UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DEVELOPMENT OF INTERACTIVE MACHINING PROCESS
DESIGN AND MACHINING TIME CALCULATION
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Management) with Honours.
By
MOHAMAD IZWAN BIN ISHAK
UTeM Library (Pind.1/2005)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap:
No 28, Jalan Kejayaan 44, Taman Universiti, 81300, skudai, Johor
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
BORANG PENGESAHAN STATUS TESIS*
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUDUL: Development of interactive machining process design and machining time calculation
SESI PENGAJIAN: 2009-2010
Saya _____________________________________________________________________
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
Mohamad Izwan Bin Ishak
DECLARATION
I hereby declare that this report entitled “Development of interactive machining process design and machining time calculation” is the result of my own research except as cited
in the references.
Signature :
Author’s name : Mohamad Izwan Bin Ishak
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Management). The members of the supervisory committee are as follow:
i
ABSTRACT
ii
ABSTRAK
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ACKNOWLEDGMENT
In name of Allah S.W.T the most Merciful and the most Beneficent. It is with the deepest senses gratitude of the almighty that give me strength and ability to complete this project.
First of all, I would like to take this opportunity to express my deepest gratitude to Mr. Hj. Abdul Rahman Bin Mahmood, the lecturer and supervisor for my project for the guidances while I am conducting my project and provide me with the material, ideas and suggestion in improving the contents of my project.
Not forgotten also to all my friends and colleagues that had been a great help for me to complete my project properly and to Mr. Joizudin, Hicom-Engineering plant manager for giving me an opportunity to conduct my project at his company.
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2.2 Machining time and cost calculation 9
2.2.2 Machining time calculation 10
2.2.2.1Fixed time elements 10
2.2.2.2Piece related element 11
2.2.3 Cost calculation and estimation 14
2.2.2.1Machining cost 15
2.2.2.2Material and tool cost 16
2.2.2.3Factory overhead 16
2.2.2.4Labor cost. 16
2.2.2.5 Machine amortization 17
2.3 Microsoft Office 17
2.3.1 Microsoft Office Excel 17
2.4 Machining time and cost estimation system 18
3. METHODOLOGY 20
3.1 Identify project title 23
3.2 Project details discussion 23
3.3 Literature review 23
3.4 Define the problem statement, objective, and scope. 24
3.5 Information collection 24
3.5.1 Interviews 24
3.5.2 Observation 25
3.6 Methodology 25
3.7 Software development 25
3.7.1 Analyze current method to calculate the machining time and cost 26
3.7.2 Sorting the relevant element and data input for the software 26 3.7.3 Translate the relevant element and data to Microsoft Excel 2007
(Databases) 26
3.7.4 Develop the software 26
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3.7.6 Result comparison 27
3.8 Completing report and submission 28
4. DEVELOPMENT PROCESS 29
4.1 Software Introduction 29
4.2 Create the main and database sheet 30
4.3 Create machining process sheet 35
4.3.1 Turning process sheet 35
4.3.2 Facing process sheet 37
4.3.3 Drilling process sheet 38
4.3.4 Parting process sheet 39
4.3.5 Boring process sheet 41
4.3.6 Grooving process sheet 42
4.2.7 Threading process sheet 42
4.3 Conditional formatting 44
4.4 Sheet duplication 45
4.5 Cost calculation sheet 45
4.6 Change background colour and add hyperlink 46
4.7 Data and formulation protection development 47
5. RESULT AND ANALYSIS
5.1 Main menu worksheet 49
5.2 Machining process worksheet 50
5.3 Cost calculation worksheet 51
5.4 Testing and verification 52
5.4.1 First test (first example) 52
5.4.2 Second test (second example) 57
5.6 Questionnaire and Comparison analysis 61
6. CONCLUSION AND RECOMMENDATION 63
6.1Conclusion 63
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REFERENCES 65
APPENDICES
A Gantt charts (PSM1 and PSM2) B Questionnaire
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LIST OF TABLES
4.1 No of sheet 29
4.2 Databases cell command 34
4.3 Turning cell command 36
4.4 Facing cell command 37
4.5 Drilling cell command 39
4.6 Parting cell command 40
4.7 Threading cell command 43
5.1 Questionnaire average score 61
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LIST OF FIGURES
2.1 Depth of cut and feed illustrated for turning operation 13
3.1 Flowchart of the project 21
3.2 Flowchart for development of the software 22
4.1 Main sheet illustrations 31
4.2 Combo box properties and hidden cell 31
4.3 Hidden process design table 32
4.4 Hidden table for processes machining time, process no and tool used 33
4.5 Databases sheet 34
4.6 Turning sheet 35
4.7 Combo box properties and turning sheet hidden cell 36
4.8 Facing process sheets 38
4.9 Drilling operation sheet 38
4.10 Drilling hidden cells 38
4.11 Parting process sheet 39
4.12 Boring operation sheet 41
4.13 Grooving process sheet 42
4.14 Threading process sheet 43
4.15 Threading process sheet hidden cell 43
4.16 Combo box for threading process 44
4.17 Conditional formatting 44
4.18 Cost calculation sheet 45
4.19 Background colour change 46
4.20 Add hyperlinks to system 46
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5.1 Main menu worksheet 49
5.2 Example of machining process sheet (Turning) 50
5.3 Cost calculation worksheet 51
5.4 Stock dimension (Creese, Robert C,1992) 52
5.5 Process design table 53
5.6 First cut parameter 53
5.7 Process design table change 54
5.8 First two pass process parameter 54
5.9 Last two pass parameter 55
5.10 Machining time result 56
5.11 example 2 illustration (M. Adithan, 2007) 56
5.12 Process design for example 2 57
5.13 First process parameter 57
5.14 Second process parameters 58
5.15 Threading process parameters 58
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LIST ABBREVIATIONS
CNC - Computer numerical control Dia - Diameter
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CHAPTER 1
INTRODUCTION
Chapter 1 will give a brief explanation about this project, starting with the background of the project title, “Development of interactive machining process design and machining time calculation”. This chapter will also discuss about the problem statement, the objectives and the scope and limitation for this project.
1.1 Background
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after a machining process plan is built. In machining processes, machines, processes, cutting tools and operation sequences are needed to make a process plan. There are many method can be used to calculate the machining time and cost before the production of the certain product started. Normally people calculate the machining time manually and referring to the standard, handbook, and machine manual before starting the production. This project will be made base on the purpose to make the work to calculate the machining time and cost easier for the production planning.
1.2 Problem statement
Machining time and cost calculation for machining process using conventional way is a difficult method to determine the machining time and cost and can be considered as a time consuming. Nowadays, the machining time and cost is calculated using conventional way and sometimes the machining time and cost are estimated based on the experience and not calculated properly. The problems to calculate the machining time and cost using conventional method are;
(1) Time consuming.
(2) There are only few people know the method of calculating the machining time and machining cost that result to the estimation of the machining time and machining cost that are not so accurate.
(3) Since calculating the machining time and machining cost require a lot of reference such as standard, manual, and handbook, it makes this work very troublesome and tedious. The purpose of this research and development is to introduce user friendly software using interactive way of calculating the machining time and machining cost.
3 1.3 Objectives
Based on the title “Development of interactive machining process design and machining time calculation”, the objectives to be achieved at the end of this project are as below;
(1) To study the conventional method used to calculate machining time and cost (2) To develop a user friendly excel-based software using interactive way to
calculate the machining time and machining cost.
(3) To compare between the conventional method of calculating the machining time and cost with the software made.
1.4 Scope and limitation
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CHAPTER 2
LITERATURE REVIEW
This chapter will explained about all the elements used for this report. First explanation will come to the machines, processes, cutting tools and operation sequences for lathe machine in order to know the element used to calculate the machining time and cost. After that, the conventional method to calculate the machining time and cost is explained. The computerized system is also explained in this chapter.
2.1 CNC Lathe Machining
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introduced into machining industry that brought along an effect of greatly reducing the times for tool positioning and movements between cuts. These new CNC design had been designed base directly to the development of numerically controlled (NC) machine tools from 1950s. In CNC machining tools, all the motions are mechanically separated and each different motion are driven by their own motor and coordinated electronically that allow more complicated feed motion can be done. As year 1970 come, the CNC lathe machine has more precise numerical control of feed motion, along with reduction of set-up time than can approximately halving the machine tools non-productive cycle times. In around 1980s, the reduction of non-productive cycle time for lathe machine had becoming more intense as the spread throughout all manufacturing industries of new types of machine tools that have become called turning centers. Nowadays, the manufacturing industries has been equipped with either manually controlled or CNC lathes for their production. The reason why CNC lathe machine had been used widely in manufacturing machining industry is because of the versatility that is the automatic tool changer. The automatic tool changer of lathe machine can change the tools between different machining operations without any user intervention. With this key of versatility, several machining operations can be executed in a single work piece setup. CNC lathe if classified according the axis of rotation can be divided into horizontal CNC lathe and vertical CNC lathe. For this study, it will focus on horizontal CNC lathe however this software is also applicable to the vertical CNC lathe.
2.1.1 Processes
6 2.1.1.1Facing
Facing is the process of removing metal from the end of a work piece to produce a flat surface. Most often, the work piece is cylindrical, but using a 4-jaw chuck you can face rectangular or odd-shaped work to form cubes and other non-cylindrical shapes. (Hoose, F. J., 2000)
2.1.1.2Turning
Turning is the removal of metal from the outer diameter of a rotating cylindrical work piece. Turning is used to reduce the diameter of the work piece, usually to a specified dimension, and to produce a smooth finish on the metal. Often the work piece will be turned so that adjacent sections have different diameters (Hoose, F. J., 2000)
2.1.1.3Parting
Parting uses a blade-like cutting tool plunged directly into the work piece to cut off the work piece at a specific length. It is normally used to remove the finished end of a work piece from the bar stock that is clamped in the chuck. Other uses include things such as cutting the head off a bolt (Hoose, F. J., 2000).
2.1.1.4Drilling
7 2.1.1.5Boring
Boring is a cutting operation that uses a single-point cutting tool to produce conical and cylindrical surfaces by enlarging an existing opening in a work piece. The cutting tool moves parallel to the axis of rotation (Todd, R. H. et al., 1994).
2.1.1.6Grooving
Groove cutting on CNC lathes is a multi step machining operation. The term grooving usually applies to a process of forming a narrow cavity of a certain depth, on a cylinder, cone, or a face of the part (Smid P., 2003).
2.1.1.7Threading
Threading operations actually involves cutting a helical groove of definite shape or angle, with a uniform advancement for each revolution, either on the surface of a round piece of material, or inside cylindrical hole (Miller R. and Miller M. R., 2004).
2.1.2 Cutting Tools
8 2.1.2.1High speed steel
The advantages of High Speed Steel (HSS) Tool (1) HSS costs less than carbide or ceramic tooling.
(2) HSS is less brittle and not as likely to break during interrupted cuts. (3) The tool can be re-sharpened easily.
Disadvantages of High Speed Steel Tool
(1) HSS does not hold up as well as carbide or ceramic at the high temperatures generated during machining.
(2) HSS does not cut hard materials well.
2.1.2.2Carbide
Advantages of Carbide
(1) Carbide holds up well at elevated temperatures. (2) Carbide can cut hard materials well.
(3) Solid carbide tools absorb work piece vibration and reduce the amount of chatter generated during machining.
(4) When inserted cutters are used, the inserts can be easily changed or indexed, rather than replacing the whole tool.
Disadvantages of Carbide
(1) Carbide costs more than high speed steel.
(2) Carbide is more brittle than HSS and has a tendency to chip during interrupted cuts.
9 2.1.2.3Ceramic
Advantages of ceramic tooling
(1) Ceramic is sometimes less expensive than carbide when used in insert tooling (2) Ceramic will cut harder materials at a faster rate and has superior heat hardness.
Disadvantages of ceramic tooling
(1) Ceramic is more brittle than HSS or carbide
(2) Ceramic must run within its given surface speed parameters. If run too slowly, the insert will break down quickly.
The microstructures of the material give a tool its required bulk hardness and toughness may not be the best to give the rake and clearance surfaces the best wear resistance. Nowadays, the solution is to use coated tools – their bulk optimized to resist failure and their surfaces coated to resist wear (Child, T. et al, 2000). Coatings should be harder than the coated material themselves, in order to give benefit in resisting abrasive wear, must be more inert to resist chemical wear, and must adhere well to the substrate.
2.2 Machining time and cost calculation
