MANUFACTURING PROCESS

ARTICLE
2018
By: Rino Andias Anugraha and Assistant Team
Telkom University

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 Manufacturing Process Laboratory Assistants 2018/2019

Audrey Rahmanti Unadi Aldyan Nurfaizi B. Tau

Aufa Rinaldo Alia Agistina
Dimas Fathurrahman Anak Agung Sri Nandini
Evita Rengganis Anggit Pratama
Fahreza Fadhil Hakeki Bagas Arganto P
Fildzah Fajrina Bela Pitria Hakim
FM Anggra Mandala Putra Damario Haznam
Husein Bimantoro Farras Burhanuddin
Lailatul Fitri Gitanjali Widayu Diatri
Nurul Farhana Mario Adiprana Muki
Maulidan Khoir Nafisha Herma Hanifha
Muhammad Ichsan Nurliyan Pangestu Rizky Purnama
Patricia Amelia Sabrina Diana Pratiwi
Putu Ayu Anggrasari Wirawardani Satria Rahmadani Putra
Raihan Muhammad Faizal Sri Yuzarnimar
Sarah Wahyuni Tri Maisyah Nugrah Samudro
Silmi Aprilia Andari Zakaria Gunada

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 Document
MANUFACTURING PROCESS LABORATORY
Number
Form
MODULE 1
Number
Valid 2018
Module Process Planning
Labwork Process Planning
Student Outcomes SO2. Able to apply mathematics, science and engineering principles to solve
complex engineering problems in integrated systems (including human,
material, equipment, energy, and information)
Learning Outcomes LO13. Students are understand the types of material formation processes,
machining and finishing along with the characteristics and usage in the
manufacturing industry
LO14. Students are able to make a process plan for a given product

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A. Tools and Requirements
Tools & Software Requirements
1. Personal Computer 1. Labwork of Module 1
2. Personal Gadget 2. Personal gadget with internet connection
3. Microsoft Excel 3. Stationary

B. References
Albert, R. (2002). The Powder Coaters Manual. Qualiteam International. .
Ceramics.(2018).NTK.CuttingTools:
http://www.ntkcuttingtools.com/product/insert_ceramics_index.html
Custompart.net. Milling: http://www.custompartnet.com/wu/milling
Degarmo, J. (2008). Material's and Process in Manufacturing.
Groover, M. (1998). Milling Machine Opeations 8th Edition. US: US ARMY WARRANT
OFFICER ADVANCED COURSE.
Groover. (2010). Fundamental of Modern Manufacturing Materials Process and Systems 4th
Edition. John Wiley and Sons Inc.
Housecroft CE, S. A. (2008). Inorganic Chemistry. Harlow: Prentice Hall.
J.BLACK. (2008). Degarmo's : Materials and Processes in Manufacturing 10th Edition.
America: John Wiley & Sons, Inc.
Laboratory, A. M. (2017). Modul praktikum proses manufaktur. Manufacturing Process
Laboratory.
Marinov, V. (2010). "Manufacturing Technology". Kendall Hunt Publishing Company.
Patil, A. (2006). A Case Study of Manufacturing Process Routing in a Medium Scale Industry
, 60.
SHOP., U. R.–M.–M. (2010). Standard Operating Procedures for Manual Milling Machines
Turning.(2018). custompart.net: http://www.custompartnet.com/wu/turning

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C. Labwork Steps
Flow Process Charts Process Description
1. Read the study case well. Because the study
START
case contained information that will be
carried out.
2. Read and understand the nine steps of the
Read The Study
Case
planning process to be carried out.
3. Do an overall shape of the part study. In this
step, use information in the case study to
Read And classify the parts and try to analyze the overall
Understand The shape of the product.
Entire Step Of
4. Thoroughly study the drawing. In this step,
The Process
Planning identify the drawing features of the drawing
thoroughly and use information to classify the
dimension part on this drawing.
Study Overall 5. Determine the best raw material to use. In this
Shape Of The Part step, select the best raw material based on the
characteristic of the product. Characteristic of
product has been written in the study case.
Thoroughly Study 6. Identify the datum surfaces. In this step use
The Drawing information on datum surfaces to determine
the setups. Determine absolute and
incremental coordinate.
Determine The
Best Raw
7. Select machines for each to use. In this step
Material To Use select the best compatible machines for each
setup. Try to analyze which operation is used
to make the product.
Identify The 8. Determine the rough sequence of operations.
Datum Surfaces In this step try to determine the rough
sequence of operations. Use the result from
the CAM process for information about the
Select Machines rough sequence of operations.
For Each To Use 9. Select tool for each operation. In this step
select tool for each operation to consider the
sequence operation. Use this information
Determine The
Rough Sequence
about cutting tool in process machining
Of Operations 10. Estimate the machining time. In this step
calculate the machining time using the result
from the previous calculation and the given
Select Tool For formulas.
Each Operation 11. Make a routing sheet. In this step Fill the
routing sheet based on the data from the
previous steps of the process planning.
Estimate The
Machining Time

Make A Routing
Sheet

END

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 MODULE 1
PROCESS PLANNING

1. OBJECTIVES

1.1 Students are able to understand about process planning.

1.2 Students are able to make a routing sheet based on the product.

2. OUTLINES

2.1 Introduction to Manufacturing Process

2.2 Introduction of Process Planning
2.3 Uses of Process Sheet
2.4 Advantage of Process Planning
2.5 Process Planning Step

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 3. BASIC THEORY

3.1 Introduction

The word “manufacture” is derived from two latin words, manus which means
hand, and factus which means made; the combination means made by hand.
Technologically, manufacturing is the application of physical and chemical processes to
alter the geometry, properties, and/or appearance of a given starting material to make parts
or products; manufacturing also includes assembly of multiple parts to make products. The
processes to accomplish manufacturing involve a combination of machinery, tools, power,
and manual labor. Manufacturing is almost always carried out as sequence of operations.
Each operation brings the material closer to desired final state.

Figure 1. 1 Manufacturing Process (J. Black, 2008)

Manufacturing adds value to the material by changing its shape or properties, or by

combining it with other materials that have been similarly altered.The material has been made
more valuable through the manufacturing operations performedon it. When iron ore is
converted into steel, value is added. When sand is transformed into glass, value is added. When
petroleum is refined into plastic, value is added. And when plastic is molded into the complex
geometry of a patio chair, it is made even more valuable. (Groover, 2010)

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 Manufacturing processes can be divided into two basic types, such as processing
operations and assembly operations.
a. A processing operation, transforms a work material from state of completion to a more
advanced state that is closer to the final desired product. It adds value by changing the
geometry, properties, or appearance of the starting material.
b. An assembly operation, joins two or more components in order to create a new entity,
called an assembly, subassembly, or some other term that refers to the joining process
(e.g., a welded assembly is called a weldment). A classification of manufacturing
processes is presented in Figure 1.2.

Figure 1. 2 Classification of Manufacturing Process (J. Black, 2008)

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 3.2 Introduction Process Planning

In manufacturing, the goal is to produce components that meet the design specifications.
The design specification ensures the functionality aspect. Next step to follow is to assemble
these components into final product. Process planning acts as a bridge between design and
manufacturing by translating design specification into manufacturing process detail. Hence, in
general, process planning is a production organization activity that transforms a product design
into a set of instruction (sequence, machine tool setup etc.) to manufacture machined part
economically and competitively. The information provided in design includes dimensional
specification (geometric shape and its feature) and technical specification (tolerance, surface
finish, etc.).
Process planning is called manufacturing planning, material processing, process
engineering and machine routing. Process planning can be defined as an act of preparing
processing documentation for the manufacturing of a piece, part or an assembly. Process
planning is the critical bridge between design and manufacturing. Design information can be
translated into manufacturing language only through process planning.
The manufacturing process selected must be an economical balance of materials,
manpower, product design, tooling, equipment, plant space, and many factors influencing cost
and practicality. The process must be selected in such a way that the produced product will be
acceptable to the consumer functionally, economically, and appearance wise.

Figure 1. 3 Process Planning (J. Black, 2008)

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3.3 The Function of Process Sheet

Below are the function of process sheet:

1. A process sheet is a document which contains a basis for all planning,
scheduling and other functions.
2. Process sheet is a tool that used in process planning for purchasing the raw
materials design and manufacture of special tools and devices.
3. Process sheet in process planning can be used in estimating the cost of the
product before it is manufactured.
4. It helps in planning for man power that required for a job.

3.4 Advantages of Process Planning

Below are the advantages of process planning:

1. It can reduce the required skilled planner.
2. It can reduce the process planning time.
3. It can reduce both process planning and manufacturing cost.
4. It can create more consistent plans.
5. It can produce more accurate plans.
6. It can increase productivity.

3.5 Process Planning Steps

Below are the steps of process planning:

1. Study the overall shape of the part
Use this information to classify the part and determine the type of workstation
needed. For example, design of wrench.

Figure 1. 4 Part Wrench

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2. Thoroughly study the drawing
Try to identify each of the manufacturing features and notes of the section image
and find the items and also know each part of the item to produce a product that
matches what will be made.
3. Determine the best raw material shape to use
If raw stock material is not given, determine the best raw material shape to use,
because material is important in manufacturing process. Raw material are
commonly used in the manufacturing, for example: aluminum has a good
formability, weldability, and corrosion resistance; cooper has characteristics higher
strength and excellent electrical conductivity; Steel has low carbon steel, poor
machinability but good formability and weldability. Material Selection Parameters:
a. Functional Requirements
The material is selected depends on the primary function of the product .The
properties of materials which have a direct relation on the functional
requirement of the part are: fatigue characteristics, strength, hardness,
electrical and thermal properties.
b. Reliability
Reliability of the materials is important for trouble-free maintenance of the
product during its life time.
c. Service Life Durability
The length of service (years or hours of operation of the product) over which
material is able to perform its function satisfactorily.
d. Aesthetics and Appearance
Factors like color, texture, smoothness and finish is determined the
aesthetics or appearance of the final product.
e. Environmental Factors
The proper material should be selected to help the product to survive from
the environmental factors such as temperature, humidity, corrosive
atmosphere which can affects the product and its performance.
f. Compatibility with other materials during service
When one type of material is used in combination with another type of
material in a product or in an assembly the properties of both types of
materials should be compatible and should suit each other.

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 g. Productability or Manufacturability
Machinability of materials for machined components is an important factor
to make sure the material can be processed easily and effectively.
h. Cost
Appropriate material for the product or component that will be selected
should consider the availability of that material and its cost.
4. Identify Datum Surfaces
Use information on datum surfaces to determine the setups. A datum point is
any point of known or assumed coordinates, which is used as a reference and from
which calculations or measurements may be taken. A datum point can be used as a
construction when modelling geometry. There are different types of datum points
that can be used, especially in modelling.
a. Absolute Coordinates
Absolute positioning is moving to a defined point. It is absolute because
it is a particular position from some point of reference known by the
machine, like a home position. If you give an absolute position, the machine
moves to that same point from wherever it is every time. Below this
paragraph, there is a picture that will help to understand to define absolute
coordinate system.

Figure 1. 5 Example of Absolute Coordinate Graph

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 Table 1. 1 Absolute Coordinate
Point X Y
Datum 0 0
A 20 -3
B 23 0
C 20 3
D -14 3
E -18 5
F -24 3
G -18 3
H -18 -2
I -24 -2
J -18 -5
K -14 -3
L 20 1
M 19 0
N 20 -1
O 21 0

b. Incremental Coordinates
Incremental coordinates are referenced from the previous point as thougt
the previous point has become a new origin. The reference point is
essentially moving with every new coordinate. Below this paragraph, there’s
a picture that will help to understand to define incremental coordinate
system.

Figure 1. 6 Incremental Coordinate

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 Table 1. 2 Incremental Coordinate
Point X Y
Datum 0 0
A 20 -3
B 3 3
C -3 3
D -34 0
E -4 2
F -6 -3
G 6 0
H 0 -4
I -6 0
J 6 -3
K 4 2
L 34 4
M -1 -1
N 1 -1
O 1 1

5. Select machines for each setup

There are many operations in process machining, such as:
Table 1. 3 Kind Of Machine
Machines Picture Explanation

Milling operations are operations in

which the cutting tool rotates to bring
cutting edges to bear against the
Milling workpiece. Milling machines are the
principal machine tool used in milling.
There are two type feed process of
milling.

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 Table 1. 4 Kind Of Machine (cont.)
Machines Picture Explanation

Turning operations are operations that

rotate the workpiece as the primary
Turning method of moving metal against the
cutting tool. Lathes are the principal
machine tool used in turning.

Drilling operations are operations in

which holes are produced or refined by
bringing a rotating cutter with cutting
Drilling edges at the lower extremity into contact
with the workpiece. Drilling operations
are done primarily in drill presses but
sometimes on lathes or mills.

6. For each setup determine the rough sequence of operations necessary to

create all the features.
Table 1. 5 Kind of Operation
Operation Picture Explanation

Facing is an operation of machining the ends

Facing of a workpiece to produce a flat surface square
with axis.

Pocketing is an operation to remove material

Pocketing from interior of a closed geometry. In
Mastercam, it’s called Contour.

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 Table 1. 6 Kind of Operation (cont.)
Operation Picture Explanation

Profiling is an operation to remove material

Profiling
from interior of an opened geometry.

Slotting is used for cutting in, shaving, and has

Slotting an angle, or doing surfaces that are difficult to
reach.

Drilling enables to perform drills and other

Drilling
canned drill cycles.

Threading enables to make a screw thread .

Threading
usually threading can be use after drilling.

Finishing is the last step of process plan for

Finishing making a part. In this process, the part will be
done of finishing process.

7. Select tools for each operation

Try to use the same tool for several operations if it is possible. Keep in mind the
trade off on tool change time and estimated machining time. Some of tools that
usually used in manufacturing process.

Table 1. 7 Cutting Tools

Tools Explanation Picture

This type of tool is usually used for facing

Face Mill
surfaces.

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 Table 1. 8 Cutting Tools (cont.)
Tools Explanation Picture

Endmill makes a plane of a material in

the right-and left direction or a plane of
End Mill a bottom side of the end mill. We can
make various shapes of mechanical parts
with the end mill.

This type of knife has a blunt and

Ball Nose
rounded end. This knife is usually used
Mill
for a smooth surface finishing

Drill This type of tool are used to make a hole

This type of tool are used to create thread

Thread Mill
in or on the workpiece

Table 1. 9 Cutting Tools Material

Tool Material Picture Explanation

The carbon content is 0.6-1.5 % with small

quantities of silicon, chromium, manganese, and
Carbon Steel
vanadium to refine grain size. This material has
low wear resistance and low hot hardness. The
use of these materials now is very limited.

High-speed Steel is a high alloy steel tool

that is able to maintain its hardness at high
High-Speed
temperatures. High-speed Steel is a high
Steel (HSS)
alloy steel tool that is able to maintain its
hardness at high temperatures.

These are the most important tool materials

Cemented today because of their high hot hardness and
Carbides wear resistance. The main disadvantage of
cemented carbides in their low toughness.

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 Table 1. 10 Cutting Tools Material (cont.)
Tool Material Picture Explanation
Ceramic materials are compounds of
metallic and nonmetallic elements (often in
the form of oxides, carbides, and nitrides)
Ceramics and exist in a wide variety of compositions
and forms.the characteristic high wear
resistance but low toughness. (Degarmo,
2008)

Diamond is the hardest substance ever

known of all materials. It is used as a coating
Cubic Boron
material in its polycrystalline form, or as a
Nitride (CBN)
single crystal diamond tool for special
and syntetic
applications, such as mirror finishing of non-
diamonds
ferrous materials. Next to diamond,
CBN is the hardest tool material.

The cutting tool materials must process a number of important properties to

avoid excessive wear, fracture failure and high temperatures in cutting.
8. Select or design fixtures for each setup.
Fixture is a device for locating, holding and supporting a workpiece during a
manufacturing operation. It is a production tool that locates, holds, and supports the
work securely so the required machining operations can be performed.
9. Estimate the machining time.
Calculate the machining time for an operation is an important aspect in the
manufacturing process Machining time is the total amount of time it take to finish
processing a part.

Feed Rate (Vf) Cutting Speed (Cs)

𝑉𝑓 = 𝑓. 𝑛 (mm/minute) 𝐶𝑠 = π. 𝑑. 𝑛 (m/minute)
Which are: Which are:
𝑉𝑓 = Feed Rate (mm/minute) 𝐶𝑠 = Cutting Speed (m/minute)
𝑓 = feed per rev (mm/rev) 𝑑 = Diameter of Cutter (mm)
𝑛 = Spindle Speed (rpm) 𝑛 = Spindle Speed (rpm)
π = Constanta (3,14)

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 Table 1. 7 Information
Operation Information

λ Facing = 15.2471 mm
Facing d = 100 mm
n = 1100 rpm

λ Profiling = 176.352 mm
Profiling d = 10 mm
n = 1100 rpm

λ drilling = 14.5 mm
d = 4 mm
Drilling
n = 1000 rpm
Vf = 100 mm/minute

λ threading = 8.35 mm
Threading d = 6 mm
n = 100 rpm

λ Pocketing = 69.806 mm
Pocketing d = 4 mm
n = 1100 rpm

fz = 0.167 mm/tooth
Additional Z = 4 flutes
i=4

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 Table 1. 8 Machining Process Formulas
Machining Process Formula

Which are:
𝜆.𝑖
t=𝑉 t = Machining Time (minute)
𝑓
Milling 𝜆 = feed length
i = amount of feed
Vf = Feed rate (mm/minute)

(0.3𝑑)+𝑙 Which are:

t= t= Machining Time (minute)
𝑉𝑓
Drilling ℓ = Depth of workpiece (mm)
d = Diameter of tools (mm)
Vf = Feed rate (mm/minute)

278 𝑥 𝐷
Which are:
Threading t= T = Machining Time (second)
𝑉𝑓𝑑
D = Thread Diameter (mm)
𝑉𝑓𝐷 = Feed at thread diameter Ø (mm/min)

Which are:
Ns = Spindle speed (rpm)
12𝑉 Fr = Depth of Cut
Turning 𝑁𝑠 = V = Cutting Speed (feed per minute)
𝜋𝐷𝑡
𝐿+𝐴𝑙𝑙 Dt = Diameter of Workpiece (mm)
𝑉𝑓 = 𝐹 T = Machining Time (minute)
𝑟 𝑥 𝑁𝑠
L = Length of Workpiece (mm)
All = Allowance (mm)

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10. Prepare the final process plan document. Make a routing sheet.
Here are the examples of blank and filled routing sheet :
Table 1. 9 Blank Routing Sheet

Table 1. 10 Filled Routing Sheet

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 4. REFERENCES

nc
Albert, R. (2002). The Powder Coaters Manual. Qualiteam International. .
Ceramics.(2018).NTK.CuttingTools:
http://www.ntkcuttingtools.com/product/insert_ceramics_index.html
Custompart.net. Milling: http://www.custompartnet.com/wu/milling
Degarmo, J. (2008). Material's and Process in Manufacturing.
Groover. (2010). Fundamental of Modern Manufacturing Materials Process and Systems 4th
Edition. John Wiley and Sons Inc.
Laboratory, A. M. (2017). Modul praktikum proses manufaktur. Manufacturing Process
Laboratory.
Patil, A. (2006). A Case Study of Manufacturing Process Routing in a Medium Scale Industry
, 60.
Turning.(2018). custompart.net: http://www.custompartnet.com/wu/turning

23