Scilab Textbook Companion for A Textbook of Production Engineering by P. C. Sharma1 Created by Mayank Sahu B.E. Mechanical Engineering M. I. T. S Gwalior, M.P College Teacher None Cross-Checked by Bhavani Jalkrish July 31, 2019 1Funded by a grant from the National Mission on Education through ICT, http://spoken-tutorial.org/NMEICT-Intro. ThisTextbookCompanionandScilab codes written in it can be downloaded from the ”Textbook Companion Project” section at the website http://scilab.in Book Description Title: A Textbook of Production Engineering Author: P. C. Sharma Publisher: S. Chanda & Company, New Delhi Edition: 11 Year: 2008 ISBN: 9788121901116 1 Scilab numbering policy used in this document and the relation to the above book. Exa Example (Solved example) Eqn Equation (Particular equation of the above book) AP Appendix to Example(Scilab Code that is an Appednix to a particular Example of the above book) Forexample, Exa3.51meanssolvedexample3.51ofthisbook. Sec2.3means a scilab code whose theory is explained in Section 2.3 of the book. 2 Contents ListofScilabCodes 4 2 Press Tool Design 5 4 Cost Estimating 17 5 Economics of tooling 30 9 Limits Tolerences and Fits 58 11 Surface finish 65 13 Analysis of metal forming processes 67 14 Theory of metal cutting 76 15 Design and manufacture of cutting tools 90 16 Gear manufacture 97 17 Thread manufacturing 98 21 Statical quality control 99 22 Kinematics of machine tools 110 3 23 Production planning and control 116 26 Plant layout 121 4 List of Scilab Codes Exa 2.1 find total pressure and dimensions . . . . . 5 Exa 2.2 To find number of draws . . . . . . . . . . . 6 Exa 2.3 To calculate bending force . . . . . . . . . . 6 Exa 2.4 find blanking force and work done . . . . . 6 Exa 2.5 To find elastic recovery of material . . . . . 7 Exa 2.6 To find cutting forces . . . . . . . . . . . . . 7 Exa 2.7 To calculate amount of shear . . . . . . . . 8 Exa 2.8 To find economy of material . . . . . . . . . 8 Exa 2.9 Calculations for designing drawing die . . . 9 Exa 2.10 Determine developed length . . . . . . . . . 11 Exa 2.11 To calculate bending force . . . . . . . . . . 11 Exa 2.12 To calculate bending force . . . . . . . . . . 12 Exa 2.13 calculate capacity of double bending die . . 12 Exa 2.14 To calculate cutting force . . . . . . . . . . 13 Exa 2.15 Determine blank and punch diameter . . . . 13 Exa 2.16 To find drawing operations and force . . . . 14 Exa 2.17 Determine developed length . . . . . . . . . 15 Exa 4.1 To calculate total cost and SP . . . . . . . . 17 Exa 4.2 To find selling price . . . . . . . . . . . . . . 17 Exa 4.3 To find factory cost . . . . . . . . . . . . . . 18 Exa 4.4 find production cost and time taken . . . . . 19 Exa 4.5 To find profit . . . . . . . . . . . . . . . . . 19 Exa 4.6 To find lot size and time . . . . . . . . . . . 20 Exa 4.7 To find time to change cutter . . . . . . . . 20 Exa 4.8 To find tool change time . . . . . . . . . . . 21 Exa 4.9 To calculate measuring time allowance . . . 21 Exa 4.10 To find direct labour cost . . . . . . . . . . 21 Exa 4.11 To find machining time . . . . . . . . . . . . 22 5 Exa 4.12 To find time to turn relief . . . . . . . . . . 23 Exa 4.13 calculate time to face on lathe . . . . . . . . 23 Exa 4.14 To find time to drill hole . . . . . . . . . . . 24 Exa 4.15 To find time to complete cut . . . . . . . . . 24 Exa 4.16 To find time to broach . . . . . . . . . . . . 25 Exa 4.17 find feed cutter travel and time . . . . . . . 25 Exa 4.18 To find cutting time . . . . . . . . . . . . . 26 Exa 4.19 To find milling time . . . . . . . . . . . . . 26 Exa 4.20 To find time to grind shaft . . . . . . . . . . 27 Exa 4.21 To find time to cut threads . . . . . . . . . 27 Exa 4.22 find time to produce one piece . . . . . . . 28 Exa 5.1 To find value of machine tool . . . . . . . . 30 Exa 5.2 To find annual investment . . . . . . . . . . 31 Exa 5.3 find project is economical or not . . . . . . . 31 Exa 5.4 selection of economical machine . . . . . . . 32 Exa 5.5 selection of machine . . . . . . . . . . . . . 33 Exa 5.6 selection of economical machine . . . . . . . 34 Exa 5.7 find ERR and economicality of project . . . 34 Exa 5.9 find ERR and economicality of project . . . 35 Exa 5.10 To determine acceptance of machine . . . . 35 Exa 5.11 find investment cost and unamortized value 36 Exa 5.13 To make decision of machines replacement . 36 Exa 5.15 Determine economic repair life . . . . . . . . 37 Exa 5.16 find time to pay for itself . . . . . . . . . . 38 Exa 5.17 selection of machine for job . . . . . . . . . 39 Exa 5.18 Calculatemaximuminvestmentonturretlathe 40 Exa 5.19 To find years for new machine . . . . . . . . 41 Exa 5.20 To find cost and pieces . . . . . . . . . . . . 42 Exa 5.21 To find number of components . . . . . . . . 43 Exa 5.22 To find number of components . . . . . . . . 43 Exa 5.23 To find time and profit . . . . . . . . . . . . 44 Exa 5.24 To find minimum number of components . . 44 Exa 5.25 To calculate number of pieces . . . . . . . . 45 Exa 5.26 To find cost for new fixture . . . . . . . . . 45 Exa 5.27 find time to amortize fixture . . . . . . . . . 46 Exa 5.28 To find profit . . . . . . . . . . . . . . . . . 47 Exa 5.29 To find BEP Cost and Components . . . . . 47 Exa 5.30 To find break even point . . . . . . . . . . . 48 6 Exa 5.31 To find break even quantity . . . . . . . . . 48 Exa 5.32 To do break even analysis . . . . . . . . . . 50 Exa 5.33 To calculate minimum number of pieces . . 50 Exa 5.34 To determine the point . . . . . . . . . . . . 51 Exa 5.35 To find quantity of pieces . . . . . . . . . . 51 Exa 5.36 To determine quantity of production . . . . 52 Exa 5.37 find preference between machines and pro- duction . . . . . . . . . . . . . . . . . . . . 52 Exa 5.38 To find BEP and various sales . . . . . . . . 53 Exa 5.39 To determine break even point . . . . . . . 54 Exa 5.40 To calculate economic lot size . . . . . . . . 54 Exa 5.41 To find EOQ and total cost . . . . . . . . . 55 Exa 5.42 Determine optimum lot size . . . . . . . . . 56 Exa 5.43 To find most economical lot size . . . . . . . 57 Exa 9.1 To find allowance and tolerence . . . . . . . 58 Exa 9.2 Determine dimensions of shaft and hole . . . 58 Exa 9.3 Determine dimensions of hole and shaft . . 59 Exa 9.4 Calculate fundamental deviations and toler- ences . . . . . . . . . . . . . . . . . . . . . . 59 Exa 9.5 Find tolerences limits and clearance . . . . . 60 Exa 9.6 Determine limits of shaft and hole . . . . . . 61 Exa 9.7 Determine dimensions of shaft and hole . . . 62 Exa 9.8 Determine size of bearing and journal . . . . 62 Exa 9.9 Determine size of two mating parts . . . . . 63 Exa 9.10 Determine size of hole and shaft . . . . . . . 64 Exa 11.1 Calculate CLA value . . . . . . . . . . . . . 65 Exa 11.2 Calculate average and rms value . . . . . . . 65 Exa 13.1 To find drawing load . . . . . . . . . . . . . 67 Exa 13.2 Calculate drawing force . . . . . . . . . . . 68 Exa 13.3 find neutral section slips and pressure . . . 68 Exa 13.4 To determine maximum force . . . . . . . . 69 Exa 13.5 Determine sticking radius and total load . . 70 Exa 13.7 To find drawing load and power . . . . . . . 70 Exa 13.8 calculate drawing load and power rating . . 71 Exa 13.9 To calculate forging loads . . . . . . . . . . 72 Exa 13.10 Determine extrusion load . . . . . . . . . . . 72 Exa 13.11 To find roll pressures . . . . . . . . . . . . . 73 Exa 13.12 Determine neutral plane . . . . . . . . . . . 74 7 Exa 14.1 calculate the tool life . . . . . . . . . . . . . 76 Exa 14.2 Calculate the optimum cutting speed . . . . 76 Exa 14.3 To find different orthogonal cutting picture . 77 Exa 14.4 To find tool life . . . . . . . . . . . . . . . . 78 Exa 14.5 find force and coefficient of friction . . . . . 79 Exa 14.6 To find terms of orthogonal cutting . . . . . 80 Exa 14.7 To solve tool life equation . . . . . . . . . . 81 Exa 14.8 Determine normal and tangential force . . . 81 Exa 14.9 To find cutting and thrust force . . . . . . . 82 Exa 14.10 find terms of orthogonal rake system . . . . 83 Exa 14.11 Calculate CLA . . . . . . . . . . . . . . . . 84 Exa 14.12 Calculate back and side rake angle . . . . . 84 Exa 14.13 Calculate inclination and rake angle . . . . . 85 Exa 14.14 find different powers and resistance . . . . . 85 Exa 14.15 Calculate percentage increase in tool life . . 86 Exa 14.16 To find percentage of total energy . . . . . . 86 Exa 14.17 To find power and different energies . . . . 87 Exa 14.18 Determine components of force and power . 88 Exa 15.1 calculate horsepower at cutter and motor . . 90 Exa 15.2 DeterminebroachingpowerandDesignbroach 90 Exa 15.3 Estimate moment thrust force and power . . 92 Exa 15.4 Design shell inserted blade reamer . . . . . . 92 Exa 15.5 To design single point cutting tool . . . . . 93 Exa 15.8 find various terms for stainless steel . . . . . 94 Exa 15.9 To find MRR power and torque . . . . . . . 95 Exa 15.10 find MRR power torque and time . . . . . . 95 Exa 16.1 Calculate settings of gear tooth . . . . . . . 97 Exa 17.1 Calculate best wire size . . . . . . . . . . . 98 Exa 17.2 Calculate size and distances over wire . . . . 98 Exa 21.1 Construct R and X chart . . . . . . . . . . . 99 Exa 21.2 Construct the control charts . . . . . . . . . 100 Exa 21.4 Calculate poisson probabilities . . . . . . . . 102 Exa 21.5 Calculate probabilities of defective items . . 102 Exa 21.6 Determine producers and consumers risk . . 103 Exa 21.7 Evaluatepreliminaryandrevisedcontrollimits 103 Exa 21.8 Find control limits for c chart . . . . . . . . 105 Exa 21.9 find control limits for charts . . . . . . . . . 106 Exa 21.10 Determine producers and consumers risk . . 108 8 Exa 22.1 Find range of cutting velocity . . . . . . . . 110 Exa 22.2 Determine speed ratios and teeth . . . . . . 111 Exa 22.3 Calculate speed and number of teeths . . . . 112 Exa 22.4 Calculate common ratio . . . . . . . . . . . 113 Exa 22.5 Calculate gear ratio teeth and speed . . . . 114 Exa 23.1 Calculate forecast . . . . . . . . . . . . . . . 116 Exa 23.2 Calculate forecat by SMA method . . . . . 116 Exa 23.3 Calculate forecat by WMA method . . . . . 117 Exa 23.4 Calculate forecast for january . . . . . . . . 117 Exa 23.5 Calculate total cost . . . . . . . . . . . . . . 118 Exa 23.6 Calculate economical order quantity . . . . 118 Exa 23.7 Calculate economic lot size . . . . . . . . . . 118 Exa 23.8 Calculate inventory control terms . . . . . . 119 Exa 23.9 Calculate discount offered . . . . . . . . . . 119 Exa 23.10 Calculate EOQ and reorder point . . . . . . 120 Exa 26.1 Calculate number of machine required . . . 121 9