Content table

1 Draw given working drawings of the parts.............................................................................2

2 Check up of the drawings: materials, dimensions, accuracy, thermal treatment, surface
roughness, technical requirements .............................................................................................2
2.1 The axle 26.00.002................................................................................................................2
2.2 The sprocket 27.00.012 ........................................................................................................3
2.3 The cover 26.00.008..............................................................................................................4
3 Analyze the assembly and part drawings for corresponding manufacturing
requirements (design for manufacture or producibility)..........................................................5
3.1 The axle 26.00.002...............................................................................................................6
3.2 The sprocket..........................................................................................................................6
3.3 The cover 26.00.008..............................................................................................................7
4 Decide the type of production and manufacturing method...................................................7
5 Selection of Blank Making Process.....................................................................................9
5.1 The axle.................................................................................................................................9
5.2 The sprocket .......................................................................................................................10
5.3 The cover .........................................................................................................................11
6 Assign machining allowance for every part ...................................................................11
6.1 Maching allowances for the axle........................................................................................11
6.2 Maching allowance for the sprocket...................................................................................12
6.3 Machining allowances for the cover...................................................................................13
7 Development of Process Route for Every Part.................................................................13
7.1 Process Route for axle......................................................................................................14
7.2 Process Route for the cover................................................................................................18
7.3 Process Route for the sprocket............................................................................................22
8 Machining time Calculation ...................................................................................................27
8.1 Sprocket.............................................................................................................................28
8.2 The axle...............................................................................................................................30
8.3 The cover.............................................................................................................................35
9 References:................................................................................................................................38

1
1 Draw given working drawings of the parts
From the assebly drawing 26.00.000.513 it was given three parts: the axle 26.00.002, the
cover 26.00.008 and the sprocket 27.00.012. The drawings are presented in the appendix in the
end of the course work.

2 Check up of the drawings: materials, dimensions, accuracy, thermal treatment,

surface roughness, technical requirements

2.1 The axle 26.00.002

In the drawing 26.00.002 all dimensions, the roughnesses, tolerances, cilindricity of the axle
are shown. The material of this detail is constructional carbon steel C T4. Constructional carbon
steel is an alloy of iron and carbon. Chemical structure:
• Carbon (0,05-0,49% );
• Silicon (0,05-0,35%);
• Manganese (0,3-0,8%);
• Sulphur (0,05%);
• Phosphorus (0,04%);
• Other impurities.
Simple constructional carbon steels (GOST 380-71) includes group A wich belong to CT4. The
details manufactured from group A constructional carbon steels are strong and durable. The
greater number of expression CT4 means more carbon in steel and it is stronger and firmer. From
this type of material is produced only details that are loaded moderately.
Surfaces 5 and 10 have no adjoinment with other parts edges, so the roughness of these parst are
Ra 12,5. Surfaces 1 and 3 have adjoinment with other parts, so roughness of it is Ra 0,32.
Surfaces 11, 2 and 4 are the chamfers of 1x45° of the axle. The diameter of surface 1 is
Ø14H6+0,011 of the length 26 mm. Surface 1 like surface 3 adjoin with the corpus of an assembly.
The diameter of surface 3 is Ø12H6+0,011 of the length 12 mm. There are 3 holes inside the axle
for the lubricant. These holes compose of 3 surfaces: 13, 9, 6. The surface 13 is the horizontal
hole of diameter Ø2 mm of the lengh 35 mm. The surfaces 9 and 6 are vertical holes of diameter
Ø2 mm. The hole that is surface 9 has the length of 5 mm, while the other hole that is surfece 6

2
has the length of 8 mm. Beneath the axle it is drilled the groove of the width of 2 mm, the length
of 26 mm and the depth of 1 mm. The groove is the surface 12 and two lateral surfaces 7. The
roughness of the groove is Ra 0,32.

Figure 2.1 The drawing of the axle with numbered surfaces

2.2 The sprocket 27.00.012

In the drawing 27.00.012 all dimensions, the roughnesses, tolerances, paralellism of the
sprocket are shown. The material of the sprocket is constructional alloy steel 45X. The sprocket
have to be resistant to wear and impact of dynamic load. Constructional alloy steel has the
components:
• Iron and carbon;
• Impurities (Si, Mn, S, P);
• Alloying additives.
Constructional alloy steel 45X is of high quality material. According to standart GOST 4543-71
in constructional alloy steel 45X it is 45% of carbon. If alloying additives in material is less than
1%, in the expression the amount of it is not written.
The outer surfaces 5 has no adjoinment with other parts and the roughness of it is Ra 12.5. The
end surfaces 4 and 9 also haven‘t connection with other parts‘ edges and the roughnesses of it
also are Ra 12.5. The diameter of surface 4 is Ø20 mm of the length 13 mm. The diameter of

3
surface 9 is Ø84 mm of the length 10 mm. The sprocket have 24 teeth, because the indicated
number z=24. The tooth is composed of surfaces: 12, 1, 11, 10. The roughness of these surfaces
is Ra 3.2, because teeth have the connection with chain ПP-9525-900 GOST 10947-64. The
height of the teeth is 6 mm. Surface 14 is the chamfer of 1x45° of the axle. Surface 6 is the fillet
of radius R3 mm. The surface 7 is the hole of diameter Ø9 mm of the length 23 mm that has an
adjoinment with the shaft and rotates on it. The roughness of it is Ra 0.8. The surface 3 is the
hole of diameter Ø3 mm of the length 20 mm with the roughness of Ra 20. The surface 13 is the
hole M6x8 GOST1476-64 of the roughness Ra 6.3.

Figure 2.2 The drawing of the sprocket with numbered surfaces

2.3 The cover 26.00.008

In the drawing 26.00.008 all dimensions, the roughnesses, tolerances, paralellism, roundness of
the cover are shown. The material of the cover is grey cast iron CЧ15. Grey cast iron is an alloy
of iron and cast with some impurities: manganese, silicon, sulphur, phosphorus and so on.
Silicon in material is to 4,2%. Grey cast iron CЧ15 is used when the walls‘ thicknes of the
product is 8-15 mm and for not important but difficult construction parts.

4
The aim of the cover is not to let the impurities from outside. The roughness of the parts that has
no adjoinment with other parts or don‘t make an impact is Ra 12.5. Cover contains of 8 holes of
diameter M4x8 GOST 1491-72 those provide better closure of the cover. The cover also
contains of 2 holes for key of diameters of 3x16 GOST3129-70. The surface 11 has contact with
other part: shaft. The roughness of surface 11 is Ra 0.8. The cover has contact with oil-filler and
the surface 9 is used. The roughness of surface 9 is Ra 6.3. The surface 7 adjoins with washer
and the surface roughness is the same Ra 6.3.

Figure 2.3 The drawing of the cover with numbered surfaces

3 Analyze the assembly and part drawings for corresponding manufacturing

requirements (design for manufacture or producibility)

In the assembly drawing 26.00.000.513 is represented gear oil pump. The gear oil pump uses
internal gears in order to transfer the liquid oil product from one reservoir to another or to create
the pressure in working capacity of hydraulic cylinders. As the gears rotate they separate on the
intake side of the pump, creating a void and suction which is filled by fluid. The fluid is carried
by the gears to the discharge side of the pump, where the meshing of the gears displaces the

5
fluid. The mechanical clearances are small— in the order of 10 μm. The tight clearances, along
with the speed of rotation, effectively prevent the fluid from leaking backwards.

The rigid design of the gears and houses allow for very high pressures and the ability to pump
highly viscous fluids.
The entire assembly consists of the axle, gears, shafts, ring, sprocket, cover, 2 washers, union,
bracket, filler-cap and other components such like keys, screws, wedges that help to carry out
the main function of gear oil pump.
The requisition for parts is quite high – 750 pieces per year. So, the annual production will be
750 units of every part separately.

3.1 The axle 26.00.002

The detail – axle 26.00.002 is very important part of the assembly 26.00.000.513 which also
contributes to transfer the liquid oil product, has the holes inside for fluid flow supply to other
parts.
The axle has a cylindrical shape and the dimensions are quit small. The part is symmetric,
rigid enough for mechanical treatment. In the drawing all the dimensions are shown with the
required tolerance (h6), the roughness of the surfaces are shown as well.
All surfaces of the axle can be mashined using standart cutting tools and the dimensions of
it can me measured by standard measuring devices.

3.2 The sprocket

Sprocket transmits rotary motion between two parts. Every sprocket is polygon, whose
angles number is equal to the number of sprocket tooth z. Tooth coincide with the chain ПP-
9525-900 GOST 10947-64 that surround the sprocket. The sprocket in oil pump is rotating on
the main shaft and fixed to it with screw M6x8 GOST 1476-64. Chain dynamic hits are less
when the number of teeth is larger. Also in this case the wear of chain is small and and decreases
noise of operation.

6
3.3 The cover 26.00.008
The aim of this cover is it not let the impurities from outside. The cover 26.00.008 is used to
protect gears, axle and shaft from the outside particles that not to pass into liquid oil. It‘s shape
is composed of planar, cylindrical and curvilinear surfaces. The roughness of the surfaces that
haven‘t the contact with other surfaces or don‘t make an impact for them is Ra12.5.

4 Decide the type of production and manufacturing method.

Type of production (small scale) is selected according to output and overall mass. As it is
necessary 750 pieces per year of every detail separately and the details are of small weight, the
mass of them not reaches 1kg per piece, a small-lot batch production is chosen.

Annual Mass
Number
No. Notation of a part output, of a part,
of parts
pieces/year kg

1. The cover 26.00.008 1 850 0,714

2. The sprocket 27.00.012 1 850 0,340
3. The axle 26.00.002 1 850 0,041

The calculation of the masses:

m = ρ ⋅V , ƍ – density of a material, V – volume of a part.
Volume of the cylinder:
V = π ⋅ r 2 ⋅ h , where r – radius of the cylinder, h – height of the cylinder, V – volume of the
cylinder.
Volume of the sphere:
4
V = ⋅ π ⋅ R 3 , where R- radius of sphere
3
Volume of ellipsoid:
4
V = ⋅ a ⋅ b ⋅ c , where a, b, c are the semi-axis of ellipsoid.
3
Volume of parallelepiped:
V = a ⋅ b ⋅ c , where a, b, a are the edges of parallelepiped.

7
Calculation of the mass of the axle:
V1 = 3,14 ⋅ 6 2 ⋅ 12 = 1356 ,48 mm 3 when R1 = 6mm and h1 = 12 mm

V2 = 3,14 ⋅ 7 2 ⋅ 26 = 4000 ,36 mm 3 when R2 = 7 mm and h2 = 26 mm

V3 , V4 and V5 are the volumes of the holes that are inside the axle

V3 = 3,14 ⋅12 ⋅ 8 = 25,12 mm 3 when R3 = 1mm and h3 = 8mm

V4 = 3,14 ⋅ 12 ⋅ 5 = 15,7 mm 3 when R4 = 1mm and h4 = 5mm

4
⋅ 3,14 ⋅ 28 3
when R5 = 1mm and h5 = 35 mm
V2 = 3 = 45952 ,85 mm 3
2
Vaxle = V1 + V2 − V3 − V4 − V5 = 1356 ,48 + 4000 ,36 − 25 ,12 −15 ,7 −109 ,9 = 5206 ,12 mm 3 = 5,21cm 3

ρ steel = 7,9 g / cm 3

m axle = ρ ⋅ v = 7,8 g / cm 3 ⋅ 5,21cm 3 = 40,64 g = 0,041kg

Calculation of the mass of the cover:

V1 = abc = 56 ⋅ 30 ⋅ 8 = 13440mm 3 , when a=56 mm, b=30 mm, c=8 mm (half area of
parallelepiped)
4
⋅ 3,14 ⋅ 28 3
, when R=28 mm (half area of the sphere)
V2 = 3 = 45952 ,85 mm 3
2
4
⋅ 3,14 ⋅ 12,5 ⋅ 3 ⋅ 4
3 (half area of ellipsoid)
V3 = = 314 mm 3
2
V4 = V2 − V3 = 45952 ,85 − 314 = 45638 ,85 mm 3 (area of cutted sphere)

V5 = 3,14 ⋅ 9 2 ⋅16 = 4069 ,44 mm 3 , when R5 = 9mm and h5 = 16 mm

V6 = 8 ⋅ 3,14 ⋅ 2 2 ⋅ 8 = 803 ,84 mm 3 , when R6 = 2mm and h6 = 8mm (area of 8 holes)

V7 = 2 ⋅ 3,14 ⋅1,5 2 ⋅ 8 = 113 ,04 mm 3 , when R7 = 1,5mm and h7 = 8mm ( area of 2 plugs)

V8 = 3,14 ⋅ 6 2 ⋅ 20 = 2260 ,8mm 3 , when R8 = 6mm and h8 = 20 mm

V9 = 3,14 ⋅ 2,5 2 ⋅ 3 = 58,875 mm 3 , when R9 = 2,5mm and h9 = 3mm

V10 = 3,14 ⋅ 6,5 2 ⋅ 2 = 265 ,33 mm 3 , when R10 = 6,5mm and h10 = 2mm

8
 3
⋅ 3,14 ⋅18 3
V11 = 4 = 678 ,24 mm 3
when R11 = 18 mm
2
V12 = 30 ⋅ 56 ⋅ 3 = 5040mm 3 when a=30 mm, b=56 mm, c=3 mm (half area of parallelepiped)

V13 = V11 ⋅ 2 + V12 = 678 ,24 ⋅ 2 + 5040 = 6396 ,48 mm 3

Vcov er = (V1 + V2 + V4 + V5 ) − V6 − V7 − V8 − V9 − V10 − V13 = (13440 + 45952 ,85 + 45638 ,85 + 4069 ,44 )
− 803 ,84 −113 ,04 − 2260 ,8 − 58 ,875 − 265 ,33 − 6396 ,48 = 99202 ,775 mm 3 = 99 ,20 cm 3
We know that density of cast iron is: ρ = 7,2 g / cm 3
mcov er = ρ ⋅ V = 7,2 g / cm 3 ⋅ 99 ,20 cm 3 = 714 ,24 g = 0,714 kg

Calculation of the mass of the sprocket:

V1 = 3,14 ⋅ 10 2 ⋅ 13 = 4082 mm 3 , when R1 = 10 mm and h1 = 13 mm

V2 = 3,14 ⋅ 36 2 ⋅ 10 = 40694 ,4mm 3 , when R2 = 36 mm and h2 = 10 mm
V3 = 3,14 ⋅ 4,5 2 ⋅ 23 = 1462 ,455 mm 3 , when R3 = 4,5mm and h3 = 23 mm
V4 = 3,14 ⋅ 1,5 2 ⋅ 5,5 = 38,858 mm 3 , when R4 = 1,5mm and h4 = 5,5mm
V5 = 3,14 ⋅1,5 2 ⋅ 5,5 = 38,858 mm 3 , when R5 = 1,5mm and h5 = 5,5mm
V6 = 3,14 ⋅ 3 2 ⋅ 5,5 = 155 ,43 mm 3 , when R6 = 3mm and h6 = 5,5mm
Vsprocket =V1 +V2 −V3 −V4 −V5 −V6 = 4082 + 40694 ,4 −1462 ,455 −38 ,858 −38 ,858 −155 ,43 =
= 43080 ,799 mm 3 = 43 ,08 cm 3
We know that density of steel is: ρ steel = 7,9 g / cm
3

mcov er = ρ ⋅ V = 7,9 g / cm 3 ⋅ 43,08cm 3 = 340 ,33 g = 0,340 kg

5 Selection of Blank Making Process

5.1 The axle

The axle is a part with cylindrical surfaces. The most efficient way to manfucture this
product is by turning and by drilling the holes inside in it. A rod of cunstructional carbon steel
CT4 can be chosen as a blank, because it is the most suitable for manufacturing the axle. The
lengh of the rod is 6000mm. For manufacturing 850 axles it is neccesarry 6 rods of the steel C T4.
From one rod we can produce 139 axles.

9
 5.1. fig. The drawing of the axle‘s blank

5.2 The sprocket

The sprocket is also a cylindrical detail. The best way to manufacture is by turning, by
drilling and reaming the holes and milling the gears in it. A rod of constructional alloy steel 45X
is chosen as a blank whose legth is 6000mm. For manufacturing 850 units of this detail it is
necessary 5 rods of the steel 45X. From one rod it is possible to manufacture 196 sprockets.

5.2. fig. The drawing of the sprocket‘s blank

10
 5.3 The cover
The cover is manufactured using casting method in metal forms, because this way is the
most economical and productive, although the cost of metal forms is expensive. Metal forms are
used when the sample size is more than several hundred of pieces. The entire corps is casted and
some surfaces are milled in order to reach better accuracy. All holes are also drilled and reamed
after the casting process also. The material used for casting is grey cast iron CЧ15.

5.3. fig. The drawing of the cover after casting

6 Assign machining allowance for every part

6.1 Maching allowances for the axle

Final
Surface Technological Surface Machining Allowance Tolerance Marginal Marginal dimension
No. process roughness accuracy e, mm T, mm dimensions, mm dimensions, mm ,
mm
2Zmin 2Zmax min max
5, 10 Rough turning Rz40 IT14 1,0 0,62 2,0 2,62 42,0 42,87 42,87
L=38 Smooth turning 12.5 IT12 1,0 0,25 2,0 2,25 40,0 40,25 40,25
1 Rough turning Rz40 H14 1,8 0,43 1,8 2,23 16,94 17,631
Ø14H6 Smooth turning Rz20 H12 0,7 0,18 0,7 0,88 15,14 15,401 17,631
Preparative 1.25 H10 0,22 0,07 0,22 0,29 14,44 14,521 15,401
grinding 14,521
Smooth 0.32 H6 0,22 0,011 0,22 0,231 14,22 14,231
grinding 14,231

11
 Rough turning
Rz40 H14 1,8 0,43 1,8 2,23 14,94 15,631 15,631
3 Smooth turning
Rz20 H12 0,7 0,18 0,7 0,88 13,14 13,401 13,401
Ø12H6 Preparative
1.25 H10 0,22 0,07 0,22 0,29 12,44 12,521 12,521
grinding
Smooth
0.32 H6 0,22 0,011 0,22 0,231 12,22 12,231 12,231
grinding
Drilling
12 1.25 H10 1,0 0,04 1,0 1,04 0,96 1,9 1,9
Smooth
Groove 0.32 H6 0,1 0,006 0,1 0,106 1,994 2,0 2,006
grinding
9,6,12
Ø2
(3 Drilling Rz20 H10 1,0 0,04 1,0 1,04 1,96 2,04 2,04
holes)

6.2 Maching allowance for the sprocket

Final
Surface Technological Surface Machining Allowance Tolerance Marginal Marginal
dimension,
No. process roughness accuracy e, mm T, mm dimensions, mm dimensions, mm
mm
2Zmin 2Zmax min max

9,4 Rough turning Rz40 IT14 1,0 1,5 2,0 3,5 28 30,2 30,2
L=24 Smooth turning Rz12.5 IT12 1,0 0,7 2,0 2,7 26 26,7 26,7

12 Rough turning 12.5 H14 3,6 0,870 3,6 4,47 88,77 90,13 90,13
z=24 Gear shaping 3.2 H12 1,05 0,350 1,05 1,4 85,17 85,66 85,66
m=23 Gear shaving 3.2 H10 0,12 0,140 0,12 0,26 84,12 84,26 84,26

5 Rough turning Rz40 H14 2,0 0,52 2,0 2,52 23,2 23,996 23,996
Ø20 Smooth turning Rz12.5 H10 0,7 0,21 0,7 0,91 21,2 21,476 21,476

Drilling
Rz20 H10 0,3 0,058 0,3 0,358 8,642 8,7 8,7
7 Reaming
2.5 H9 0,2 0,036 0,2 0,236 8,764 8,9 8,9
Ø9 Smooth
0.8 H8 0,1 0,022 0,1 0,022 9,0 9,037 9,037
grinding
3
2,96
Ø3 Drilling Rz20 H10 1,0 0,04 1,0 1,04 3,04 3,04

13 Drilling Rz20 H10 0,2 0,048 0,2 0,248 5,752 5,8 5,8
M6x8 Screw-tap 6.3 H8 0,04 0,018 0,04 0,058 6,04 6,058 6,058

2
Ø84 Smooth turning Rz 12.5 H12 3,6 0,160 3,6 3,76 84,16 87,76 87,76

12
 Marginal Marginal Final
Surface Technological Surface Machining Allowance Tolerance dimensions, mm dimensions, mm dimension,
No. process roughness accuracy e, mm T, mm
2Zmin 2Zmax min max mm

1 Rough milling Rz20 H10 0,5 0,350 0,5 0,85 83,58 84,07 84,07
Smooth milling 12.5 H12 0,08 0,140 0,08 0,22 83,08 83,22 83,22

6 Smooth milling 12.5 H10 0,11 0,120 0,11 0,23 66,11 66,23 66,23

Drilling
11 Rz20 H10 1,0 0,07 1,0 1,07 10,93 11,0 11,0
Reaming
Ø12H6 2.5 H9 0,47 0,043 0,47 0,9 11,53 11,9 11,9
Smooth
0.8 H8 0,1 0,045 0,1 0,145 12,0 12,045 12,045
grinding

7 Drilling Rz20 H10 1,0 0,07 1,0 1,07 11,93 12,0 12,0
Ø13 Reaming 6.3 H8 0,05 0,033 0,05 0,083 13,05 13,0850 13,0850

9 Drilling Rz20 H10 0,2 0,075 0,2 0,275 4,725 4,8 4,8
M5 Scew-tap 6.3 H8 0,04 0,002 0,04 0,062 5,04 5,062 5,062

16
Ø5x8 Drilling Rz20 H10 1,0 0,048 1,0 1,048 4,952 5,048 5,048

5
Ø3x2 Drillimg Rz20 H10 1,0 0,04 1,0 1,04 2,96 3,04 3,04

10, 12 Rough milling Rz20 H10 1,0 0,048 1,0 1,210 26 26,294 26,294
L=24 Smooth milling 12.5 H12 1,0 0,04 1,0 1,084 25 25,084 25,084

6.3 Machining allowances for the cover

7 Development of Process Route for Every Part

The turning machine, milling machine and grinding machine were chosen from the products
catalog of www.staklija.lt . The turning tools, milling tools were chosen from products catalogs

13
of the company “Tungaloy“. The grinding tools were chosen from products catalog of Yinglong
Superhand Materials Manufactury. Measuring tools were chosen from the book “Inžinieriaus
mechaniko žinynas“.

7.1 Process Route for axle

The entire process route is taken in the following table:

Operation No. Operation Machine Cutting tools and Notes

measuring devices
005
Rough turning Universal 3 jaw chuck During this
of the end of a turning Turning knife: operation the
blank of the machine JCCWSR/L1616K2 The axle is fixed in
axle of GS5264 p.21 3 jaw chuck.
diameter Ø 12 Insert: Taking off 1 mm of
mm, that is JCCN200F p.21 end surface by one
surface 5, pass ap=1.0, f=0.2
taking of 1mm Rz40

Turning knife: 1 pass  2 mm

Toolholder: Ø 17,63mm 
Rough turning JSVJ2BR-L1616H11 Ø15,63mm
of outer surface p.14 2 pass  Ø
1 from Ø 17,63 Insert: 15,63mm Ø
mm mm to VBGT110300-FR/L- 15,40mm
Ø15,40 mm in J10 ap= 1 mm, f=0.2
the distance of p.23 mm/rev
26 mm by 2 Rz40
passes

Turning knife:
Rough turning Toolholder: 1 pass  2 mm
of outer surface JSVJ2BR-L1616H11
Ø 15,63mm 
3 from Ø15,63 p.14
Ø13,60mm
mm to Ø13,40 Insert:
mm in the VBGT1103-FR/L- 2 pass 
distance of 12 J10 13,6013,40mm
mm by 2 pass p.23 ap= 1 mm, f=0.2

14
 Rz40

Smooth turning Turning knife:

of the end of a JCCWSR/L1616K2
blank of the p.21 Taking off 1mm of
axle of Insert: end surface by one
diameter Ø 12 JCCN200F p.21 pass ap=1.0, f=0.2
mm, that is Rz12.5
surface 5,
taking of 1mm.
.

Turning knife:
Smooth turning Toolholder: 1 pass  2 mm
of surface 3 JSVJ2BR-L1616H11 Ø 13,40mm 
from 13,40 mm p.14 Ø12,52mm
to 12,52 mm in Insert: ap= 1 mm, f=0.15
the distance of VBGT1103-FR/L- mm/rev
26 mm by 1 J10 Rz20
pass p.23

Turning knife:
Smooth turning Toolholder: 1 pass  2 mm
of surface 1 JSVJ2BR-L1616H11 Ø 15,40mm 
from 15,40 mm p.14 Ø14,52mm
to 14,52 mm in Insert: ap= 1 mm, f=0.2
the distance of VBGT1103-FR/L- mm/rev
12 mm by 1 J10 Rz20
pass p.23

Making Turning knife:

chamfers of 45 Toolholder: by one pass
degrees of PSSNR/L202K12E ap= 1 mm, f=0.2
1mm of Insert: mm/rev
surfaces 4, 2, SNGN120408-DIA Rz12.5
11 by 1 pass

Cutting of the Turning knife:

end of a blank JCCWSR/L1616K2
of the axle of p.21 1 pass 2 mm

15
 diameter Ø 14 Insert: Rz12.5
mm, that is JCCN200F p.21
surface 10
taking off 2
mm

Technical Control table Control board Checking the

control 100x100 surface roughness
Calipers ШЦ-1-125- and
010 01 GOST 166-89 checking the
dimensions of
surfaces 5, 1, 3, 4,
2, 11

Drilling of the Drilling GIGA JET DRILL: In this case hole is

surface 13 of machine DSX0300F08 drilled up to 2,04
diameter Ø2,04 GS2116 p.450 mm, ap= 0.3 mm,
015
mm of the f=0.3 mm/rev
depth 35 mm. Rz20

Drilling of the Drilling GIGA JET DRILL: In this case groove

groove (2 mm) machine DSX0300F08 is drilled up to 1,9
of the length 26 GS2116 p.450 mm; ap= 0.3 mm,
020 mm, that is f=0.3 mm/rev
surface 12. Rz1.25
Drilled up to Ø
1,9 mm.

025
Drilling of the Drilling GIGA JET DRILL: In this case hole is
surface 9 of machine DSX0300F03 drilled up to 2,006
diameter Ø2 GS2116 p.449 mm, ap= 0.3 mm,
mm of the f=0.3 mm/rev
depth 6 mm Rz20

16
 GIGA JET DRILL:
Drilling of the DSX0300F03 In this case hole is
surface 6 of p.449 drilled up to 2,006
diameter Ø2 mm,
mm of the ap= 0.3 mm, f=0.3
depth 6 mm mm/rev
Rz20

Technical Control table Control board Checking the

control 100x100 surface roughness
Calipers ШЦ-1-125- and
030 01 GOST 166-89 checking the
dimensions of
surfaces 13, 12, 9,
6

Hardening Furnace of Oil reservoir Temperature of oil

035
HRC=62 heating is
(840 - 860)°C

Preparative Combined Plain Wheels from12,52 mm till

grinding of the grinding IAI/T2(P) 12,23 mm
surface 3 of the machine D-150mm W-4mm Rz1.25
length 12 mm BP-100 Y-20mm H-32mm
040 from12,52 mm CBN Content (carat/
till 12,23 mm piece): 121.09

Smooth Plain Wheels from12,23 mm till

grinding of the IAI/T2(P) 12,0 mm
surface 3 of D-150mm W-4mm Rz0.32
the length 12 Y-20mm H-32mm
mm from12,23 CBN Content (carat/
till 12 mm piece): 121.09

Preparative Plain Wheels from14,52 mm till

grinding of the IAI/T2(P) 14,23 mm
surface 1 of the D-150mm W-4mm Rz1.25
length 26 mm Y-20mm H-32mm
from14,52 mm CBN Content (carat/
till 14,23 mm piece): 121.09

17
 Smooth Plain Wheels
grinding of the IAI/T2(P) from14,23 mm till
surface 1 of the D-150mm W-4mm 14 mm
length 26 mm Y-20mm H-32mm Rz0.32
from14,23 till CBN Content (carat/
14 mm piece): 121.09

Smooth Plain Wheels From 1,9 mm to

grinding of the IAI/T2(P) 2,006 mm
surface that is D-150mm W-4mm Rz0.32
groove, up to Y-20mm H-32mm
the width CBN Content (carat/
2,006mm piece): 121.09

Washing of a Pressure water Machine clamps by removing all

045 part jet cleaners Pressure water jet metal remainders
from work

Technical Control table Control board Checking the

control 100x100 surface roughness
Calipers ШЦ-1-125- and
050
01 GOST 166-89 checking the
dimensions of
surfaces: 3, 1, 12

7.2 Process Route for the cover

The entire process route is taken in the following table:

Operation No. Operation Machine Cutting tools and Notes

18
 measuring devices

Casting of the Casting of the cover

005
cover in metal form

Rough milling Universal 3 jaw chuck The part is fixed

of the surface 10 milling Mill: in 3 jaw chuck.
of diameter the machine TM054001/317 taking off 1 mm
cover 83 mm PROMA FHV- p.317 (ap=1,0 mm,
taking off 1 mm 50 Insert: f=0,1 mm/rev)
(ap=1,0 mm, TMD5404R/LIE Rz20
f=0,1 mm/rev) p.339

Smooth milling 3 jaw chuck taking off 1 mm

of the surface 10 Mill: (ap=1,0 mm,
of diameter 83 TM054001/317 f=0,25 mm/rev)
mm taking off 1 p.317 Rz12.5
mm (ap=1,0 Insert:
mm, f=0,1 TMD5404R/LIE
mm/rev) p.339
010
3 jaw chuck from the length
Rough milling Mill: of the cover
of the surface 1 TM054001/317 84,07 mm to
of length 25 mm p.317 83,22mm by 1
from 84,07 mm Insert: pass (ap=1,0
to 83,22mm. TMD5404R/LIE mm, f=0,1
p.339 mm/rev)
Rz20

3 jaw chuck from the length

Smooth milling Mill: of the cover
of the surface 1 TM054001/317 83,22 mm to
from 83, 22 mm p.317 83,00mm by 1
to 83,00 mm Insert: pass
TMD5404R/LIE (ap=1,0 mm,
p.339 f=0,25 mm/rev)
Rz12.5

19
 Smooth milling Mill: from 66,22 mm
of the surface 6 TN4405 R/LIE to 66 mm by one
015 from 66,22 mm p.317 pass (ap=1,0
to 66 mm. Insert: mm, f=0,25
SEKN1203AGTN mm/rev)
p.346 Rz12.5
Drilling of the
surface 16 of
diameter Ø5 Tool: The hole is
mm ( 8 holes). DSX0500F03 drilled to
It is drilled the p.449 diameter of Ø
hole to diameter 5,048 mm
of Ø 5,048 mm (ap=1,0 mm,
f=0,3 mm/rev)
Rz20

Drilling of the Tool: The hole is

surface 5 of DSX0300F03 drilled to
diameter Ø3 (2 p.448 diameter of Ø
holes). 3,04 mm
(ap=1,0 mm,
f=0,3 mm/rev)
Rz20

Drilling of Tool: The hole is

surface 9 of DSX0700F03 drilled to
diameter M5 p.448 diameter of Ø
mm. We get 4,8 mm
hole of diameter (ap=1,0 mm,
Ø4,8 mm. f=0,3 mm/rev)
Rz20

Drilling of the The hole is

surface 7 of Tool: drilled to
diameter Ø13 DSX1210F03 diameter of Ø
mm. Firstly, p.448 12,0 mm
hole is drilled to (ap=1,0 mm,
12,0 mm f=0,3 mm/rev)
Rz20

Reaming of Tool holder: The hole is

surface 7 from JS08H-SEXPR047 reamed from

20
 Ø 12 mm to Inserts: 12,0 mm to Ø
Ø13 mm. EPGT040102L-J08 13,085 mm
(ap=1,0 mm,
f=0,3 mm/rev)
Rz6.3

Screw-tapping
of the surface 9 Insert: The hole is
of diameter M5 11NR15ISO screwed to
and after screw- M5, Rz20
tapping we get
the hole of M5
mm.

Technical Control board Checking the

control Control table 100x100 surface
Calipers ШЦ-1-125- roughness and
020 01 GOST 166-89 Checking the
dimensions of
surfaces: 1, 7, 9,
6

Drilling of the Tool: The hole is

surface 11 of DSX1100F03 drilled of
diameter Ø12 of p.448 diameter
the depth 22 Ø11mm (ap=1,0
mm. Firstly, it is mm, f=0,3
drilled the hole mm/rev)
of diameter of Rz20
Ø11.

025
Reaming of the Tool holder: The hole is
surface 11 of JS08H-SEXPR047 reamed from
diameter Ø12 of Inserts: Ø11mm to Ø
the depth 22 EPGT040102L-J08 11,9 mm
mm. It is (ap=1,0 mm,
reamed the hole f=0,3 mm/rev)
to 11,8 mm. Rz2.5

030
Technical Control board Checking the

21
 control Control table 100x100 surface
Calipers ШЦ-1-125- roughness and
01 GOST 166-89 Checking the
dimensions of
surface: 11

Smooth Plain Wheels From Ø 11,9

grinding of the IAI/T2(P) mm to Ø 12 mm,
surface 11 of D-150mm W-4mm Rz0.8
035 diameter Ø12 of Y-20mm H-32mm
the depth 22 CBN Content (carat/
mm from 11,8 piece): 121.09
to 12 mm

Washing of a Pressure water Machine clamps by removing all

part jet cleaners Pressure water jet metal
040
remainders from
work.

Control board Checking the

Technical Control table 100x100 surface
control Calipers ШЦ-1-125- roughness and
05 01 GOST 166-89 Checking the
dimensions of
surface: 11

7.3 Process Route for the sprocket

The entire process route is taken in the following table:

Operation Operation Machine Cutting tools and Notes

No. measuring devices
005
Rough Universal 3 jaw chuck The part is fixed in 3 jaw
turning of turning Turning knife: chucks taking off 1 mm
the end of a machine JCCWSR/L2020K2 (ap=1, f=0.3),
blank of GS5264 p.21 Rz40
sprocket of Insert:
diameter 20 JCCN200F p. 21
mm, that is

22
 surface 4
taking off 2
mm

Rough
turning of 1pass2mm90,13mm
Turning knife:
outer 88,13mm
JTTACR/
surface 12 2pass
L0810K08 p.12
from 90,13 88,13mm86,13mm
Insert:
mm to 85,66 3pass86,13mm85,66m
TCMT110204-PM
mm in the m
p.11
distance of where ap=1 mm, f=0,3
13 mm by 3 mm/rev.
passes. Rz12.5

Rough Turning knife:

turning of JSCACR/L1010H06
outer p.15 by 30 passes, where ap=1
surface 5 Insert: mm, f=0,3 mm/rev,
from 84,0 CCMT060204PM
1 pass  2mm
mm to 24,0 p.10
Rz40
mm in the
distance of
11 mm by
30 passes

Turning knife:
Making JSCACR/L1010H06
chamfers of p.15 1pass 1mm
45 degrees Insert: by 1 pass, (ap=1.0 mm,
of 1mm of CCMT060204PM f=0.3 mm/rev)
surface 14 p.10 Rz12.5
by one pass

Turning knife:
Smooth JCCWSR/L2020K2
turning of p.21
the end of a Insert: taking off 1 mm
(ap=1, f=0.15)

23
 blank of JCCN200F p. 21 Rz12.5
sprocket of
diameter 20
mm, that is
surface 4
taking of
1mm

Smooth Turning knife:

turning of JSCACR/L1010H06
surface 5 p.15 1pass2mm21,47mm
from Insert: 20,0mm
21,47mm to CCMT060204PM where ap=1 mm, f=0,15
20mm p.10 mm/rev.
Rz12.5

Smooth Turning knife:

turning of JCGSSR/L1616K3
the surface p.20 1pass2mm13,76mm
2 of width Insert: 11,36mm
10 mm from JTGR/L3095F 2pass2mm11,36mm
13,76 mm to p.20
10mm
10 mm by 2
where ap=1 mm, f=0,15
passes
mm/rev.
Rz12.5

Drilling of
the surface
7 of GIGA JET DRILL:
diameter Ø9 DSX0830F03
The hole is drilled to 8,7 mm
mm of the p.448
ap= 0.3 mm, f=0.3 mm/rev
depth 24
Rz20
mm. hole is
drilled to
8,7 mm

Reaming of Toothholder:
The hole is drilled to 8,9 mm
the hole 7 of JS08H-SEXPR047
ap= 0.3 mm, f=0.3 mm/rev
diameter Ø9 Inserts:
Rz2.5
mm of the EPGT040102L-J08
depth 24

24
 mm. The
hole is
reamed to
8,9 mm

Cutting off
the end of a Turning knife: by 1 pass taking off 2 mm
blank of the Toolholder: (ap=1,0 mm, f=0,3 mm/rev).
shaft of JSTGR/L1616K3 Rz12.5
diameter Ø p.20
14 mm, that Insert:
is surface 10 JTGR/L3050F
takking off p.20
2 mm

Control board Checking the surface

010 Technical 100x100 roughness and
control Calipers ШЦ-1-125- checking the dimensions of
01 GOST 166-89 surface: 4, 12, 5, 9, 7

Drilling of Vertical Drilling of the surface 3 of

GIGA JET DRILL:
the surface drilling diameter Ø3 mm of the
015 3 of machine DSX0300F03 depth 20 mm, where (ap=0,3
diameter Ø3 mm, f=0,3 mm/rev).
p.449
mm of the Rz20
depth 20
mm.

020
Drilling of Vertical
GIGA JET DRILL:
the surface drilling Hole is drilled of Ø5,8 mm
13 of machine DSX0530F03 of the depth 20 mm.
diameter (ap=0,3 mm, f=0,3 mm/rev).
p.448
M6x8. Hole Rz20

25
 is drilled of
Ø5,8 mm
of the depth
20 mm

Screw- tap Insert: Screw tapping pf the hole to

of surface M6,
11NR15ISO
13 of (ap=0,3 mm, f=0,3 mm/rev).
diameter Rz6.3
M6x8 from
diameter of
5,8 mm M6.

Control board Checking the surface

Technical 100x100 roughness and
025
control Calipers ШЦ-1-125- checking the dimensions of
01 GOST 166-89 surfaces: 13, 3

Gear Mill: Making teeths of the

shaping of CoroMill® 245 sprocket, when z=24, m=24,
the surfaces PROMA Holder: where ap= 0.3 mm
1, 11, 10. FPX-25E P/N 3077 (8.0 mm s=0.2mm/rev
030 Making End Mill Holder) Rz3.2
teeths of the Pneumatic clamps
sprocket,
when z=24,
m=24

Control board Checking the surface

035 Technical 100x100 roughness and
control Calipers ШЦ-1-125- checking the dimensions of
01 GOST 166-89 surfaces: 1, 11, 10

Smooth Combined Plain Wheels Smooth grinding of the teeth

grinding of grinding IAI/T2(P) of surfaces 1, 11, 10
040 the teeth of machine D-150mm W-4mm to the length l=6mm, where
surfaces 1, BP-100 Y-20mm H-32mm ap= 1.0mm, f=0.2mm/rev.

26
 11, 10 to CBN Content (carat/ Rz3.2
length of piece): 121.09
teeth 6mm

Grinding of Combined Grinding of the hole 7

Elaboric grinding
the hole 7 grinding of diameter Ø9 mm of the
disk:
of diameter machine depth 24 mm from diameter
1A1-1 (LLP-1)
Ø9 mm of BP-100 of Ø 8,9 mm till Ø 9 mm.
p.435
045 the depth 24 Rz0.8
mm from
diameter of
Ø 8,9 mm
till Ø 9 mm.

Machine clamps
Washing of Pressure Pressure water jet Removing all metal
050 a part water jet remainders from work.
cleaners

Control board Checking the surface

055 Technical 100x100 roughness and
control Calipers ШЦ-1-125- checking the dimensions of
01 GOST 166-89 surface: 1, 10, 11, 7

Coating Combined The part is coated by the

grinding layer of lubricant
machine
060
BP-100

8 Machining time Calculation

L ⋅i
Tm =
sm

L⋅z
Tm = , where z= number of teeth of the sprocket
sm

27
 L ⋅i
Tm = - formula used screw-tapping
n⋅s
Where
Sm= s ⋅ n , mm/min
s- feed for one revolution, mm/rev
n- frequency of a blank:
1000 v
n= , rev/ min
πd
where v- cutting speed, m/min
d- diameter of the blank before machining, mm
L- full required length L=l+l1+l2, mm
l- length of the surface to be machined, mm
l1 – length of the travel required for tool aproach, mm
l2 – length of the overtravel of the tool or workpiece in the direction of the feed, mm
i- numer of passes

8.1 Sprocket

Operation No.015
Time required for the drilling surface 3
s=0.3mm/rev
v=230m/min
d=3mm
Calculation:
L=l+ l1+l2
l=20 mm
l1 = tan α ⋅ d / 2 = tan 20  ⋅ 1,5 = 0,54mm
l1=l2=0,54mm
L=20+0,54+0,54=21,8mm
1000 v 1000 ⋅ 230
n= = = 24416 rev / min
πd 3.14 ⋅ 3
s m = sn = 0.3 ⋅ 24416 = 7324 ,8mm / min

28
 L ⋅i 21,8 ⋅1
Tm = = = 0.003 min
sm 7324 ,8

Operation No.020
Time required for the drilling surface 13
s=0.3mm/rev
v=140m/min
d=6mm
Calculation:
L=l+ l1+l2
l=5,5 mm
l1 = tan α ⋅ d / 2 = tan 20  ⋅ 3 = 1,09mm
l1=l2=1,09mm
L=5,5+1,09+1,09=7,68mm
1000 v 1000 ⋅140
n= = = 7430 rev / min
πd 3.14 ⋅ 6
s m = sn = 0.3 ⋅ 7430 = 2229 mm / min

L ⋅ i 7,68 ⋅1
Tm = = = 0,003 min
sm 2229

Time required for the screw-tapping for the surface 13:

s=0.3mm/rev
v=140m/min
d=6mm
L=5,5mm
Calculation:
1000 v 1000 ⋅140
n= = = 7430 rev / min
πd 3.14 ⋅ 6
L ⋅i 5,5 ⋅ 6
Tm = = = 0,009 min
n ⋅ s 7430 ⋅ 0.3

Operation 030
Shaping of surface (making teeth) 1,11,10 (sides of the teeth)

29
d=84mm
s = 0,2 mm/rev (feed),
v = 180 m/min (cutting speed)
In this case .
1000 v 1000 ⋅180
n= = = 682 rev / min
πd 3.14 ⋅ 84
s m = sn = 0.2 ⋅ 682 = 136 ,4mm / min

Machining time:
L⋅z 6 ⋅ 24
Tm = = = 1,048 min
sm 136 ,4

8.2 The axle

Operation 005
Time required for rough turning of the surface 5
The data for Tm1, which is taken from the table:
s= 0.2 mm/rev
v=120m/min
d=12 mm
L=12mm
Calculation:
1000 v 1000 ⋅120
n= = = 1005 rev / min
πd 3.14 ⋅ 38
s m = sn = 0.2 ⋅1005 = 201 mm / min

L ⋅ i 12 ⋅1
Tm1 = = = 0,06 min
sm 201

Time required for rough turning of the surface 1

The data for Tm2, which is taken from the table:
s= 0.2 mm/rev
v=150m/min
d=14mm
L=26mm

30
Calculation:
1000 v 1000 ⋅150
n= = = 3412 rev / min
πd 3.14 ⋅14
s m = sn = 0.2 ⋅ 3412 = 682 ,4mm / min

L ⋅ i 26 ⋅ 2
Tm 2 = = = 0,076 min
sm 682 ,4

Time required for rough turning of the surface 3

The data for Tm3, which is taken from the table:
s= 0.2 mm/rev
v=120m/min
d=12mm
L=12mm
Calculation:
1000 v 1000 ⋅120
n= = = 3184 rev / min
πd 3.14 ⋅12
s m = sn = 0.2 ⋅ 3184 = 636 ,8mm / min

L ⋅ i 12 ⋅ 2
Tm 3 = = = 0,04 min
sm 636 ,8

Time required for smooth turning of the surface 5:

The data for Tm4, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 12mm
l=1mm
Calculation:
L=l+ l1+l2
l1= l2 =0,84mm
L=1+0,84+0,84=1,68mm
1000 v 1000 ⋅180
n= = = 47770 rev / min
πd 3.14 ⋅12
s m = sn = 0.2 ⋅ 47770 = 9554 mm / min

31
 L ⋅ i 1,68 ⋅1
Tm 4 = = = 0.0002 min
sm 9554

Time required for smooth turning of the surface 3:

The data for Tm5, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 12mm
l=12mm
Calculation:
L=l+ l1+l2
l1= l2 =0,84mm
L=12+0,84+0,84=13,68mm
1000 v 1000 ⋅180
n= = = 4190 rev / min
πd 3.14 ⋅13 ,68

s m = sn = 0.2 ⋅ 4190 = 838 mm / min

L ⋅ i 13,68 ⋅1
Tm 5 = = = 0,016 min
sm 838

Time required for smooth turning of the surface 1:

The data for Tm6, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 14mm
l=26mm
Calculation:
L=l+ l1+l2
l1= l2 =0,84mm
L=14+0,84+0,84=15,68mm
1000 v 1000 ⋅180
n= = = 3655 rev / min
πd 3.14 ⋅15 ,68

s m = sn = 0.2 ⋅ 3655 = 731 mm / min

32
 L ⋅ i 15,68 ⋅1
Tm 6 = = = 0,02 min
sm 731

Time required for making chamfers of surface 4:

The data for Tm7, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 12mm
l=1mm
Calculation:
L=l+ l1+l2
l1= l2 =6mm
L=1+6+6=13mm
1000 v 1000 ⋅180
n= = = 4777 rev / min
πd 3.14 ⋅12
s m = sn = 0.2 ⋅ 4777 = 955 ,4mm / min

L ⋅i 13 ⋅1
Tm 7 = = = 0,013 min
sm 995 ,4

Time required for making chamfers of surface 2:

The data for Tm8, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 14mm
l=1mm
Calculation:
L=l+ l1+l2
l1= l2 =7mm
L=1+7+7=15mm
1000 v 1000 ⋅180
n= = = 4094 rev / min
πd 3.14 ⋅14
s m = sn = 0.2 ⋅ 4777 = 818 ,8mm / min

L ⋅ i 15 ⋅1
Tm 8 = = = 0,018 min
sm 818 ,8

33
Time required for making chamfers of surface 11:
The data for Tm9, which is taken from the table:
s= 0.2 mm/rev
v=180m/min
d= 14mm
l=1mm
Calculation:
L=l+ l1+l2
l1= l2 =7mm
L=1+7+7=15mm
1000 v 1000 ⋅180
n= = = 4094 rev / min
πd 3.14 ⋅14
s m = sn = 0.2 ⋅ 4777 = 818 ,8mm / min

L ⋅i 15 ⋅1
Tm 9 = = = 0,018 min
sm 818 ,8

Time required for cutting of the surface 10:

The data for Tm10, which is taken from the table:
s= 0.4 mm/rev
v=250 m/min
d=14 mm
L=1mm
Calculation:
1000 v 1000 ⋅ 250
n= = = 5686 rev / min
πd 3.14 ⋅14
s m = sn = 0.6 ⋅ 5686 = 2274 ,4mm / min

L ⋅i 1 ⋅1
Tm 10 = = = 0.0004 min
sm 2274 ,4

Total time required for operation 005

Tm=Tm1+Tm2+Tm3+Tm4+Tm5+Tm6+Tm7+Tm8+Tm9+Tm10=
0,06+0,076+0,04+0,0002+0,016+0,02+0,013+0,018+0,018+0,0004=0,261min

34
8.3 The cover

Operation 010
Time required for rough milling of the cover end (surface 10):
The data for Tm1, which is taken from the table:
s= 0,2 mm/rev
v=150m/min
n= 477rev/min
L=56mm
Calculation:
s m = sn = 0,2 ⋅ 477 = 95,4mm / min

L 56
Tm1 = = = 0,587 min
sm 95,4

Time required for smooth milling of the cover end (surface 10):
The data for Tm, which is taken from the table:
s= 0,3 mm/rev
v=200m/min
n= 636rev/min
L=56mm
Calculation:
s m = sn = 0,3 ⋅ 636 = 190 ,8mm / min

L 56
Tm 2 = = = 0.293 min
s m 190 ,8

Time required for rough milling of the surface 1:

The data for Tm3, which is taken from the table:
s= 0,2 mm/rev
v=150m/min
n= 477rev/min
L=25mm
Calculation:
s m = sn = 0,3 ⋅ 477 = 143 ,1mm / min

35
 L 25
Tm 3 = = = 0,174 min
s m 143 ,1

Time required for smooth milling of the surface 1:

The data for Tm4, which is taken from the table:
s= 0,3 mm/rev
v=200m/min
n= 636rev/min
L=25mm
Calculation:
s m = sn = 0,3 ⋅ 636 = 190 ,8mm / min

L 25
Tm 4 = = = 0,131 min
s m 190 ,8

Total time required for operation 010

Tm = Tm1 + Tm 2 + Tm 3 + Tm 4 = 0,587 + 0,293 + 0,174 + 0,131 = 1,185 min

Operation 020
Time required for drilling the hole of surface 11:
The data for Tm1, which is taken from the table:
s=0.25mm/rev
v=100m/min
d=12mm
L=22mm
1000 v 1000 ⋅100
n= = = 2653 rev / min
πd 3.14 ⋅12
s m = sn = 0.25 ⋅ 2653 = 663 .48 mm / min

L ⋅i 22 ⋅1
Tm1 = = = 0.033 min
sm 663 ,48

Time required for rough boring of the surface 6:

The data for Tm2, which is taken from the table:
s= 0.2 mm/rev
v=150m/min
d= 30.13mm
Calculation:

36
L=l+ l1 +l2
l1 = tan α ⋅ h = tan 17.5  ⋅ 2 = 0.63mm
l1=l2=0.63mm
L=25+0.63+0.63=26.26mm
1000 v 1000 ⋅150
n= = = 796 rev / min
πd 3.14 ⋅ 60
s m = sn = 0.2 ⋅ 796 = 159 .2mm / min

L ⋅ i 26 .26 ⋅ 9
Tm 2 = = = 1.48 min
sm 159 .2

Total time time required for operation 020:

Tm=Tm1+Tm2= 0,033+1,48=1,513min

37
9 References:
1. Mašinų gamybos technologijos pagrindai : vadovėlis / Antanas Juozas Bražiūnas. Kaunas, 2004.
512, [1] p. ISBN 9955-09-558-X
2. Užlaidų mechaniniam apdirbimui analitinis apskaičiavimas ir parinkimas : mokomoji knyga /
Ramutis Krančiukas. Kaunas, 2007. 102 p. ISBN 978-9955-25-341-9
3. Inžinieriaus mechaniko žinynas / Balys Dragūnas, Kęstutis Pilkauskas, Antanas Stasiūnas,
Raimundas Stasiūnas. Vilnius, 1988. 526 p. ISBN 5-420-00028-8
4. UAB Staklija produktų katalogas. www.staklija.lt;
5. „Tungaloy“ įrankių katalogas. www.tungaloy.co.jp/ttj/english/products/cutting/cutting_11.html

38