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Design of a section of the tool shop for the manufacture of molds using electrical technology for the manufacture of a part of the type "bumper basket" in the conditions of mass production

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The project considers and solves a number of tasks of technological design and production preparation in relation to the manufacture of the "matrix" part to obtain the "bumper basket" part. The technological process of manufacturing was developed due to the use of high-efficiency CNC equipment and physical and chemical processing processes, due to the concentration of operations at a limited number of jobs and their reduction. The modes and conditions of processing by calculations, patent and theoretical studies have been clarified. The result is reduction of labour intensity and cost of processing. A version of the production site organization is proposed; analysis of safe working methods has been performed; issues of environmental safety of production are considered.

Project's Content

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Additional information





1. Characteristics and technological expertise of the production facility

1.1. Analysis of "basket bumper" part drawing, general requirements to its design, its functional purpose, structural and technological features

1.2 Analysis of material process properties

1.3 Comparative analysis of modern processes of plastics processing into a product

1.4. Select a method for obtaining a basket bumper part

2. Analyze existing mold design methods

2.1. Overview of modern CAD systems used in the design of casting equipment

2.2. Pro/Engineer Automated Mold Design Sequence

2.3. Design a 3D model of a basket bumper part

2.4. Calculation and Design of Mold Functional Systems

2.5. Selection of equipment for production of "bumper basket" part and description of its operation

2.6. Automated FOE Design for Basket Bumper Part

2.7 Modeling the Mold Filling Process in Plastic Advisor Software to Design Injection Molding Modes

3. Development of manufacturing process of "matrix" part with development of EEO operation

3.1 Design of routing process of part processing "matrix"

3.2. Patent search for a method for obtaining narrow slots

3.3. Pre-establishment of process route and selection of equipment groups by process operations

3.4. Establishment of the list of necessary transitions for forming the surfaces of the part "matrix" and generation of operations

3.5. Selection of equipment for "matrix" part manufacturing

3.6. Process Step Flow Definition

3.7. Calculation of processing allowances and final procurement selection

3.8. Calculation of cutting modes

3.9. Instrument Selection and Setup Design for Drilling and Boring

3.10. Development of the EEA operation

3.10.1. Operating fluid selection

Calculation of EEO operation modes

3.10.3. Automated tool electrode design

3.10.4. Selection of accessory and design of adjustment for EEA

4. Analyzing Existing Matrix Part Inspection Methods

4.1 Recommendations for Product Quality Management


5. Organization of facility production

5.1 Organization of production on the basis of object-closed area

5.2 Calculation of organizational parameters of the production process

5.3. Preparation of shop cost estimates

5.4.Defining workshop cost of part


6.1. Analysis of harmful and hazardous production factors

6.2 Measures to eliminate and reduce harmful and hazardous industrial factors

6.3. Calculation of artificial lighting

6.4 Calculation of protective grounding

6.5 Fire Safety

6.6. Environmental protection


Bibliographic list



"Design of a section of the tool shop for the manufacture of molds using electrical technology for the manufacture of a part of the type" bumper basket "in the conditions of mass production"

Calculation and explanatory note to the diploma project in specialty 150206 "Machines and technology of high-efficiency processing processes"

/ Student gr. 430131 A.A. Kozyrev- TULA, TulSU, 2008. –

Page 175 ; Figure 34; Table 50; bibliologist. nazv.35; approx. 14 l ./


The project considers and solves a number of tasks of technological design and production preparation in relation to the manufacture of the "matrix" part to obtain the "bumper basket" part. The technological process of manufacturing was developed due to the use of high-efficiency CNC equipment and physical and chemical processing processes, due to the concentration of operations at a limited number of jobs and their reduction. The modes and conditions of processing by calculations, patent and theoretical studies have been clarified. Result is reduction of labour intensity and cost of processing. A version of the production site organization is proposed; analysis of safe working methods has been performed; issues of environmental safety of production are considered.


The most important tasks facing special branches of mechanical engineering engaged in the production of automatic machines are the rapid development and production of new types of products of high quality with the lowest labor costs and technological cost of production. To solve these problems in mechanical engineering, where products are manufactured under conditions of small-scale and serial production, it is necessary to ensure high labor productivity.

A significant reserve for productivity growth is a reduction in the labor intensity of machining parts on metal cutting machines. In the context of a constantly changing program and range of manufactured products, it is possible to automate the machining of parts only on the basis of the use of CNC metal cutting machines, as well as lines and sections based on these machines.

The efficiency of production, its technological progress, the quality of the produced products largely depends on the technology of manufacturing the product. The correctness of part machining and assembly processes is very important. The developed technological processes should be progressive, ensure increase of labor productivity and quality of parts, reduction of labor and material costs for its implementation, reduction of harmful effects on the environment.

In small-scale and mass production, which covers 7580% of mechanical engineering products, it is necessary to give preference to processes that focus on the use of CNC machines. CNC machines do not require lengthy renegotiation when moving to another part. To do this, it is enough to change the program, cutting tool and accessory. This allows you to process a wide range of parts on the machine. Working in an automatic cycle, the NC machine retains the properties of a universal machine. In technological terms, the use of CNC machines opens up the opportunity to implement a fundamentally new concentrated version of building technological processes for machining parts with a minimum number of operations. Unlike the traditional and obsolete version of the process design of parts processing based on differentiation of operations, a concentrated version of the technology construction along with a significant reduction in the time and costs of technological preparation of production, allows to increase labor productivity and ensure higher accuracy and quality of processing.

Engineering Section

1.1.2. Part Working Conditions

The part works under normal conditions. The load to which the basket bumper part is exposed can be considered small. Basically, this load is experienced by the part of the product where the slots are located.

Under operating conditions, reduce the roughness of the groove profile by reducing the roughness of the mold mass surfaces. This will reduce friction and increase cycle strength of the part due to elimination of surface stress concentrators.

1.1.3. Analyzing Part Geometric Properties

The product should be designed simultaneously with the analysis of its processability, since the design of the plastic product significantly affects the design of the mold, depending on the processability of the product.

When designing plastic products, it is necessary to strive to ensure rational conditions for the flow of material in the mold, improve manufacturing accuracy, reduce internal stresses, warpage, and the production cycle.

The following requirements apply to the construction of a plastic product:

the article must have process slopes;

if possible, avoid undercuts (protrusions and depressions);

tolerances shall be technically justified;

the article must have roundings in the wall conjugations to increase mechanical strength and facilitate the shaping process;

walls of the article should be as thick as possible, without abrupt transitions.

Analyzing the technical specifications for the manufacture of the "bumper basket" part, we conclude that the necessary dimensions and geometric shape are obtained by a tooling made taking into account the properties of the part material, recommendations regarding the design of the products (their processability ).

1.1.4. Complexity of part configuration

The total number of basket bumper surfaces is insignificant and all have different shapes. The design of the part is complicated by the small thickness of the walls, roundings and the presence of complex-facial slots. In general, a part can be considered of medium complexity.

1.1.5. Surface Accuracy and Quality Requirements

The following process conditions are not allowed on the part surface:

cracks, shells, bloating;

- traces from pushers with depth more than 0.5 mm;

- chips at grinding points and depth more than 0.5 mm (not more than one chip by 20 mm of machined edge length);

-deposition more than 10% of the total surface of the part;

- cracks and deformation;

underfilling, underfilling and bloating of more than 0.5 mm;

- arrangement of structural and technological thickenings inside the part at the distance less than 4 mm from the part edge, at that shrinkage value should not exceed 0.3 mm.

On the internal surface of the part, as well as on the surfaces of the part, not

determining the presentation, it is allowed: traces from pushers protruding or drowning by a value of not more than 0.5 mm.

Dimensions of internal radii of part R = 0.5 mm. Surface roughness is due to the inner surface of the press mold, the working surfaces of which must be polished and lubricated (silicone lubricant or model wax composition) after each pressing cycle in order to avoid undesirable defects.

Plastic articles shall not have significant protrusions. No process protrusions are provided on the surface of the article to accommodate the ejectors. Due to the fact that the product does not have undercuts, it is easily removed from the seats and does not require the use of additional design elements.

The appearance of the part must match the approved pattern. All dimensions are provided by the mold form of the part, which is evaluated at startup.

1.1.6. Product Shape Analysis

Minimum wall thickness = 1.5 mm;

Maximum wall thickness = 2.2 mm.

The overall dimensions of the part are 96.8 × 7.1 × 12 mm;

The volume of the part is 3848.6 mm3.

After manufacturing, the part is subjected to locksmithing, during which a number of operations are carried out:

- removal of the gate;

- cleaning the trace from the gate;

The part does not have sharp corners and has two slots.

Based on the above, it is possible to conclude that the part to be manufactured is technological, which allows further simplifying the tooling design process. The part meets the requirements for the construction of plastic products, ensures rational conditions for the flow of material in the mold and obtaining manufacturing accuracy (based on the design), and also ensures the production of internal stresses (based on technological conditions) of the minimum possible values ​ ​ and the absence of warpage.

1.3 Comparative analysis of modern processes of plastics processing into a product

The use of advanced polymer processing equipment using so-called "high" technologies, as well as modern materials, obliges technologists to take a new look at the development of technological regimes, relying not only on the recommendations of manufacturers of equipment and materials.

Any process of polymer processing is inevitably associated with the flow of melts under the influence of various forces that cause elastic, highly elastic and plastic deformations in it and the study of such systems causes the need to attract rheology, which characterizes the patterns of deformation and flow of material under the influence of mechanical stresses.

Currently, more than 20 main and a number of specialized methods of processing plastics have become widespread. The number of recyclable types and brands of plastics is more than 100. Under these conditions, it is of particular importance to choose the correct method of processing the polymer depending on its grade, the design of the obtained product, the serial production and the available equipment.

By purpose, the methods of processing plastics are divided into preparatory, main and final.

Preliminary preparation methods are used to improve the processing properties of the processed raw materials, as well as to obtain semi-finished products and blanks (granules, tablets, sheets) used as starting materials in the main processing methods. Preparatory methods include mixing, rolling, tableting, drying and preheating, granulation.

Mixing is one of the most important methods for preparing polymer compositions, which serves to obtain a mixture of the main polymer and various components and significantly improves the properties of the material and articles therefrom. At the same time, the resulting mixture should be uniform in physical and chemical properties and should have a uniform distribution of components throughout the entire volume of the mixture.

Rolling is the process of mechanical and thermal treatment of polymer materials in order to increase their plasticity and uniformity or transfer them to a state that facilitates further processing (heating, plasticization).

Tableting is the process of preparing material for further processing by compression. In this case, stable weight-resistant tablets of a given shape are obtained. Application of tableted raw materials increases accuracy of dosing, reduces losses of raw materials, preheating time and compression cycle, improves working conditions.

Drying and preheating of materials is carried out to increase their looseness and remove excess moisture and volatile substances from them. Use of dried and preheated polymer raw materials enables to obtain articles with high physical and mechanical properties and good surface quality.

Granulation is used to obtain a granular material from the melt of the polymer, which is most convenient for processing.

Granulate is a loose material consisting of particles that are uniform in size and shape. The use of pellets stabilizes the operation of the processing equipment, facilitates the dosing of raw materials, improves the productivity of machines and the quality of finished products. Granulation is often combined with processes of plasticization, stabilization, filling, staining.

Granulation will be used as the pre-preparation method of the material, since the granulate is most convenient for processing.

The main processing methods are the processes of producing the polymer material of the finished product of a given shape from the initial raw material. The articles are manufactured mainly by extrusion, injection molding, pneumatic and vacuum molding, pressing, calendering, sintering, pressure-free casting, centrifugal and autoclave casting.

Extrusion is the process of producing a given cross-section from the starting polymer material of an article by continuously pressing the polymer melt through a forming head and then cooling the article. Extrusion produces sheets, pipes, films, gaskets, ladder handrails and other profiles; method is used to apply polymer insulation on wires and cables, to coat paper, cardboard, foil, etc. with polymeric materials. The production of granular plastics, monofilaments, meshes is also based on the extrusion of polymer melts.

Injection molding is one of the main methods of processing thermoplastics into products. The method allows you to produce high-quality products of varying degrees of complexity with high accuracy.

The processing of thermoplastics by injection molding consists in heating the material until softening and subsequent transition to a viscous-flowing state in the heating cylinder and injecting (injecting) it into the mold, where the material acquires the necessary shape (moulding) and solidifies.

Cooling water of preset temperature circulates in mold channels. The injection molded articles are varied in both weight and configuration and size. Casting products are widely used in the automotive industry, instrument making, in construction, shipbuilding, aircraft engineering, in medicine and in everyday life.

The method is characterized by high productivity, since the material is heated outside the mold. Casting products are obtained with high dimensional accuracy and require minimal machining.

The pressing consists in heating the pressurized material in the mold. The design and hardening of the product takes place in a form. The duration of heating, holding under pressure and curing (for reactoplastics) or cooling (for thermoplastics) depends on the nature of the material, size and shape of the article.

There are two types of pressing: direct (or compression) and casting (or transfer).

In direct pressing, the pressure directly acts on the material in the mold cavity. Since pressure is directly transmitted to the material in the mold, the mold parts are subject to relatively rapid wear. In addition, some anisotropy of properties can occur in the articles, which under certain conditions can cause warping.

In injection molding, the dose of material becomes viscous in the chamber before the mold, then the melt is fed into the mold where the compression itself takes place.

Injection of the polymer through a narrow nozzle increases the uniformity of the temperature field in the mass of the material, as well as improves its homogenization. The advantage of injection molding is also the slight wear of mold parts due to the fact that the pressure in this case does not directly affect the material in the mold, as is the case with direct pressing. The method allows you to manufacture articles of complex configuration with reinforcement, since the latter is not subjected to large shear forces and does not shift, as in direct pressing.

Pressure-free casting is the molding of articles of monomers, or polymeric monomer compositions, polymerized directly in the form in the presence of initiators or catalysts without applying external pressure. This method combines polymer synthesis and processing into a single technological cycle, allowing you to obtain products according to the scheme: a monomer-finished product. When cast without pressure, the monomer or its mixture with the polymer with the necessary additives is poured into a mould in which the processes of structuring and forming the article take place simultaneously. As a result, thermoplastic materials with an ordered structure and a high content of the crystalline phase are formed, which provides high physical and mechanical properties.

At present, articles from polyamides (e.g., caprolone) and compositions based on

The final methods give the finished products a certain appearance, create an integral connection of the elements of the product. The most important of these methods are machining, welding, gluing and coating.

Of these methods of processing plastics, injection molding, pressing, extrusion are the most productive. These methods are related to the manufacture of expensive tooling (presses, extrusion heads) and are suitable only for mass, large-scale and medium-scale production. In small-scale production, depending on the type of product and material, processing methods are used that do not require significant costs for tooling (mechanical treatment, welding, gluing, stamping).

It is recommended to manufacture single articles by machining from blanks (monolithic small and medium sizes) or from sheets by welding, gluing, etc.

Analyze existing design methods

2.1. Overview of modern CAD systems used in the design of casting equipment

At the stage of technological preparation of the production, to which the design of molds belongs, the designer is forced to perform detailed design of the tooling in a short time and transfer it to the production. He has a great responsibility not only for making a technical decision on the design of the tooling, but also for the entire subsequent cycle of its production operation.

Modern technologies based on the use of expensive injection molding equipment require the use of high-quality molds. The injection mold is tailor-made for each case. Even the development of typical tooling is often difficult.

The overall design sequence of the forms, including the justification for the choice of the type of the entire structure and its individual functional systems, can be most optimally implemented using CAD. Currently, various versions of such CAD molds for injection molding based on banks of data on equipment, materials, standards for typical normalized mold parts, drawings of products and form analogues are becoming widespread. Among which are the following most popular:

CAD/CAM/CAE/PDM/TDM mid-tier system SolidWorks 2007. Its developer is the American company SolidWorks Corp.;

CAD/CAM/CAE/PDM/TDM is a high-level Pro/ENGINEER WildFire 3 system. Its developer is the American company RTS (Parametric Technology Corporation);

CAD/CAM/CAE/PDM/TDM high-level Unigraphics NX3 system. The developer of this system is EDS (Electronic Data Systems) Corp.;

CAD/CAM/CAE/PDM/TDM high-level CATIA V5 R16 system. The developer of this system is Dassault Systemes;

CAD/PDM is a hybrid modeling system that combines Power SHAPE 7 surface and solid design capabilities. Its developer is the English company Delcam.

In this degree project, Pro/ENGINEER CAD designs the basket bumper part.

Pro/ENGINEER is a computer-aided design system with the unique capabilities of optimal design and allows you to quickly and qualitatively design and manufacture new products at minimal design costs.

Pro/ENGINEER-Enables you to design products of any complexity. These can be multi-component designs of high-tech products with complex surfaces. Design of process tooling (dies, presses, molds, tools) and cutting tools, and machining programs on a variety of CNC machines, as well as post-processors for these machines and much more.

2.2. Pro/Engineer Automated Mold Design Sequence

1. A mold model is created. Reference models, workpieces, fasteners, or mold plate components are collected or created.

2. You check the slopes on the reference model to see if it can be freely ejected from the mold. You define additional draft elements in the model design or reference model.

3. The shrinkages for the mold model are considered.

4. Define parting surfaces to split the workpiece into separate volume components.

5. Defines the mold volumes to create mold components.

6. Runners and other cast features are added. They will be used when creating a mold, as well as when checking collisions during the process of opening the mold.

7. Specifies the steps to open the mold. The impact with the stationary components for each step is checked.

8. The preliminary size of the mold is evaluated and the corresponding mold plate is selected.

9. Assemble mold components.

10. Completion of the project, with placement on layers of the ejection system, signs and other elements.

11. Transfers mold components to Pro/NC for NC machining.

Development of manufacturing process of "matrix" part with development of EEO operation

3.1 Design of routing process of part processing "matrix"

To develop the manufacturing process of mass elements, we will carry out a technological analysis of the design of the mold element - cavity.

The main criteria for the processability of the "matrix" part to be treated are the labor intensity, accuracy of obtaining geometric dimensions and roughness of the obtained surfaces.

An equally important requirement for the processing process is to ensure the accuracy of the form and operating conditions. This also largely depends on the design features of the matrix. The accuracy and stability of processing is largely due to:

a) simplicity of structural shapes of machined surfaces;

b) reliability of technological bases ;

c) rigidity of matrix application, absence of deformations under action of fixing forces and processing forces;

d) combination of design, technological and measuring bases.

The die has a rather complex structure, this is due to the presence of narrow long slots, radii of rounds and holes. Thus, the die forming element is quite laborious to manufacture.

The die has flat side surfaces that can be used as process bases to provide reliable orientation and rigid attachment in the tool.

3.1.1. Part assignment in the product, its functions

The die part is a mold element for making a basket bumper part from a polypropylene material. The part must have the necessary and sufficient dimensional accuracy and surface roughness, as well as ensure sufficient processability and cost.

3.1.2. Part Working Conditions

The part operates under medium temperature conditions (20003000C). Negative factors (exposed to cyclic, force and temperature, pressing pressure and variable loads, abrasive wear from the material of the pressed article) most significantly affect the operational performance of the matrix. Under operating conditions, the surface roughness should be reduced (chrome-plating of the inner surface). This will help to reduce friction and increase the cycle strength of the part due to the elimination of stress concentrators along the internal profile of the matrix, as well as wear and erosion resistance.

3.1.3. Complexity of part configuration

Die surfaces have a simple configuration of cylinders and planes, so they are available for traditional machining methods using a standard tool. However, the presence of narrow and long slots complicates the use of conventional processing methods.

3.1.4. Degree of stiffness of the part

The die is a plate with a thickness of 22 mm and plan dimensions of 156x156 mm, so the die is a rigid part.

3.1.5. Design and design bases

The main design base is the outer section for fitting the matrix into a shape measuring 156156mm, and the design base is the side of the matrix measuring 15622mm.

3.1.7. Coatings, special types of finishing and strengthening treatment of surfaces

The matrix is heat treated in order to increase hardness and strength. Typical operation, it should be carried out according to the process plan at the end of rough processing operations.

Special types of processing regulated by technical requirements: chroming of the matrix surface.

3.1.8. Defects of the part regulated by technical conditions

Defects of the part are not regulated by the technical requirements

3.1.9. Control tests

The monitoring complex is selected according to GOST 917881 and is installed depending on the conditions and capabilities of the manufacturer.

3.1.12. Physical and mechanical properties of surface layers

To be made a covering of surface KH24tv., roughness after a covering - Ra of 0.16 microns.

3.1.13. Typing the processing process

The die can be referred to as a group of flat parts of the plate type with an inner shaped surface .

For the development of the part processing process, a typical technological route for manufacturing flat parts of the plate type can be used. It provides for a number of sequential operations: milling, drilling, grinding, heat treatment, as well as coating. Thus, these operations provide roughing and finishing of all the main surfaces of the die.

3.1.14. Nature of the proposed process

Production type is serial.

3.1.15. Using Progressive Blanks

Matrix form - a plate with the parallel planes of 156Х156Х22 mm in size therefore it is expedient to use the goryachekalny GOST 1990374 sheet metal 1200Х3800Х25 in size as preparation. The usage factor of the workpiece material in this case is Kim = 0.89 (Kim = Vdet/Vzag), that is, the ratio of the part volume to the workpiece volume. The volume of the part in the calculation is defined as the sum of the volumes of elementary geometric bodies that make up the workpiece. This Kim value satisfies the efficiency of mass production.

3.1.16. Requirements for special equipment and equipment

Appropriate equipment (CNC Multi-Operation Machines, Cutout Machine, Flat Grinding Machine), accessory and tool shall be provided to obtain die surfaces.

3.9. Instrument Selection and Setup Design for Drilling and Boring

Based on the dimensions of the part, its surfaces, we select the assembly-disassembly device PSA (GOST 2169076), which has permanent adjustable mounting clamping elements and is intended for installation of blanks of different shape with relatively simple basing schemes.

The SPR is composed mainly of units on the elements only longitudinal T-shaped slots and systems of accurate coordinated cylindrical holes are provided. Fixation of units and parts is performed by means of "cylindrical pin - precise hole." PSA is characterized by a high level of mechanization and adjustment. They provide (compared to USS) greater accuracy of the product processed in them and performance.

In step 0140, processing is performed on the OS40A universal processing center. For machining on the machine of this model, a single-seat device is used. The part is based on a plane and two bars.

The fixture is oriented by two pins which enter the slots on the machine table. Attachment of the accessory is performed by means of two bolted connections.

The assembly drawing of the accessory is shown on DP sheet 08.420131.03.005.

We design adjustment for operation 0140 in accordance with the selected equipment, calculated modes and the selected device.

Adjustment drawing is presented on DP sheet 08.420131.03.006

Analyzing Existing Matrix Part Inspection Methods

There are certain methods for quality control of the matrix part:

1). Accuracy of geometric dimensions of the part;

2). Physical and mechanical control.

The accuracy of the geometric dimensions of the matrix part is checked with a measuring tool that provides the necessary measurement accuracy. To measure overall dimensions, a stangelcircle protrudes with an accuracy factor of 0.05mm .

Gauges are used to control the hole.

The calibers are designed for scale-free verification of the dimensions of the parts. By purpose, calibers are divided into the following groups: working, receiving and control. The working and receiving gauges are called limit gauges, since their dimensions correspond to the limit sizes of the controlled surfaces.

As-built dimensions of gauges are calculated by formulas or determined according to GOST 2140175 without calculations.

Calibers according to technological characteristics can be divided into four classes: 1- calibers - plugs, 2 - calibers - rings, 3 - calibers - stamped and cast staples, 4 - calibers - staples.

By the nature of the production of blanks, calibers are divided into sheet, stamped, cast and made of round rolled stock. Stamped calibers are made of carbon structural steels 10, 15 (GOST 105088) and alloyed structural steels 15X, 20X (GOST 454371). To increase the resistance of calibers, their working parts are equipped with solid alloy VK8.

The surface quality of the part is checked visually. In practice, the method of inspecting the appearance of the "matrix" part by comparing it with a reference (sample part), which is agreed in advance, is widespread.

Properly carried out quality control of the "matrix" part, will protect the enterprise from penalty, (return of scrap), will lead to well-established production and optimal operation of the enterprise.

4.1 Recommendations for Product Quality Management

Product Quality Management (matrix part), follow a number of recommendations during part production.

Recommendation No. 1

Quality control of the workpiece - hot-rolled sheet. Procurement must be stored in factory batches. After laying out the received batch of blanks, the number of the room and rack is indicated in the passport compiled by the supplier or in a special card.

In accordance with the assortment plan, the specifics of the manufactured products and the data of the passports, the batches of material are assigned to specific products, which are indicated in the passport and in the process card posted at the workplace.

Quality of blanks shall comply with GOST or specifications. In case of large differences in quality indicators, they are not allowed to work and are returned to the supplier.

Recommendation No. 2

Quality control of the "matrix" part during manufacturing. The main condition of good quality of the "matrix" part is operation in optimal mode with automatic control of process parameters with constant interoperative visual inspection.

An important place in the quality control of the "matrix" part from belongs to the working interoperative disassembly during the production process: at the beginning after milling, then after drilling and thread cutting, after grinding and EEO operations.

Recommendation No. 3

Control operations of OTC. Delivery and acceptance of finished products shall be carried out in batches. A lot is considered to be products of the same type, from one batch of raw materials, made on the same equipment in the same mode and executed in the same document .

For inspection, 5% of the parts are taken from each batch. Selected samples shall be checked according to appearance and dimensions in accordance with the requirements of the group specifications. The appearance of the parts is checked by visual inspection, measurement by a universal measuring tool. If 3% of the samples taken do not comply with the requirements of the group specifications, only the actually detected number of poor-quality parts is rejected. If more than 5% of the samples taken do not match, the whole batch is married .

Organizational and Economic Division

5. Organization of facility production

In mechanical engineering, three main types of production are distinguished: mass, serial and single. In turn, serial production is divided into large-scale, medium-scale and small-scale.

An important characteristic of the type of production is the degree of specialization of workplaces, characterized by the coefficient of fixation of operations, which means the number of part operations performed at one workplace. It most fully characterizes the degree of concentration of single-profile work at the workplace. [27]

In accordance with GOST 3.110874, various types of production are characterized by the following fixation factors:

1. Mass 1;

2.krupnoseriynoye 110;

3. Medium batch 1020;

4. Small-scale 2040;

5.Unit more than 40.


In this diploma project, in accordance with the issued technological assignment, the manufacturing technology was developed and a section of the tool shop for the manufacture of the "matrix" part was designed to obtain a "bumper basket" type part using electrical technology.

In the process of disclosing a given topic, various methods of obtaining a "basket bumper" part were considered. Analysis of these methods led to the choice of the optimal option - injection molding.

The functional elements of the press mold were calculated, optimal casting parameters were chosen using computer technologies, on the basis of which the casting machine was chosen.

The technological route for manufacturing the "matrix" part has been developed. Equipment selection was made, machining modes for mechanical and electrical erosion machining were calculated.

Organize the production of the object and calculate the economic parameters during the production of the matrix part.

Measures on labor and environmental protection were analyzed.

Drawings content

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