Complete the procedure of making a workpiece with a proper shape from blank metal and drilling on it to make the required workpiece.

1. Technological documents
for Mechanical Processing Process Plan
Name Nafiz Ahmed
Student number 2019905504
Class 2019
Major Mechanical Design
Tutor Zengnmin Shi
College of Mechanical & Power engineering of Three Gorges University
Date 30/09/2022

3. CONTENTS
Abstract …………………………………………………………………………………………………………………1
Process Document…………………………………………………………………………………………………2
1 Structural processability analysis…………………………………………………………………
2 Operation steps and setups …………………………………………………………………………
3 Technical economic analysis…………………………………………………………………………
Process Sheet …………………………………………………………………………………………………………

4. Process planning document of a drilling jig
Designer name：
Abstract:
We have discussed the components of the drilling rig, now let’s discuss the drilling process
itself. An oil or gas well is drilled in a very ordered sequence. The steps in this sequence are
almost universally applied to the drilling of all wells.
Requirement of a Drill Jig
Quick and accurate location of the workpiece. Easy loading and unloading of the workpiece.
Prevention of wrong loading. Prevention of bending or movement of the workpiece during the
drilling operation. Ample chip clearance. Facility for swarf removal and cleaning. Lightweight
to minimize operator fatigue. Prevention of loss of parts by using chains. Clearance for
overshoot of the drill.
Task:
The final dimension of the drilling jig and dimension tolerance： Part Drawing
I choose “A4”
mm
mm
mm
mm
mm

5. Process planning document
1 Structural processability analysis：
Analysis and review of the structural processability of parts
According to the processed workpiece material. contour shape. machining accuracy. etc. Select
the appropriate machine tool. develop a processing program. determine the processing order
of the parts. each process used tools. fixtures and cutting dosage. etc.
2 Determination of the blank：
We need to use a mold folding process to make this metal.
Mold Forging: Forging is the repeated deformation of heated solid metal to refine the grain
structure and improve part strength without adversely affecting the material’s ductility. Forging
produces the strongest metals used in industry today. Forging is used for both low and high-
volume part production.
Use a tiny metal in the middle of the blank metal and press with a hydraulic hammer to make
a hole in the middle of the blank metal.
3 Process design：
3.1 Selecting the positioning datum
The positioning datum of the inner hole and outer circle should be parallel and perpendicular
to the face. Two faces should be parallel, and the hole should be centered.
3.2 Principle of the process planning for the outer surface：
① Selection of the processing equipment and tooling:
By using the turning process, we can get a proper shape of our model. Turning is a machining process
in which a cutting tool is. We need to use two cutting processes Rough and finish cut.
Rough cut Finish cut
Higher feed rate Low feed rate
Higher depth of cut Low depth of cut
Higher chip load on the cutter Lower chip load on the cutter
The higher stock removal rate The low materials removal rate
Poor surface finish Good surface finish
Poor dimension accuracy Higher dimensional accuracy
Poor tolerance Close tolerance

6. ② Determination of the machining allowance
—We need to remove some parts from blank materials. We will remove around 5mm from blank
metal by using Roughing and finishing process.
③ Determination of the cutting parameters
The cutting parameters chosen were cutting speed, feed rate, and depth of cut.
Roughing high Feed Vc = 160, Vf = 6112, ap = 0.18
Pre-finishing Ground Vc=150, Vf= 1585, ap= 0.15
Finishing Vc= 200, Vf = 1950, ap = 0.12
Super finishing Vc = 240, Vf = 1765, ap = 0.03
3.3 Principle of the process planning for the two end faces:
① Selection of the processing equipment and tooling:
The milling process is appropriate for making two end faces plane. Milling is performed
primarily to generate a flat surface. Milling is carried out in a milling machine. The milling
process utilizes a multi-point cutting tool, called a milling cutter. In milling, the tooth
continuously engages and disengages during operation (intermittent cutting). Here the cutting
is rotated at a fixed revolution per minute (RPM). Rotating the cutter provides the necessary
cutting velocity. In milling, feed motion is derived by moving the workpiece.
② Determination of the machining allowance
We need to remove some parts from blank materials and keep the height to 14mm. We will
remove around 5mm from blank metal by using the milling process.
③ Determination of the cutting parameters
The cutting parameters chosen were cutting speed, feed rate, and depth of cut.
Roughing high Feed Vc = 160, Vf = 6112, ap = 0.18
Pre-finishing Ground Vc=150, Vf= 1585, ap= 0.15
Finishing Vc= 200, Vf = 1950, ap = 0.12
Super finishing Vc = 240, Vf = 1765, ap = 0.03

7. 3.4 Principle of the process planning for the center hole
① Selection of the processing equipment and tooling:
The boring cutting process is appropriate for a cutting large hole.
We will use a boring tool to cut extra metal from blank metal to
give the actual shape
② Determination of the machining allowance
We need to remove some parts from blank materials and keep the inner hole diameter to
⌀56mm. We will remove around 2.5mm from blank metal by using the Boring process.
③Determination of the cutting parameters
3.5 Principle of the process planning for the four holes:
① Selection of the processing equipment and tooling:
We need to drill 4 holes in the workpiece. First, we need a drill that is a
smaller diameter than the actual hole after that we need Carbide Reamers
to make the diameter 7.5 mm, and then we use a hand reamer to give it
the finishing touch.
② Determination of the machining allowance
After making the first small hole we need to drill with ⌀6.8mm Drill bit and the distance
of the 4 holes should be 42.5mm from the center of the workpiece after that machine
reaming and give a finishing touch with hand reaming.
③ Determination of the cutting parameters
First Cutting speed 900m/min. Feed rate 0.017mm/rev, Diameter of drill 8mm, MRR
768.978mm3/min
Second, Cutting speed 900m/min, Feed rate 0.017mm/rev, Diameter of Drill 10mm, MRR
1602.012mm3/min.

8. 3.6 Analysis of the green blank:
Considering the processing allowance from the analysis, the dimension of the green blank is
as followed:
A= 123mm
B= 85mm
C= 51mm
D= 19mm
E= 0
The density of low carbon steel is about ρ=7.9g/cm3
, and then the calculated weight of the
green product is as followed:
W0= ρ×V0= 7.99g/cm3
× V0=0.0079g/mm3
× (πR2
×H-πr2
×H)=0.0079×{3.1416(59)2
×14-
3.1416× (28)2
×14}
= 937.1022
The weight of the product:
W= ρ×V= ρ×(πR2
×H-πr1
2
×H - 4πr2
2
×H) = ρ×[π×H{(59)2
-(28)2
-4(3.75)2
}]
= ρ×π×36970.5 = 917557.53= ρ×116146.523=917.56
Then the metal removal is about:
W' = W0–W= 937.1022 – 917.56 = 19.5422
4 Operation steps and setups
4.1 The process of the product machining
Forging: Forging is a manufacturing process involving the shaping of metal through
hammering, pressing, or rolling. These compressive forces are delivered with a hammer or die.
Forging is often categorized according to the temperature at which it is performed—cold, warm,
or hot forging. A wide range of metals can be forged.
Drilling Process: The tool creates or refines round holes in a workpiece. This is usually done
through a rotary tool with two or four helical cutting edges
Milling Process: This type of tool creates designs by removing material from the working piece
by rotating a cutting tool
4.2 Analysis of the operation position:
① To machine the finished datum surfaces in advance:
then it acts as the location datum.
② To perform the rough machining first, then the finished
machining.
③ To arrange major surfaces, then minor surfaces;
④ Machining plane is in advance of hole making.
4.3 Operation steps and setups:

9. Firstly, we heat our workpiece and by using the mold forging process we give a blank shape to
our workpiece and make a hole center of our workpiece. After that, we use the Turning and
Finishing process and give our workpiece a clear and proper outer surface.
After that, we use the Milling process to give our workpiece a perfect shape and keep the height
14mm. After finishing this process, we use a Boring process to create our workpiece’s inner
hole diameter of 56mm. after that, we did our final process and its drilling process. We make
four holes in our workpiece and keep the same diameter of four holes.
5 Technical economic analysis
Any blast-furnace department attempts to reduce production costs to increase its profitability
and reduce manufacturing costs. This is accomplished by reducing individual components
of those costs through some actions aimed at intensifying the process in question
1. CHARGE COSTS: A substantial reduction of charge costs is not possible, as the charge must
be appropriately prepared and must contain such an iron content as to make its processing cost-
effective. A lower price may entail lower quality which, in turn, might cause higher fuel costs,
which would counterbalance the savings. However, it is possible to reduce this cost to some
extent by using recycled materials.
2. FUEL COSTS: The reduction of iron production costs can most easily be achieved by
reducing fuel expenditures, primarily on stabilized coke, which is very expensive. Reduction
of fuel costs can be achieved through increasing the charge richness, using properly prepared
charge in the form of sinter or pellets, utilizing recycled materials, eliminating crude flux from
the charge, using fine equivalents for stabilized coke; using other substitute fuels, such as
natural gas, oil, coal dust, or plastics; improving the distribution of charge in the blast furnace,
changing the blast parameters (by using hot oxygen-enriched blast and introducing substitution
fuels with it), and increasing pressure in the blast furnace throat.
3. PROCESSING COSTS: The substantial reduction of these costs is rather not possible,
because their components constitute fixed costs, including, but not limited to amortization, the
costs of maintaining auxiliary departments, or the costs of repairs.
One of the basic elements of analysis of the influence of process running factors on the costs
is the technical and economic analysis of the process. In the case of the blast-furnace process,
it is necessary to continuously monitor the basic process indices defining the main production
factors' consumption and the process's productivity.