Simplified Time Estimation Booklet for Basic Machining Operations K. C. Polgar, T. G. Gutowski, G. W. Wentworth Table of Contents: Topic 3, TIME ESTIMATION TABLES 4 7 x12" Wet Horizontal / Vertical Bandsaw 6 Cold Saw 2, ‘Manual Vertical Mill 10. CNC 3-Axis Vertical Mill 2 ‘Manual Horizontal Mill 4 ‘Manual Turret Lathe Vv. ‘CNC Turret Lathe 18. Drill Press 2. CNC 3-Axis Surface Grinder Belt Sanding Inspection ‘The process plan Estimating the time 31, ‘Comparisons 2B. 24. 2. APPENDIX A: HOW TO USE THIS BOOKLET 2. 27. 33, APPENDIX B: OTHER USEFUL TABLES 34 B.1 Surface finish requirements for various design applications 35. B2 Tolerance and surface roughness for various manufacturing processes 36. B3 Process tolerances 37. BA Standard material shapes and sizes 38. BS Material densities and costsKARCH C. POLGAR, "SIMPLIRD TIME ESTIMATHON FOR BASIC MACHINING OPERATIONS", M.S, THESIS, DEPARTMENT OF MECHANICAL ENGINEERING, M.I.T. NE 1996.Time Estimation Tables The proposed time estimation method has the following sequence: 1. Begin with an engineering drawing 2. Develop a process plan 3. Estimate the times from simplified tables The tables which follow are divided into three categories for each machine: ~ Machine setup time - Part fixturing time ~ Material removal time Machine setup time: Includes such things as cleaning up the machine from the last time it was used, loading tools and fixtures, and zeroing axes. Part fixturing time: These times scale with weight (heavier parts take longer to load) and represent the time to pick up a part and secure it in place for the machining operation. Material removal time: It is important to note that the removal rates in the tables are for high speed steel (HSS) tooling. * For sawing: removal rate is based on cross-sectional area of the cut + For milling, turning, grinding, and sanding: removal rate is based on volume removed for roughing passes, and surface area finished for finish passes * For drilling and tapping: plunge feed rate is based on the diameter and the depth of the hole ‘Also included in the tables are times for tool changes, time to index parts (in a part indexer), time to index tools (advance turret on a turret lathe), and programming times for CNC equipment. The Appendices will help explain how to select machines and generate a process plan from a part drawing. Appendix A is a detailed time estimate of a “rod support”. Additional useful data tables are given in Appendix B.TIME ESTIMATION TABLES 1.) 7” x 12” Wet Horizontal / Vertical Bandsaw Figure 1: Standard vise Standard “SV” Series Locking Mechanism STANDARD identied by black knobs Fer Gerais Patrons. pas {atoingev ecutestoscniiecert wich ose ecg me, bere otra Ihe entre crooner oo cote ba {rg omar pat woveies Fang te lasrg rete {Spontonpemis oe peng oun De ‘etn ge no poten Stoming into ae boo rane he workpiece ‘asing aren sre cover bao " and 8" Grip-Master Vises Max" Jaw dew Shipping Order Price wt Welght” Number Each Sevier ee Tole. 21050005 “Foe BPAVes = NaN6 YOloe. atoa-on10 | Brae Svea = = TTY i puos0o1s at Saves sae sian tie, Pins. Irae GPAs SHE HBN Salbe. 2ios-ones I7Eae ewveen — SSS MIEN See 2io30000 386 SSvVao eae «te, 2ias.ones TRAN SPAVes = & Bane tbe Brasco an70 Bveveoe = = See Btosoms “ane Figure 2: Quick-locking viseTIME ESTIMATION TABLES 1.) 7” x 12” Wet Horizontal / Vertical Bandsaw (cont.) {Ee 7” x 12” WET HORIZONTAL VERTICAL BANDSAW 7x12” stock size $3,600 (in our shop) can be up to $5K Pre-welzec Biases avaiable gia" $10.20 with autofeed $15K my Model 2673 4985, “ee $1,68500 * Setup machine: 10.2 min. ¢ Load stock and fixture: Weight [Ib.]_ (Times are in min.) Fixture type 3 8 12 25 35 Standard vise 023 028 035 O4T 0:70 Quick-locking vise 0.20 025 035 ‘Automatic feed 015 020 028 ° Cut material: Material Material removal rate [in2/min] Aluminum ‘Copper alloysTIME ESTIMATION TABLES 2.) Cold Saw (ES cou saws with hydraulic cutting and feed: The Hottest $15K-20K Cold Sawon the Market! tolerance +0.005” * Setup machine: — 10.2 min. * Load stock and clamp with standard vise: Weight [lb] (Times are in min) 2.0 | 4.4 | 8.1 | 13.1} 18.0 | 24.2 0.41 | 0.45] 0.50 © Cut material: Material Material removal rate jin2/min] ‘Aluminum 12.5 Copper alloys 8.33 Steel 6.25TIME ESTIMATION TABLES 3.) Manual Vertical Mill First cut Letting) Saf eS cond eu 5] I Tslot ‘Workpiece Figure 3: (a) Horizontal surface, (b) slot/ewds Figure 4: Milling a T-slot (©) dovetail, (4) T-slot a ob ITH we | Werk o Figure 5: Some vertical milling machine operations 2TIME ESTIMATION TABLES 3.) Manual Vertical Mill (cont.) Figure 6: Fixturing to a t-slotted table with clamps @ + Designed or ming, cing, borg tnd ated mactoang operons, + Spl ered comport concruston ro ws for? types of ig. + Arguing canbe pestered {trough gradation ng fom © Soo: ninsomente ot ‘Basle ingexrgis sone by mean oh fateh device This permis veo 215, 4,6,8, 12 and 2e woul wy ‘Gaassombly operation, Furniss? piece versbiojenta ‘sper precise al to enuk or dra By ae acurcy SPECIFICATIONS: Inding moray se ‘Squarenocs (ase chuck) 009 max (Cancontny of ehisk OTS TAL 8" HORIZONTAL - VERTICAL ‘SIMPLE INDEX DIMENSIONS: Deb’, a 20", BeID45%, 15.18; Bont foes Gar nite, Cael: 1.024, Woiht 129 be Order Number 1982-0010 $569.00 Figure 7: A part indexerTIME ESTIMATION TABLES 3.) Manual Vertical Mill (cont.) + Setup machine: (includes load one tool) 2hp. spindle with digital readout $15K 3-axis ( degrees of freedom) EZ Trak Faug NC vu B2OK, © Tool change: Fixture type Time [min] Vise, clamps, or direct boltin, 45 Part indexer 30 2min. © Load part and fixture: Fixture type Weight [ib] (iimes are in min) 25 10 ‘Standard vise 025 0.28 Quiciclocking vise 08 O21 ‘Clamps or direct bolting (3 t-bolts) Index part: Mill materi ‘Type of tool 0.1 min ‘Material removal rate O77 ost ‘Aluminum ‘Copper allo} Steel 0/8)" end mill (0.82 fin /min] 0.39 fin? min] 0.14 fin?/miny (1/2 end mill 5.46 [in3/min] 1.80 [in?/min} (0.63 [in /min} ‘Maamum MRR 72 [8 2.35 [in® min} 091 [in /min} Finish passes 15 fir®/min] 15 fin?/min] 15 [in?/min}TIME ESTIMATION TABLES CNC 3-Axis Vertical Mill 2 7 Figure 8: A typical automatic tool changer on a CNC vertical mill. Tools are stored in pockets connected to an endless chain conveyor. 10TIME ESTIMATION TABLES 4.) CNC 3-Axis Vertical Mill (cont.) 7hp. 24-tool changer $90K (1986) $120K-130K replacement + Setup machine: (includes load one tool) Fare Type Tie cimnps, or dues boing = are 0 + Tool change: Tirnua change Tintomatic change (one BA) Touch-off tol 2am fool ceavge \) © Programming: 5 min. +3 [min,/part dimension] ‘© Load part and fixture: Weight [ip] (Times are in min) Fixture type 3 25 Standard vise O22 0.28 Quiek-locking vise 0.15 0.21 ‘Clamps or direct bolting (3 tbolts) 074 ost Index part: 0.1 min, © Mill material: ‘Material removal rate ‘Type of tool Aluninam ‘Copper alloys Steel 0.50” end mill 5.48 [in /min] 1.80 fin /min} (0.65 fin3 min] T.007 end mill 1638 [in /min] 4.21 [in® min} 47 [in min} Maximum MRR 255 fin® min} 8.24 [in /min} 3.18 [in min] Finish passes 15 [in?/min] 15 [in?/min} 15 [in?/min} iTIME ESTIMATION TABLES 5.) Manual Horizontal Mill FACE MILLING OR SLABOR PLAINMILLING SIDE MILLING SLOTOR KEYWAY MILLING STRADDLE AaILLING WIP FORM MILLING [ANGLE CUTTERS Ewan 2 eNO MILLING. saw MILLING. Figure 9: Some horizontal milling machine operationsTIME ESTIMATION TABLES 5.) Manual Horizontal Mill (cont.) Shp. spindle with digital readout $20K 3-axis * Setup machine: (includes load one tool) Fixture ‘Time [min] Type [- Vise, clamps. or drectboling [| [Partindexer 90] * Tool change: 2 min. * Load part and fixture: Weight [ib] (limes are in min) Fixture ype z 3 zB 3B = Standard vise 720 ta oa oa Tar Cuieklocking vise [078 os oe oa tai ‘Clamps or direct bolting (3 Uballs) om o7 077 081 oss © Index part 0.1 min. * Mill material: Waterial removal rate Type of tool ‘Aluminum: ‘Copper alloys ‘Steel 0:50" end mill ‘548 [ine /min] 1.80 [in/min] (0.63 fins min] 1.007 end mill 768 [in /min} 4.21 in? min} 147 [in®/min} 18.2 [in3 min} 5.88 [in3/min} 2.27 [in3/min] 19 [in?/min]} 19 fin?/min} 19 fin?/min] 13TIME ESTIMATION TABLES 6.) Manual Turret Lathe _— Dog (amped 0 wor, ‘even by dog plate) Workpart CContor (othar cantor J stheadstock ene) (Dog plate (riven by lathe spincle) @ CCotlet wih three sits to 4/_ Permit squeezing of work Workbar Sleeve (advances forward 10 squeeze collet) © Jaws @), adjustable to clemp work Shy, /— Wertoart ” Faceplate (attached to spindle) Tumed sutace Workpart Camps (4) 0 Figure 10: Four fixturing methods used in lathes: (a) mounting the work between centers using dog, (b) three jaw chuck, (c) collet, and (d) face plats for noncylindrical workparts. 14TIME ESTIMATION TABLES 6.) Manual Turret Lathe (cont.) This requires @ ; a4 HL i @ i @) © “ @ i ’ ‘A - 4 = =H _ , ted me oe 4 fe es o o o Figure 1: Machining operations other than turning that are performed on a ate (a) facing, (b) taper turning, (c) contour turning, (d) form. (©) chamfering, (f) cutoff, (g) threading, (h) boring, (i) Gelling and () knurling 15TIME ESTIMATION TABLES 6.) Manual Turret Lathe (cont.) 5 hp. spindle power feed digital readout (not CNC) 8 tools $25K * Setup machine: ‘Number of fools (Times are in min) 2 3 4 5 6 = 76.2 T 87.0 | 97.8 | 109.2 | 120.0 [130.2 * Load part and fixture: Weight [lb.] (Times are in min.) Fixture type oz 52 20 z Chuck 0.27 0.39 053 0.88 Collet 0.26 035 « Advance turret to next tool: 0.1 min. «© Turn material: Diameter of part Material removal rate before cutting Aluminum Copper alloys Steel 0.50” 8.83 [in3 /min] 1.64 [in3/min] 0.69 [in3 /min]} 1.007 13.5 [in3/min] [251 [in3/min] | 1.05 [in3/min] Maximum MRR 18.2 [in3/min] 5.88 [in3/min] 2.27 [in3/min] | Finish passes 17 [in2/min] 17 [in2/min] 17 [in2/min]7.) CNC Turret Lathe TIME ESTIMATION TABLES [ Setup machine: 15 hp. spindle power feed 10 tools $80K (In our shop, have also Bridgeport 7 hp. EZ-Path CNC Lathe No turret $37K) ‘Number of fools (Times are in min) Time Load part and fixture: 410. 52 0.39 Programming: 5 min. + 2 [min./part dimension] Advance turret to next tool: 0.1 min. Turn material: Diameter of part ‘Material removal rate before cutting Aluminum ‘Copper alloys Steel 0.50" 8.83 [in3/min} 1.64 [in3 min) (0.69 [in3 /min] 1.007 135 [in /min] 251 fin3/min) 1.05 [in3/min] ‘Maximum MRR 545 [in? /min) 176 fin?/min) 6.82 [in? /min] Finish passes 17 [in?/min] 37 fin? min] 17 [in?/mnin] 7TIME ESTIMATION TABLES 8.) Drill Press Figure 12: Using parallels in a drill press vise (oy Twit dei (er Stenght ute det) Clos: Cl: (&) Seapeil (@) Spade dit Cass <__s) (@) Gone (Dri with brazed carbide tip (g) Drill with indexable carbide inserts Figure 13: Various types of drills 18TIME ESTIMATION TABLES 8.) Drill Press (cont.) Resming Center diting tg Jownetning High possare slant S33 o ‘Shane Cotting acs Workpiece Figure 15: (a) Trepanning tool, (b) Trepanning with a drill-mounted single cutter Figures 16 and 17 below are hand tools used to make external and internal threads: Figure 16: A die Figure 17: A tapTIME ESTIMATION TABLES 8.) Drill Press (cont.) Modified versions of Figures 16 and 17 are used in drill presses (also can be used on milling machines and lathes). The die head shown in Figure 18 automatically opens to release the work at the end of the threading operation. Figure 18: Self-opening die head The tapping head shown in Figure 19 incorporates such features as torque control, self-reversing feed at the completion of the tapping, and a cushicned drive mechanism to prevent cross-threading. Figure 19: Self-reversing tapping head 208.) Drill Press (cont.) TIME ESTIMATION TABLES Setup machine: 10.5 min. (includes load too!) Tool change: 0.30 min. (keyed-drill chuck) Load part and fixture: Fixture type $700 Manual, 1-axis, 3/4 hp. Automatic: $2K-15K depending on spindle power and options cht (ib) (Times are in min) 25 100 ‘Standard vise ‘Oa7, oid Quickclocking vise Drill or ream hole: Diameter of hole Plunge feed rate fin min] ‘Copper alloys Drilling 0.060" 32 Drilling 0.5007 40 Reaming 0.06 36 Reaming 0.500" + Threading: 120 Threads per inch 0 i [ie 3 21TIME ESTIMATION TABLES 9.) CNC 3-Axis Surface Grinder 5 hp. 12x24” stock size $17K * Setup machine: 36 min. * Load part and fixture on magnet table: Weight [1b] (limes are in min.) 0.2 52 20 45 Time O04 0.09 1d : ¢ Programming: 5 min. + 2 [min./part dimension] © Grind material: (Only steel included here since non-magnetic parts require special fixturing and are not commonly ground) Material removal rate for Steel 2TIME ESTIMATION TABLES 10.) Belt Sanding Gi er Bett sander 12" DISC SANDER COMBINATION a FeaTunes: warm Phe, 1 pio: 3 iS e.r wacom reATURES: ‘With Parchasel ALUMINUM OXIDE ‘CLOTH BELTS. 6x 48" 60 10 per Pack + Ph 3 PHASE Mode! 9000 6031 $1,550 _,:08,, i 2 be ¢ Setup machine: No fixture: 10 min. Simple fixture: 30 min. ¢ Load part and fixture: Weight [Ib] (limes are in min) Fixture Type 3 5 7 35 =] No fixture 0.08 O10 o15 O16 019 Timple fiture 0.20 022 0.25 028 O31 ¢ Sand part: Material removal rate Aluminum | Copper alloys Steel 0.25 [in3/min} | 0.17 [in3/min] | 0.13 [ind/min] 38 [in?/min] | 38lin2/min] | 38 [in2/min] 23TIME ESTIMATION TABLES 11.) Inspection * Measure dimension: (tolerance +0.005 in.) Visual inspect Vernier caliper Micrometer Dial bore gage ” Radius gage * Deburr edge with hand scraper: Material Material Removal Rate [in/min] ‘Aluminum Hand deburring tool orAppendix A How to Use this Booklet The following is a step-by-step example of a time estimate. It will illustrate the various steps involved and help explain the different sections of the time estimation tables. Consider the aluminum part below with a tolerarance of 1/64” for the two 0.50” radii and +0.005” otherwise: Figure Al: Rod support The process plan The first step is to generate a process plan. Let's assume we begin with a stock size of 2.5"x2.25"x12” and that this will be manufactured in a job shop for very low quantities. We will use: — Abandsaw to roughly cut the stock to size ~ A manual vertical mill to create the planar features and the holes -- A belt sander to sand the radii (we can do this since the tolerance is not very high)APPENDIX A Number the features in the order they will be produced as follows: Figure A2: The machining sequence Now we can write the process plan which is: Feature Machine number Operation Horizontal band saw T___[Saw stock to ~4.125” Manual vertical mill ‘Mill two ends to length 4” Mill width to 2 Mill out 2°x1.5 "x4" Drill hole 1” diameter Bore 1” radius Belt sander Sand 0.5” radii 26HOWTO USE THIS BOOKLET Estimating the time The times are estimated by referring to the time estimation tables. In this example, the time for deburring, inpection, and measurement will be included. These times can be omitted when they are insignificant compared with the machining time. Feature #1: Saw stock to ~4.125” From page 5, Setup machine: 10.2 min Load stock and fixture with standard vise: 0.23 min (using the lightest weight column — 3 Ibs) . _ _ (5.625 in*) Saw stocks ea inj "22 mio (cross section of cut is 5.625 in?) From page 24: + Deburr cut edges: i) = 0.30 min (G0 in / min) {perimeter deburred is 9 in.) «Inspect: 0.05 min. Feature #2: ill two ends to length 4” From page 9: * Setup machine with a vise and load one tool: 45 min * Refixture stock with standard vise: 0.20 min (for first side) 0.20 min (for other side) (using the lightest weight column —1 Ib) © Change tool to a milling tool: 2.0 min (boring tool was on machine from last part) 103 in* (5.48 in’ / min) ).13 min. + Mill the two ends rough cut: 7 (volume removed is 0.703 in3) (assume a 1/2” end mill is used to get the removal rate) (11.25 in*) (15 in? / min} (surface area finished is 11.25 in?) * Mill the two ends - finish cut: 75 min. 27APPENDIX A From page 24: (19 in) © Deb itedges; —~——+_ ure cut eaBeSs: (50 in min) © Inspect: 0.05 min. * Measure with vernier caliper: 0.13 min. 1.63 min. ll width From page 9: © Refixture stock with standard vise: 0.20 min 2.5 in? © Mill the width - rough cut: 7 * Mill the width - finish cut: From page 24: (in) _ (80 in/ mi + Deburr cut edges: + Inspect: 0.05 min. * Measure with vernier caliper: 0.13 min. Feature #4: Mill out 2”x1.5’x4" From page 9: (Stock already fixtured and ready) . (12 in’) . + Mill out 2”x1.5"x4” - rough cut, 7) 29.19 min (5.48 in? / min) + Millout2"«L.5"x4" finish cut: (4) 9.95 min (15 in? / min) From page 24: (15 in) (G0 in/ min) + Deburr cut edges: 0.50 min. * Inspect: 0.13 min. * Measure with vernier caliper: 0.26 min (measure 2 dimensions) 28HOW TO USE THIS BOOKLET Feature #5._Drill hole 1” diameter From page 9: Refixture stock with standard vise: 0.20 min Tool will have to be changed four times: 8 min. (need to drill in stages otherwise cannot meet tolerance of +0.005”) ~ Center drill to start hole - Drill (1/2”) to remove most of material - Drill (63/64”) to leave a light cut for reamer - Ream to get to exact size From page 21 (use these numbers whenever drilling on any machine): (0.25 in) (7.78 in’ / min) (Linearly interpolate to get plunge feed rate for the size hole being drilled ~ denominator) (Assumed diameter of center drill is 0.25” - used to interpolate for feed rate) (Assumed depth of hole is 0.25” ~ how far the tool will feed - numerator) Center drill: 0.03 min, (0.50 in) (9.6 in’ / min) (Diameter of drill is 0.5”) (Depth is all the way through -- 0.50”) Drill 1/2”: =0.05 min, Drill 63/64”: Tain min) (Diameter of drill is 63/64”) (Depth of hole is 0.50") (0.50 in) © (39.7 in® / min) (Diameter of reamer is 1”) (Depth of reamed hole is 0.5”) Ream 1/ =0.01 min, From page 24: (6.28 in) G0 in/ min) Deburr cut edges: .21 min. Inspect: 0.05 min. Measure with vernier caliper: 0.13 min. 29APPENDIX A radi From page 9: + Refixture stock with standard vise: 0.20 min + Change tool toa boring tool: 2.0 min (0.79 in?) «Bore the 1” radius-rough eut: ©) 996 min (0.82 in? / mi (Use the lowest removal rate from the table, single point cutting tool, not always in contact with the part) 1.57 in?) * Bore the 1” radius - finish cut: fist) 10 min, (15 in? / min) From page 24: . . _(7.28 in) Deburr cut edges: Go Inspect: 0.05 min. + Measure with radius gage: 0.06 min. = 0.24 min. ature #7; Sand 0.5” rai From page 23: * Setup machine with no fixture: 10 min * Load stock with no fixture: 0.08 min (0.05 in?) * Sand the two radii - roughing: (easel) 20 min (0.25 in* / min) (0.79 in? «Sand the two radii finishing: 9in’) 0.21 min, (3.8 in? / min) From page 24: + Deburr cut edges: —@:4i9) 9.10 min, G0 in/min) Inspect: 0.05 min. + Measure with radius gage: 0.12 min. (measure two radii)HOWTO USE THIS BOOKLET Comparisons To check this time estimation model, we had our in-house expert machinist, Gerry Wentworth, provide us with his own estimate of the manufacturing time (see next page). The table below summarizes the results for the rod support made of aluminum: ‘Omi. Simin. i Rod Support Tstimate of ] Estimate using Aluminum experienced method of Job Shop this thesis We manufactured this part in our machine shop and stopwatch-timed the various operations. The actual machining operation differed from the estimates in many ways. The mill already had a vise on the table. Subtracting 45 minutes for not having to set up a vise (see page 9), we obtain 20 minutes setup as our estimate. This agrees well with the observed time of 19 minutes. The actual machining time of 61 minutes is much higher than the 26 minute estimate. Many factors account for this. We did not have 2.5x2.25” stock, so we had to machine several additional surfaces. We had to look for tools and spent time finding things. Basically, we were not well prepared. Thus, we caution against estimating for these kinds of situations. However, when tools and stock are laid out and arranged, this model has been shown to agree well with the actual times. After machining one part, our expert machinist said he felt that the part could be made (machining time) in about 30 minutes. Further, this estimating method is effective in applications that require a relative measure of time, rather than an absolute one, like choosing between alternative processes. 31APPENDIX A Gerry Wentworth's Process Plan Tolerance + .005 Rod Support Mafl Alum. 2"x21/2" Bar Conventional Machining Ope | Machine Decripion Ban ain) ins Setup Rn Tota Time Tine Time | Hore Band | Carmiaria 76mg 1 io 7 ‘Sew 20 | Bench Debur Saw Cut isp. ° 10 19 30 | vert Mitt | Setup 6° Vise-Tearn Mach, 00 50 380 Sq. one saw cut end to dear, Deburr Fp Part Mach. Other end to 4" long (ating 3/4 EM. w/in leg ‘ofext) (1500 PM 10 1PM 40 | Benen Deburr&Inep. ° ry 10 so | ver. ast | Rest parton Parallels griping by | 150 150 309 the 2" Dimension with 21" of (Mat exposed above the vise ws. ‘Mach. 1/2" wall e 1/2" bottom thickness Using 3/4° 2 FEM. “S00 RPM 107M eo | Bench Deburr fe Insp. ° 10 10 70 | Vert mit | Reposition part to dri hole. | 100 80 180 Center drill plot drill 1/2" @ Hol pllotdnll 15/16" & hat Finnish Dill 17 (G00RPM IPM) 20 | Bench Dabur & Insp. ° 1 10 50 | Vert man | Reposition Par to Mach. "RAD. | 150 60 no set Boring Head to 1” Rad. Mach (DO) passes and one Finnish 500 RPM at 207M 100 | Bench Dabur & Insp, 0 10 10 10 | Vert Min | Setup Rotary Table to Machs* | 30 50 350 RAD. 2s, 20 | Bench Finnish Deburr de Insp. ° 20 20 TOTALS 1019 0 a0 Note: Ithoies were to have = 005" tolerance ad 5 min to setup #Smin runtime two 1/2" Rad were 1/64" would not have to have 30 min sep ering op he oy Te Figure A3: Gerry's estimate (a rotary table was not used so the setup time is 71 minutes) 32Appendix B Other Useful Tables Bi B2 B3 BA BS Surface finish requirements for various design applications Tolerance and surface roughness for various manufacturing operations Process tolerances Standard material shapes and sizes. Material densities and costs 33APPENDIX B BA SURFACE FINISH REQUIREMENTS FOR VARIOUS DESIGN APPLICATIONS (250 pin) 6.3 wm, Sonera (16 pin) 0.40 wm, pare (x25) 3.2/7 Mangoes V et ‘gankets 63) 1¢0/ oe as) 032 case Ratchet and pawl ‘damecers ‘een ccrankatal beer Milles threads To Seatestoces Sevengine nator Paton cows is) 0.20 / ‘inde Turse bine Valretaoete sowie sptecintr Brosched holes (32) 0.80 / rons ourasl Lagpedentiicton Sanne oa Gearseeth “ a Fireman Slewtreand te Eyeicham Pinan rod both (carbonaeal ma on shopgnae ee — @ 0.050 ange cee seal ttc tr sos : ee @ ons /~ ee Migionear nals FIGURE 31.8 Typical surface roughness design req} gineering components. Not roughness in these applications is two orders of magnitude. 34OTHER USEFUL TABLES B.2 TOLERANCE AND SURFACE ROUGHNESS FOR VARIOUS MANUFACTURING PROCESSES Ni N2 N3 Né N5 N6 N7 NS NQ NiO Nil N12ISONo. 0100-00250 01 02 04 08 16 32 63 125 35 S0um 3 Teo PO iP oF dio Oe 4 we y 70.5 HOY * Fok SB ae / 3 OE 2 ee sete fol 8 se oe z 7 5 Z A jo.0s 5 pe 3 vey = 0.001 ee eo rtd - on oe 7 hg 40.01 sero er {0.005 0.0001 1 - 4 05 1 2 4 8 16 32 63 125 250 500 1000 2000yin. Surface roughness (R,) FIGURE 35.24 Tolerances and surface roughness obtained in various manufacturing processes. These tol apply'to a 25-mm (1-in.) workpiece dimension. Source: J. A. Schey.APPENDIX B B.3 Process Tolerances +£Tolorance (0.05 mn) 0.008 in. 0.0008 in. (@.013 mn) (0.075 mm) ‘0.005 i (0.125 mm) ‘0.0101 (025mm) (0.050 in. (1.25 mm) (0.002 in, Tuning, boing Diameter<1.0in, = == 1.0 Diameter < 20. = Diameter > 2.0 in. Dailing” Diameter < 0.1 in 0.1 < Diameter <0.25 in. ss] 0.25 < Diameter <0 in. = 05 Diameter 1.0% Diameter> 1.019. Reaming Diameter< 0.5, (05 1.0 in. iting Pere —— Face End ‘Shaping, siting —— Planing reaching Sawing Fe “Dilng tolerances typically expressed as a biased bilateral tolerance (for example, ++0.005/-0.001). Values in this tabulalon aro expressed es closest biatrel tolerance (e.., £0,002). 36OTHER USEFUL TABLES B.4 Standard Material Shapes and Sizes ‘Standard Material Shapes and Ranges of Sizes Name ‘Shape Pte 675 mm (025-3 in) Sheet 01-5 mm (0.00402 in) Round bar of rod 3-200 mm dia (0.125-8 in. dia.) Hexagonal bar 6-75 mm (025-3in) Square ber $100 mm (0375-4 in) Rectangular bar 3 x 12-100 x 150mm (0.125 x 05-4 x 6in.) ‘Tebing ‘S:mm dia, 1 mm wall-100 mm dia., 3m wall (0.187-5 in, dis, 0.035 in, wall-4 in, dia, 0.125 in, wall) 37APPENDIX B B.5 Material Densities and Costs oosz sz vst ort sy ro s4oqe wane. - ost ost ost or “9 eco shoqe ourz see 909 909) see sce eT 9900 ‘sore umtsoniey ~ ors os. os ws oc oro. sKore PON ost ost ost wl oe a8 Ico sug wr os sou 1 61 ut oro hoy woaquyy snans97U0N = wo - ws ewe pam on, = ose ost os ee pas sme = ~ ort sLo ase pais Aonly wo wo 90 Ise L pats woe sn ont, ws0< “wso> Pout =e “aw “vat emia ous Bees ‘rs (©7 Aa Aya 85,208 eajop 01 RDG OF) THO SMO A 305 q| 2d EANTOG U MHED L961 eMUIPOXATY