Process Planning and Cost Estimation Practical detail syllabus for Production Engineering (110), M scheme is taken from TNDTE official website and presented for diploma students. The course code (32588), and for exam duration, Teaching Hr/week, Practical Hr/week, Total Marks, internal marks, theory marks, duration and credits do visit complete sem subjects post given below.
For all other production 6th sem syllabus for diploma m scheme tndte you can visit Production 6th Sem Syllabus for Diploma M Scheme TNDTE Subjects. For all other Elective Practical II subjects do refer to Elective Practical II. The detail syllabus for process planning and cost estimation practical is as follows.
Rationale:
Process planning bridges the design and manufacturing activities. This subject aims to provide basics to prepare process plan for various components of an assembly in an effective way. It also exposes the students to the area costing, an important field in any engineering discipline.
Objectives:
At the end of the study of VI Semester the student will be able to
- Prepare process plan which would be helpful to carryout the process in least time.
- Automate the processes involved in the manufacturing.
- Group the components to achieve manufacturing excellence.
- Work out the cost of producing a product.
Exercises
- Consider the simple component illustrated in Fig.1. An analysis of the geometry, based on the matrix in Fig.2, indicates that this type of component would be produced by milling the slots and drilling the holes. The production of both the slots and the holes can be carried out on a milling machine. Therefore, determine the sequence of operations to produce these features on a milling machine if the billet is 200mm x 120mm x 65mm.
- For the component shown below, determine what tooling would be required to turn it. The brass billet is represented by the rectangle that is 100mm x Dia.20mm. Therefore, the material to be removed is the shaded area in both Fig.3&4. The part is to be turned on a small bench lathe. To produce this part four distinct operations have been identified as detailed below. Identify the tooling required to produce this part.
- Consider the component in Fig.5. The component is to be made from mild steel with carbide tooling at a constant surface speed of 100 m/min on a lathe with a maximum spindle speed of 1500 rpm. The machining allowance is 2mm. Determine the total machining time for the component if the lathe is capable.
- A semi automatic turret lathe costs. Rs. 80000 and it produces 16 pieces per hour and its operator receives Rs 2 per hour. An engine lathe which costs Rs. 32000 produces to pieces per hour and its operator receives Rs 2,50 per hour. Calculate the minimum number of pieces which makes turret lathe more economical.
- The aircraft flap nose rib can be produced either by hydropress or by steel draw die. The following data is available for Total number of parts to be produced per single run (Nt) = 500 Unit tool process-a cost Pa = Rs 8,40 and Unit tool process-b cost (Pb) = Rs 14,80; Total tool cost for process-a (Ta) = Rs 6480,00 and Total tool cost for process-b (Tb) =Rs.1616,00. Determine the quantity of production at break even point’ and tool unit cost for method a’ and method b’
- The following Fig.6 shows a lathe stock. Estimate the weight and cost of material if C.I. weighs 7,787 gm/cc and material cost is 60 per kg.
- A hexagonal bolt with a finished diameter of 25mm, shank length 110mm and bolt head height of 25mm is to be forged. What would be the size of the stock and its length, if forging loss is 3%? Find the total length of stock for 300 bolts, if scrap loss is 4%.
- Estimate the material cost for welding two flat pieces of ms 15cm*6cm*1cm size at an angle of 90 by gas welding. Neglect preparation cost and assume cost of O2 is Rs.60/m3, cost of C2H2 is Rs.350/m3 and cost filler metal is Rs.75/kg.
- Cost of filler material = Rs. 35/kg
- Cost of oxygen = Rs. 400 per 100 cu.m
- Cost of acetylene = Rs. 4000 per 100 cu.m
- Consumption of oxygen = 0,8 cu.m
- Consumption of acetylene = 0,8/cu. m
- Diameter of filler rod = 4mm
- Density of filler material = 7,3 gm/cc
- Filler rod used/m of weld = 350 cm and Speed of welding = 2,5 m/hr
- Figure 10 shows a cast bevel gear blank made up of mild steel. Find the weight and cost of material required for it. Assume the density of mild steel=7 85 gm/cc and its cost as Rs.60/kg.
- Estimate the weight and cost of the mild steel casting as shown
- A mild steel bar 100mm long and 40mm in diameter is turned to 38mm diameter and was again turned to a diameter of 35mm over a length of 40mm as shown in Figure 12 The bar was chamfered at both the ends to give a chamfer of 45*5mm after facing. Calculate the machining time. Assume cutting speed of 60m/min and feed 0 4mm/rev. The depth of cut is not to exceed 3mm in any operation.
- Find the machining time to finish the job as shown in Figure 13 from a 45mm diameter and 95mm long raw material.
- Estimate the cost of manufacturing high carbon steel spanner as shown in Figure 14 is to be made by die forging. The following data are available:
- Batch size = 500 pieces
- Die cost per batch = Rs.1500
- Stock cutting charges = Rs.25 per batch
- Set-up and machine operation cost = Rs.375 per batch
- Labour charges = Rs.150 per batch
- Density of steel = 8 5gm/cc
- Cost of high carbon steel = Rs.400 per kg.
Assume
V’ for turning = 30 m/min; V’ for thread cutting = 10 mm/min
f’ for turning = 0 35 mm/rev; Depth of cut = 1 25mm
V’ for drilling = 30 m/min; f’ for chamfering = 0 25 mm/rev
f’ for drilling = 0 1 mm/rev
Assume suitable allowances for calculating the weight of the component.
Board Examination
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For detail syllabus of all other subjects of BE Production, M scheme do visit Production 6 syllabus for M Scheme.
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