Preparation of Process Drawings

20M103 - Akash V B
20M104 - Amruth M S
20M130 - Mukunth A G
20M131 - Muthunila B
20M154 - Vasanth R
20M155 - Vengatramanan R
21M416 - Raghunathan R
Introduction

● Process drawings are detailed illustrations of the part or product being

manufactured, including all dimensions, tolerances, and other requirements.
● They provide a step-by-step guide for the manufacturing process, including the
required tools and equipment.
● Process drawings ensure that the manufacturing process is carried out accurately
and efficiently, resulting in a high-quality end product
● Process drawings cannot be drawn without deciding upon the process sequence
Need for Process Drawings
A part contains multiple dimensions, where every
dimension needs a specified tolerance. But, when the
whole part is formed, each dimension’s error add up
resulting in an huge error.

To achieve the end part tolerance in only one fine

tolerance machine is not economically feasible,
Hence multiple machines are required.

For each machine/operator a unique process drawing

is presented to make it easy for them to concentrate
only on that part.
A Process drawing must contain -
1) Operation Number
2) Datum Planes
3) Type of Machine Tool and Cutting Tool
4) Highlighted tool movement
5) The Achievable feature tolerance of a machine in which the
operation is made
6) Minimum Stock removal per face
7) Mean Machine to Dimension values and their tolerances (from
tolerance chart)
Minimum Stock per Face

What is stock required per face?

For every subtractive machining process, some amount of extra material is needed to
machine from.

The less the accuracy of the machine tool the more amount of stock is required per face.

If very less stock is available, then the machine may not able to achieve the required
dimensions, possibly removing more material than intended.

If more stock is available, then it is not economical.

Hence, It is important to specify the appropriate amount of stock per face

Quantifying Stock Allowance
The appropriate level of stock allowance is almost always determined on a case-by-case
basis.

Planners must analyze the entire project from start to finish before any metal is cut, but
stock allowance also depends on a series of small decisions made over the course of the
project.

This is done systematically and efficiently using the tolerance charting technique.
The Dangers of Under-Budgeting Stock Allowance
Leaving too much extra material can be expensive, but failing to leave enough can be
even more costly to both schedules and budgets.

In some cases where stock allowance is insufficient, manufacturers will have to add
replacement material by welding, straightening the part or modifying the mating piece
to accommodate the deviation.

In the most severe cases, the part may not be usable at all, forcing the team to start all
over again, which comes with obvious implications for both cost and schedule.
Process sequence Example - End Capped Bearing Housing
CAD Visualization (As Cast Part)
Manufacturing Considerations
● the 100 mm and 50 mm bores cannot deviate from the nominal size

by more than 0.01 mm;

● the 100 mm diameter bore must also be perpendicular to the flange face

within 0.1 mm tolerance zone;

● the 100 mm and 50 mm bores must be machined to a surface finish of

0.1 um;

● the flange face and centreline of the 12 mm hole must be parallel to

each other to within a tolerance zone of 0.1 mm;

Manufacturing Considerations (contd)
● the flange face must be machined to a surface finish of 0.8 mm;

● the 12 mm hole must be perpendicular to the component centreline

within a 0.01 mm tolerance zone;

● all holes must have a surface finish of 1.6 um;

● all fillets are R7 unless otherwise stated;

● the general dimensional tolerance is 0.5 mm;

● the general surface finish is 12.5 mm.

Using the considerations, Machines are selected
The requirement says that one batch contains 350 parts, to produce this much quantity
and also considering the dimensional accuracy required, Investment casting is
selected.
Process selection using process tables
These are all the parameters that are required in process specifications.
Process table for foundry process
Operation sequence
Selection of process parameter for all operations
Finish Grinding
Desired Dimension = 100 +- 0.01mm

Finish Grinding = 100 +- 0.01mm

=> LL = 99.99, UL = 100.01,

Finish Grinding = 50 +- 0.01mm

=> LL = 49.99, UL = 50.01

Finish Boring
Stock per face for grinding = 0.02mm (4 times its tolerance)

Finish Boring (Stock = 0.02) =>

LL = Next operation Lower Limit - Stock to leave for next

operation - Tolerance of NC Lathe 2

UL = Next operation Lower Limit - Stock to leave for next

operation

LL = 99.99 - 0.02*2 - 0.05 = 99.90, UL = 99.99 - 0.02*2 = 99.95

Finish Boring (Stock = 0.02) =>

LL = 49.99 - 0.02*2 - 0.05 = 49.90, UL = 49.99 - 0.02*2 = 49.95

Rough Boring
Stock per face for finish boring = 0.2mm

Tolerance of Rough Boring machine = 0.1mm

Rough Boring (0.2) = 99.90 - 0.2*2 - 0.1, 99.90 - 0.2*2

LL = 99.5, UL = 99.6

Rough Boring (0.2) = 49.90 - 0.2*2 - 0.1, 49.90 - 0.2*2

LL = 49.5, UL = 49.6
Need for Revision of Process sequence
Let us consider the following process sequence with the tolerance chart drafted already,
Now it is important to check whether the this sequence will assure that the machined
dimensions match the blueprint dimension
Revision of Process sequence - Example (contd)
In tolerance chart, the tolerances of the final balance dimensions must not exceed the
tolerances given in blue print. If it exceeds, the process sequence must be revised.

All tolerances are within blue print tolerance

Line 42 tolerance exceeded the blue print tolerance

Thank You