.en.alibaba.com/product/50357811/51342390/Cutting_Machine /Miter_ Saw__YY_131_004_.html Eitel Presses Inc Web Site, http://www.eitelpresses.com/rp.htm http://www.ine.es/inebase2/leer.jsp?L=1&divi=EIE&his=0
[14]
[15]
Page 156
[16]
http://www.insee.fr/en/ffc/chifcle_fiche.asp?ref_id=NATTEF11102&tab_id=175 http://www.destatis.de/basis/e/prohan/unternehmentab1.htm http://www.bfs.admin.ch/bfs/portal/fr/index/infothek/publ.Document.49244.pdf http://www.bfs.admin.ch/bfs/portal/fr/index/infothek/publ.html?publicationID=853 http://www.statistics.gov.uk/STATBASE/ssdataset.asp?vlnk=7070
[17]
Power Technology, Lecture Chapter 7: Electric Sector, Carme Pretel ( ETSEIB, UPC, Barcelona ) Steel Price List, http://www.southernsteel.com.au/pricelist.htm http://www.psiru.org/
[18] [19]

Manufacturing Process - Gearbox

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Manufacturing Process - Gearbox

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Master Thesis Erasmus Mundus Master of Mechanical Engineering

Author: Sarawut WONGTHIANCHAI Adviser: IRENE BUJ CORRAL

Escola Tcnica Superior dEnginyeria Industrial de Barcelona

Introduction of the Project

Objectives of the Project

Gear Box Overview

1. Marketing Study for Gear Box of Industrial Vehicle in Spain

Year 2001 2002 2003 2004 2005

Pexpect = 10% * Mgear = 0.1 * 75130 = 7513 units/year

Table1.2: Number of Company in 4 European Country, year 2004 [16]

The total expected production are shown in the following table :

Year 2008 2009 2010 2011 2012

In Spain (units/year) 7513 7513 7513 7513 7513

In Europe (units/year) 0 2623.25 5246.5 7869.75 10493

Total (units/year) 7513 10136.25 12759.5 15382.75 18006

Table1.3: Total expected production from year 2008-2012

2. Manufacturing Process of Shaft 1

Figure2.1: Operation of Phase10

Tool Data az(mm.) Zt(teeth) 0.015 60

Table2.1: Calculation data of Phase10

Figure2.2: Operation of Phase20 Step1

Table2.2: Class of surface rugosity [1]

Figure2.3: Operation of Phase20 Step2

n (rpm) 1308 1061

a(mm/turn) 0.045 0.06

Fc(N) 120 324

Pc(kW) 0.301 0.027

Pm (kW) 0.401 0.036

L (mm) 36.5 10.6

Va(mm/min) 58.267 63.662

tc(min) 0.626 0.167

Table2.3: Calculation data of Phase20

Figure2.4: Operation of Phase30 Step1

Figure2.5: Operation of Phase30 Step2

n (rpm) 1308 1061

a(mm/turn) 0.045 0.06 Va(mm/min) 58.267 63.662

Fc(N) 120 324

Pc(kW) 0.301 0.027

Pm (kW) 0.401 0.036

L (mm) 36.5 10.6

tc(min) 0.626 0.167

Table2.4: Calculation data of Phase30

Figure2.6: Operation of Phase40 Step1

Figure2.7: Operation of Phase40 Step2

Figure2.8: Operation of Phase40 Step3

Figure2.9: Operation of Phase40 Step4

Figure2.10: Operation of Phase40 Step5

rp(mm) 0.031 0.031

n (rpm) 1084 1393 1469 1432 2329

p(mm) 3 1.5 3 2.4 1.3

a(mm/turn) 0.5 0.045 0.1 0.1 0.1

Fc(N) 2700 120 540 432 234

Pm (kW) 9 0.481 2.16 1.728 0.936

L (mm) 954 222.3 3 9.695 0.7

Va(mm/min) 541.87 62.03 146.912 143.239 232.91

Table2.5: Calculation data of Phase40

Figure2.11: Operation of Phase50 Step1

Tool Size OD (mm.) ID (mm.)

Table2.6: Tool size data for gear shape tool [4]

Number of tool Number of teeth

8 more than 135

Table2.7: Number of tool data for gear shape tool [4]

Tool Data az(mm.) Zt(teeth) 0.015 25