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Using Datums for Economic

Process Planning

Dr. R. A. Wysk
IE550
Fall 2008
Process Planning

• Single datum planning


• Multiple datum plans
Process Tolerance Chart

•Process Boundary Matrices

Values in Process Tolerance Charts


typically represent the BEST attainable
values. They also represent single-feature
relationships. We refer to these intra-
feature process planning.
Example #1 - The simplest case; single datum, single feature

+ .005
4.0
- .0

2.0 + .005
- .005

A 2” piece or bar stock needs to be “faced” so


that the required length and surface finish can be
obtained.
Solution:

In checking the work piece, datum -A-


becomes the reference plan for the
+ 0.005
length, 4.0 - 0.0 . The OD accuracy is
obtained at the rolling mill, and no OD
turning is required. The length needs
to be faced to final dimension.
Process Plan-Example #1
Oper. Description Machine Tool

10 Retrieve 2’’ Bar Warehouse --

20 Cut to 4.25’’ length Cut-off saw --

30 Face backside (remove Lathe Facing tool


1/8 ‘’ stock)
40 Flip and face front-side Lathe Facing tool

50 Remove and inspect -- --


Example #2 -- Single datum; 2 features.
5  .005

4 + .005
- 0

2.0 + 0.01
1.0  .005
- 0

Sort of like Example #1 but with a 2nd feature related


to the same datum -A-.
Solution:

- 4” segment is the same as in Example #1

-Addition segment requires that:


-OD is reduced to 1”
-Length needs to be reduced to 5  .005
Process Plan for Example #2
OP# Description Machine Tool Time
10 Retrieve 2” bar Warehouse
20 Cut to 5.25” Cut-off saw
30 Face backside and Lathe Facing
invert
40 Turn 1” Dia. @ .25 in Lathe Turning
depth
(2 passes)
50 Face to 4” Lathe Facing
60 Face to 5” Lathe Facing
70 Remove and Inspect
The General Case and Notation.

C12 C23

C4

M12
M13
A
Cij is part specification or
Constraints
Mij is Manufacturing method were
i is the datum feature, and
j is the surface produced
From the part, you can see that
C12 @ M12
This reads, “C12 comes directly from process
M12 (our facing operation).”
Also from the drawing, one can see that
TC23 = TM12 + TM13
This reads, “the tolerance for feature C23 can be
as large as the sum of the tolerance for
producing M12 and the tolerance for producing
M13”  Tolerance Stacking
Notation: subscript m implies minimum
M implies maximum
C23m = -M12M + M13m
Let’s suppose

C12  4  .005 C 23  1 .005


0 .005

Then
TM12 = .005
TC23 = TM12 + TM13
.010 = .005 + TM13
TM13 = .005
If a negative value results then the process
specification is unfeasible
Since C23m = - M12M + M13m

.995 = -4.005 + M13m


5.000 = M13m
 Set the process specifications for M13 at
5.000 - 5.005
Example #4
4 .008
2 holes
.250  .010
 Ø .008 M
C A B
2.0  .01 + + +
1
B
1 1 1
Raw Material 4’’ x 2’’ x .5’’
A
.750  .010
 Ø .01 MC A B .5  .01
C

All hole features are specified with respect to


datums A-B-C and can be treated as intra-feature
entities.
Process Plan for Example #4

OP# Description Machine Tool

10 Load part in vise Fadal CNC

20 Drill 1st small hole Fadal CNC .25  drill


30 Drill 2nd small hole Fadal CNC .25  drill
40 Drill large hole Fadal CNC .25  drill
50 Unload and inspect
Example #5
.750  .010
B
  .01 
M CDE
.5 1 1
.25  MAX
+
  
.75
D
.25± .01 A
.5 ±
2 holes .01
.250  .010
E
  .008
M CDE

.25±.01
.50 ±.01
C C23
M12
Raw Material 4’’ x 2’’ x
M13 .5’’
M14 M15
C12 @ M12
TC12 = ± .01
TC23 = TM12 + TM13
C23m = -M12M + M13m
.008 = -.51 + M13m

From 
.518 = M13m
TC23 = TM12 + TM13
.008 = .01 + TM13
TM13 < 0  infeasible
We need to position w.r.t -E-

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