TABLE OF CONTENTS
INTRODUCTION
.Obschaya Part 1
1.1 Purpose and working conditions specified details
1.2 Specifications for acceptance details
1.3 Material components and their characteristics
1.4 Analysis of technological design details
Technological part 2
2.1 Type of production and its characterization
2.2 0predelenie exhaust stroke details
2.3 The choice of method blanks production
2.4 Determination of machining allowances
2.5 Calculating the size of the workpiece and the utilization of metal
2.6 Plan of Operations of the part
2.7 Selection of bases
2.8 Separation of operations on the installation and transitions
2.9 Selection of equipment for operations
2.10 Selection tools, cutting and measuring tools for
Operations
2.11 The interim allowances and sizes
2.12 Calculation of cutting conditions on standards
2.13 Analytical calculation of cutting conditions on two diverse operations
2.14 Calculation of norms time for all operations, the establishment of discharges
2.15 "The economic rationale for the selected treatment option
PART 3.KONSTRUKTORSKAYA
3.1 Designing a special cutting tool
3.2 Design of the measuring instrument
3.3 Design of machine tools for milling operations
4 INDUSTRIAL BALANCES AND SITE PLAN 4.1 Calculation of technological equipment and its load
4.2 Selecting the required amount of lifting and handling equipment
4.3 Calculation of the main and auxiliary workers
4.4 Calculation of production space, a description of the site plan
5 ORGANIZATIONAL PART
5.1 Organization of jobs and system maintenance
5.2 Measures for the Protection of the pile and Safety
5.3 Measures to save energy and metal
5.4 Determination of annual needs of materials, tools,
energy and water
ECONOMIC PART 6
6.1 Valuation of fixed assets
6.2 Determination of the cost of materials
Determining the value of lowvalue 6.Z tools and equipment
6.4 Determining the value of all forms of energy and water
6.5 Definition of the payroll
6.6 Estimated costs of shop
6.7 Calculations costing shop cost per unit of output
6.8 Calculation of the costeffectiveness of the project and the level of profitability
6.9 Technical and economic indicators section
Output
References
Sheet comments normokontrolera
Graphic materials
Sheet 1 f A2 "Site Plan"
Page 2 f A2 "Corpus"
Page 3 f A2 "Body casting"
Sheet 4l A1 "Map setup"
Page 5 f A3 "Hand taps for metric thread"
? 6 A3 sheet "Fuses carving"
Sheet 7 ft A1 "Tool milling"
Sheet 8 p A1 "Tool milling"
INTRODUCTION
The Republic of Kazakhstan needs to raise and restore come in recent years in unsuitable equipment valves.
In the presidential program "Kazakhstan2030" for raising the economy of the Republic of Kazakhstan much attention is paid to raising and development of agriculture, as well as shutoff valve is an integral part of the equipment of agriculture, there is a need to create specialized repair shops shutoff valves on the ground.
In this thesis work a project of specialized workshops that can produce the repair and overhaul of valves.
With the creation of this workshop is to create new jobs, reduce costs for repair and maintenance of equipment.
1 GENERAL
1.1 PURPOSE AND WORKING CONDITIONS DETAILS
GL 21003100ASB housing is a basic part of the valve. The valve is a valve spindle, is screwed into the threaded nut fixed hodovoy located in the cap or yoke. The use of threads, having the properties of selfbraking, by leaving the plate valve in any position with the confidence that this situation will continue and will not spontaneously change under the pressure of the environment.
Using thread allows the use of small efforts on the flywheel to control valve. The valve is simple to design and creates good conditions for reliable density at the closed position of the shutter.
For these reasons, the valves got very widely used mainly in the shutoff valve.
The valves are designed to work on pipelines and gas pipelines (water, steam, corrosive environments PN = 6 MPa (60kgs / cm2))
1.2 TECHNICAL REQUIREMENTS FOR ACCEPTANCE DETAILS
1) You can surfacing 15x15 N9G2S Hb = 200 TU 2 078I08477
2) For valves with electric smelting to produce electrode
CM6L5,02.
3) Unspecified casting radii up to 6 mm.
4) Unspecified tolerances of the holes on the H14 shafts h14 others  by ± (IT14 / 2)
5) At the end of the balance of profit traces autogenous cutting does not affect the thickness of the wall.
PN40
6) for general release end balance of profit is allowed not handle.
100
7) marked with the type number 14 according to GOST 466675 mark of the manufacturer.
1.3 part material and its characteristics.
Detail  GL21003100ASV body is made of steel castings 25JI GOST 97775 of the first group.
For the manufacture of castings used basic or acid openhearth or electric steel.
The chemical composition shall conform to the requirements specified in Table 1.
Table 1  Chemical composition.
Steel grade: C Mn Si P S Cr Ni Cu
25L 105074 0.22 0.35 0.30  0.90 0.20  0.52 0.06 0.06 0.30 0.30 0.30
1.4 Analysis of technological design details
One of the most important factors that influence the nature of the process is the design manufacturability.
Hull construction GL210Z 100 ASB complex configuration, but this design has convenient technological base that provide the required guidance and reliable fastening of the workpiece on the machine when its processing capabilities with multiple parties and a free supply of the instrument to the surface. The housing has a sufficient rigidity at which exclude the possibility of vibration during handling or excessive deformations of the cutting forces and the fastening.
Technological part 2
2.1 TYPE OF PRODUCTION AND ITS CHARACTERISTICS
The annual program statement valve GL 21003  100 ASB conditionally accepted
35000 pieces
Given the weight of the part and the annual program, the type of production is determined by the ratio
KZ.O. = Q / PM = 8/7 = 1.14;
Q where the number of different operations;
RM number of jobs that are running these operations,
Highvolume production.
In largescale production for each workstation attached one operation, which is carried out for a long time without a changeover to other operations using special equipment.
Special equipment is widely automates and mechanizes processes, inline methods. Such work organization provides high performance and relatively low production costs.
2.2 0PREDELENIE exhaust stroke PARTS
The value is calculated based on the measure adopted in the draft twoshift operation.
Time  is the time interval over which periodically release of products made certain names and sizes.
Tact is determined by the formula [7]:
t =,
where: t  exhaust stroke in minutes;
Fy  actual annual fund operating time per hour .;
N  annual program of manufacture of the product.
t = = 6,88 m
2.3 CHOICE OF METHOD OF PRODUCTION BLANKS
Guided by the design details, material specifications,  the scale of production and objectives, in order to save metal adopt the method of producing a green  casting in sand molds. This method is used for complex shaped workpieces.
In today's manufacturing and technological process, the flask with the mold halves, custommolding machines, come to build on the tables. At the same time the conveyor fed rods with rod section. Collected forms are filled with dogs. Metal flows from the furnace via ladles suspended. Further conveyor drenched form is transported to the cooling chamber and the knockout lattice, where the separation of the casting from the flasks and the moldable mixture.
Dimensional accuracy of castings corresponds to I class.
Casting requires molding core to form the internal cavities of [3].
2.4.OPREDELENIE machining allowance
Allowance is called a layer of metal to be removed from the surface of the workpiece during processing.
Assign machining allowance body parts GL21003  100 ASB
Mass m = 27,4
The largest size of 350 items
Estimated size of the blank:
Ap = bottom. ZOn + 2, Table 3.6 [4]
where: Dr. raschetny diameter of the workpiece;
rated Bottom diameter of the workpiece;
Z0 general allowance for processing to one side.
When processing the linear dimensions
Hp = Nnom. + Zo, Table 3.7 [4]
where: Hp  estimated size of the flat surfaces;
Nnom.  The nominal size of the flat surfaces.
?230 + 2x4 = 238 mm
?115  2x4 = 107 mm
?100  2x4 = 92 mm
l 20 4 = 24 mm
l 19 4 = 23 mm
350 l + 4 x2 == 358mm
Tolerances, ie, deviations for billets GOST I85555 and AINO 200955:
?238 + 2 = 240 mm + 358 mm l 2 = 360 mm
?107  2 == 105 mm
?922 = 90 mm
l 1 = 24 mm 25mm
l 1 + 23 mm = 24 mm
2. Calculation of the size 5 Billets and metal recovery
The shape of the workpiece  a figure complicated configuration.
Harvest volume is determined from the plustolerances, which divide the figure by 8 elementary geometric solids:
F1 = (P2 r2) p = (107,52572) p = 25, 918.14;
V1 = F · h = 25 ? 25 = 918.14 669 657.3;
F2 = (P2 r2) p = (1202 502) p = 37 384, 95;
V2 = F · h = 22 = 37 384,95x. 834 383.2;
F3 = (P2r2) p = (8I2 502) p = 12 758;
V3 = F · h = 12 758 x 8 = I23 432,1;
F4 = (P2r2) p = (65 ^ 45 ^) p = 6 911.5;
V4 = F · h == 6 911,5 x 23. 168 = 964.5;
F5 = (P2r2) p = (87,52 52,52) p = 15393, 82;
\ / 5 = F · h = 15 393,82 x 40 = 636 753.3; _
F6 = (P2r2) p = (602 502) x 0,7854 = 3455,76;
V6 = F · h = 3455,76 x 110 = 401,345, 2;
F7 = (P2r2) p = 0,7854 (I302 1202) = 1963,5 x. 4 = 7854;
V7 = F · h = 7854 x 120 = 973,860;
F8 = (P2r2) p = (752. 502) p = 9 817.47;
V8 = F · h = 9817,47 x 20 = 196 349.4;
Vobsch 669 657.2 + 834 383.1 + 123 432.1 + 168 964.5 + 636 753.5 + 401 345,2+ + 973 860.3 + 196 349.4 = 4 004745.3
G = Y · V3 = 0,00785 x 4004 745.3 = 31.450 kg
Since when calculating the volume of the workpiece can not account for all casting radii, gradients, round off, then take them equal to 20% of the total weight of the workpiece
DS = + 31.450 = 37.74 kg
Utilization rate of materials is [4]:
Ki.m. = Su: Cs;
Ki.m. = 27.4: 37.74 = 0.73.
2.6 PLAN DETAILS processing operations
05 Operation Drill  molding machines
10 Operation milling  GF 14 00
15 Operation Turning  MK 112
Operation 20 machine gun  I B 284
25 Operation surfacing  VKSM  1000 RB  301
30 Operation automaton  1B 284
35 Operation aggregate  1 AMI 443
40 Operation locksmith
45 Operation Control
2.7 SEPARATION OF OPERATIONS FOR THE INSTALLATION AND TRANSITIONS
05 Operation Drill  casting
10 Operation Milling  machine GF 1400
Please refer to the TB.
1. Set .Remove item.
2.Frezerovat casting profit
15 Operation Turning  Machine GF 1400
Follow the instructions for TB.
1.Set, removing,
2 .Tochit simultaneously two flange ? 230 mm and 350 mm l trim on both sides.
20 Operation of machinegun  machine 1B284
Soblyudat instructions T B.
1.Set, removing.
2.Podrezat end ? 215 mm.
3.Tochit ? 115 mm. t = ZMMblank.
? 124 mm 4.Tochit blank.
5 .Remove chamfer on the surface ? 215 mm.
6.Podrezat end ? 215 mm, sharpening ? 135 mm at point blank range.
25 Surfacing  VKSM  1000 RB  301
Please refer to the TB.
1.Set, removing.
2 Overlap surface ? 124mm h = b mm.
30 Operation of machinegun  machine 1B284
Observe the safety instructions.
1.Set, removing.
2.Tochit surface ? 124mm,
3.Tochit groove ? 113 mm t = 4 mm
4 .Tochit ? 120 mm.
5.Tochit ? 100 mm.
6.Tochit ? 120 mm.
35 Operation aggregate  machine 1AMO 443
Please refer to the TB.
1.Set, removing.
2.Sverlit 8 holes ? H4mm.
3.Sveryait 8 holes ? 23mm.
8 countersink holes ? 18mm.
8 drill holes ? 23mm.
4.Narezat thread MI6 step 2 to 8 holes.
40 Operation locksmith  workbench
Please refer to the TB.
1.Zachistit burr after porting.
2.8 SELECTION OF BASES
Called base surface, replace it with a set of surfaces, the axis, the workpiece or assembly unit, in relation to which other components are oriented products come workpiece surface, processed or collected on this operation,
Group design bases constitute the main and auxiliary base, which account in the design (choosing the shape of the surface, their relative positions, dimensioning, design standards of accuracy, etc.) is essential. The main base determines the position of the part or assembly unit in the product, and auxiliary baza position of the connecting parts or assembly unit with respect to the part.
Technological base called surface defining the position of a part or assembly unit during the manufacturing process.
Machine Planing GF I400. Basing the workpiece is made by flanges ? ? 240mm and 215mm flange. (Prism)
MK 112 machine.
Basing made the holes ? 100 mm. (Cams)
1B 284 machine.
Basing on the two flanges made ? ? 230mm and 215mm flange. (Cams)
Machine 1AMO 443
Bazirovanie two flanges ? 230 mm. (Prism)
2.9 SELECTION OF EQUIPMENT ON OPERATIONS
10 Operation milling
On offer milling operations take Planing a special machine model GF 1400 C16H8. The machine is designed for milling profits simultaneously from three sides in detail GL 21003  100 ASB.
Material Details Steel GOST 25111 97775.
Basic data of the machine GF 1400:
Table working surface dimensions according to GOST 695570:
width 500mm
length 1250mm
Maximum table travel 1250mm
Number of table feeds 18
Limits table feeds 201000 mm / min
Rapid traverse table 4500mm / min
The number of horizontal spindles 2
Number of vertical spindles 1
The greatest movement of spindle quill:
1 spindle 200mm
2 spindle 200mm
3 spindle 200mm
The distance from the surface of the table to the end
vertical spindle 30550 mm
Number of spindle speed:
1 spindle 19
2 spindle 19
3 spindle 19
Limits of spindle speeds:
1 spindle 251600 rev / min
2shpindel 25  I600 / min
3 spindle 251600 / min
Overall dimensions:
length 4290mm
width 3425mm
height 2900mm
Drive power kW 7,5h3
Machine weight 13100 kg
Price 186,710 tenge
Operation 15 machine gun, turning
On turning operations offer to take special flange lathe MK 112.
Basic data of the machine:
Maximum diameter of workpiece over bed 40vmm, distance between centers 710mm
The length of treatment with one caliper 640mm
Spindle speed 12,52000vb / min
Limits of working feeds:
74,16 longitudinal 0.0 mm / rev
cross 0,042,08mm / v
Machine dimensions:
width 2010mm
length 2522mm
height 1324mm
Machine weight 2178kg
Drive power 7.5 kW
20 Operation automaton
On turning operations offer to take six lathe spindle vertical semiautomatic model 1B284.
Basic data of the machine:
The largest diameter of the installed product passing over the guide when you turn the table Z6Omm
The largest diameter of the installed product on a round bottom of the column 548mm
Spindle diameter 470mm
Number of spindles 6
The greatest vertical movement of the caliper 200mm
Machine dimensions:
length 3285mm
width 2987mm
height 4040mm
Machine weight 15000kg
Price 115,430 tenge
Calipers;
The greatest number of supports on the machine 5
Number of carriages of various kinds:
simple vertical caliper 1
Caliper sequential steps of adjustment
Universal Caliper
Caliper drill head
Number of steps 22 innings
Rpm 20224
Feed per revolution of the spindle 0,085,00mm
Duration table rotation 3.4 seconds
Power LP kW
25 Operation surfacing BKCMIOOO RB301
30 Operation automaton 1B284
35 Operation aggregate
On an aggregate operation offer to take a threepronged horizontal drilling and threading spindle 40 with fourposition rotary table machine model IAM0443.
Operations: drilling, countersinking, threading.
Basic data of the machine:
Machine dimensions:
length 6350mm
width 4860mm
height 2500mm
Machine weight 23000kg
Price 150,798 tenge
Main motor power
motion 30kW
Table 1. Power UM2464011 with spindle box
horizontal layout
course of moving parts unit 500mm
spindle box:
envelope 800h720mm
number of spindles 8
main motor power
movement 5,5kBt
Table 2. Power UM2474012 with spindle box
horizontal layout
course of moving parts unit 800mm
spindle box:
envelope 1200h720mm
number of spindles 24
main motor power
movement 17,0kVt
Table 3. Power 5U4651S with spindle box
horizontal layout
course of moving parts unit 400mm
spindle box:
envelope 800h720mm
number of spindles 8
main motor power
movement of 7.5 kW
2.10 SELECTION devices. Cutting and measurement equipment ON OPERATIONS
10 Operation milling machine GF 1400
To hold the workpiece GL 21003100ASB
"The valve body is" designed single pneumatic device.
The workpiece is mounted on rigid supports and inclined plane of the prism strips. Clamp the workpiece by turning the handle pneumatic crane to '' hold 'by sticking leverage selfaligning,
Finished part is removed from the device.
Cutting tool:
Face cutter ? 160mm Standard
Face cutter ? 250mm Standard
The tool measuring:
Caliper 1125001 GOST 16680
15 Operation Lathe MK 112
Fitting: Insert PRK320
Cutting tool:
Cutter GOST 1887773 21020059 T5K10
Cutter Criminal 2I3040I5
Measuring tools:
Caliper 1125001 GOST 16680
Bracket 230mm ? n 14 STP 1742 16383
? 230mm bracket Criminal 8II34003 / 2
20 Operation automaton 1B284
Fitting: chuck model 425P
Cutting tools:
1.Rezets 10C2573 (20h32h100)
2.Rezets 10321000226IOO T5K10 STP 2100474
3.Rezets 1032101089465T5K10 STP 2101374
4.Rezets 12CC2573 (16h16h65)
5.Rezets 11S2573 (16h16h75)
GOST 1887773 6.Rezets 21020060
7.Rezets 10S2573 (20h32h100)
8.Rezets 10321000226100 T5K10 STP 2100474
Measuring tools:
Caliper ShTs112500,1 GOST 16680
Caliper ShTs 11250.1 GOST 16680
Cork ?115mm N14PR STP 0742.17283
Cork ?115mm N14NE STP 0742.17383
Cork ? 94mm N14PR STP 0742.17283
Cork ? 94mm H14 NOT STP 0742.17383
25 Operation surfacing BKSM 1000 RB301
30 Operation automaton 1B284
Fitting: chuck model 425P
Cutting tools:
Criminal 1.Rezets 21024010 (16h16h70)
Criminal 2.Rezets 21024010 0 (16h16h70)
Criminal 3.Rezets 21024011 (16h16h75)
Criminal 4.Rezets 21024009 (16h16h70)
5.Rezets 5S2808 (16h16h70)
6.Rezets 13C2573 (16h16h85)
7.3enker 2329 Criminal Code 400501
Measuring tools:
Caliper ShTs112500.1 GOST 16680
Cork ? 140mm STF N12PR 074217283
Cork ? 140mm STF N12NE 074217383
Caliper ShTs 112501GOST 16680
Cork 0 N14PR 100mm STF 074217283
Cork 0 H14HE 100mm STF 074217383
Template Criminal 84244199
Template Criminal 8424420001
35 Operation Machine 1AM0443
Device when the machine IAM0443050
Cutting tools:
? 14mm drill GOST 1212177 23013439
? 23mm drill GOST 1090377 23010079
Tap M1b 26201619N2 GOST 326671
Measuring tools:
Cork ? 14mm HI2 STP 0742.16983
Cork ? 23mm HI5 STF 0742.1693
Cork GOST 1775672 82210068 7H
Cork 822I10687H GOST 1775772
40 Operation locksmith
Grinding machines IP2013
Grinding PP 60h25h20 GOST 242475
GOST 7146569 Files 28220024
2.11 The interim allowance for processing
Calculation of allowance for processing the inner surface 140 ? + 0.40
D = 0.7 ± 1 mm / mm
rzagot. DUxL = 0,7x = 350 = 245 m
RAfter roughing = 245 x 0,06 = 14,7mkm
RAfter finishing = 14,7 x 0,05 = 0,74mkm
Because of the small value of r after finishing miss,
Ku = 0.06
Ku = 0.05
eu = eb + eZ
eb = 0
eu1 = 140
eu2 = 140 x 0.06 = 8.4
EAfter finishing = 8,4 x 0,05 = 0,42
Tolerances:
400  general admission to drawing
460  Annex 3
2000  Table 3.3
Estimated allowances
Ziminpo clean. 2 = (R · Zi1 + Ti1 + r2ie2u + 1)
Zimin = 2 (+ 100 + 100) = 429;
Ziminpo black. = 2 (250 + 250 + =
2 = (+ 500) = 1490;
Estimated size after roughing and maximum size limit
Estimated nominal plus the minimum allowance
140 + 0.429 = 140.429
Estimated size after finishing
Estimated size after roughing minus the estimated allowance:
139.57  1.49 = 138.08
The minimum size limit
Limiting the maximum size of minus tolerance:
after finishing
140  0.4 = 139.6
after rough
139.57  0.46 = 139.11
workpiece
138.08  136.08 = 2.0
The maximum allowance after roughing
The minimum size limit after finishing minus the size limit after the draft:
139.6  139.11 = 0.49 mm = 490 mm
139.11  136.08 = 3,030mm = 3030 mm
Minimum allowances
The maximum size limit after finishing minus the maximum size limit after roughing:
140  139.57 = 0.43 mm = 430 mm
139.57 138.08 = 1.49 mm = 1490 mm
Verification:
d1 d2 = 2000  460 = 1540;
Zimin Zimax = 3030  1490 = 1540;
1540 = 1540.
Linear dimension 200,84
r and e tezhe data
Ziminposle finishing = R · Zi1 + Ti1 + ri1 + Eu =
= 100 + 100 + 14.7 = 214.7
Ziminposle rough = 250 + 250 + 245 + 8.4 = 753.4
Estimate the size and the minimum size limit
after finishing
20  19.16 = 0.84
after rough
19.6 + 0.21 = 19.37
workpiece
19.37 + 0.75 = 20.12
Limiting the maximum size Estimated size plus tolerance:
19.16 + 0.4 = 19.56 19.37 + 0.46 = 19.83 20.12 + 2.0 = 22.12
The maximum allowance
The maximum size limit of the workpiece minus the maximum size limit after roughing:
22.12  19.83 = 2.29
The maximum size limit after roughing minus the maximum size limit after finishing:
19.83  19.56 = 0.27
Minimum allowance
The minimum size limit of the workpiece minus the minimum size limit after roughing:
20.12  19.37 = 0.75
19.37  19.16 = 0.21
Verification:
d1 d2 = 2000  460 = 1540;
Zimin Zimax = 3030  1490 = 1540;
1540 = 1540.
Table 2. payment of allowances, tolerance and interoperational dimensions on technological transitions.
Analytical method of calculation.
Technological operations and transitions processing individual surfaces Elements allowance, m
Calculated
allowance
Z, m Calculated
Tolerances
microns in size limits Limit allowances
R zi1
T i1
r i1
e at max min
Z imax
Z imin
The inner surface 140 ? 0 0.4
Harvesting, casting 250250245200  2000 138.08 138.08 136.08
Turning rough 100 100 14.7 12 1490 139.57 460 139.57 139.11 1490 3030
Finish turning 25 25   430 140 400 140 139.6 430 490
Linear dimension of 20 0.84
Harvesting, casting 250 250 245 140 20.12 2000 22.12 20.12
Boring roughing 100 100 14.7 8.4 753.4 19.37 19.83 19.37 360 750 2290
Boring finishing 25 25   214.7 19.16 840 19.56 19.16 270 210
2.12 Calculation of cutting conditions according to the standards
10 Operation milling
Determining the length of the stroke at each transition
1. milled casting profit [8]
L BC = L + l1 = 160 + 70 = 230 mm
2. milled casting profit
L BC = L + l1 = 215 + 130 = 345mm
3. milled casting profit
L BC = L + l1 = 160 + 70 = 230 mm
Depth of cut
t1 = ZMM
t2 = ZMM
t3 = ZMM
Assign supply for each transition [8].
S1 = 0,24
S2 = 0,24
S3 = 0,24
As we take the calculated value for each transition S minute under the directory [8]
SM1 = 160 mm / min
SM2 = 160 mm / min
SM3 = 160 mm / min
Assign speed [8]
V1 = 80 m / min
V2 = 125 m / min
V3 = 80m / min
Find the speed of each spindle
n1 = 1 000 * V / p D = 1000 * 80/160 = 3.14 * 160 rev / min
n2 = 1000 * V / p D = 1000 * 125/215 * 3.14 = 160 rev / min
n3 = 1 000 * V / p D = 1000 * 80/160 = 3.14 * 160 rev / min
Cutting power [8]
N1rezaniya = 5.6
N2rezaniya = 6.4
N3rezaniya = 5.6
.Use Power factor of the machine
KN = Nras / nst = 17.6: 22.5 = 0.78
Nras = Nrez / h = 17,6: 0,8 = 22
15 Operation Turning MC 112
Determining the length of stroke [4]
1. L AD = 162  100/2 = 31 mm
l1 = 6 mm; L BC = 31mm + 6mm = 37 mm
2. L AD = 22mm + 6mm = 28 mm
3. L AD = 31mm + 6mm = 37 mm
4. L AD = 22mm + 6mm = 28 mm
Depth of cut
t1 = 5mm
t2 = 5mm
t3 = 5mm
t4 = 5mm
Assign supply for each transition
S1 = 0,23
S2 = 0,23
S3 = 0,23
S4 = 0,23
Assign speed [8]
V = 148
Cutting speed prescribed with correction factors
Knv correction factor for the surface condition of the treated
Knv correction coefficient for the material of the cutting tool
Knv = 0.5
Knv = 0.6
V = 148 x 0.5 x 0.6 = 44 m / min
Find the speed of the spindle
n = 1 000 * V / p D = 86 rev / min
adjust the passport: n = 90 rev / min
Assign speed by limiting the length of treatment
V = p D n / 1000 = 3,14 * 160 * 90/1000 = 45 m / min.
Determination of the power tool to [8]
Cutter N1 Table. = 1.0 kW.
when t = 5 mm S = 0,3 mm / rev
Cutter N2 Table. = 1.0 kW.
when t = 5 mm S = 0,3 mm / rev
Cutter N3 Table. = 1.0 kW.
when t = 5 mm S = 0,3 mm / rev
Cutter N4 Table. = 1.0 kW.
when t = 5 mm S = 0,3 mm / rev
Aggregate capacity
Nrez = N1 + N2 + N3 + N4 = 4 kW
Determination of the adequacy of the power of the machine
S Nrez ? Nshn, Nshn = nst · h,
where: h = 0,8; Nst = 7.5 kW
Nshn = 7.5 kW 0.8 kW = 6. <7.5 kW
4 kW. <6 kW.
Capacity utilization rate of the machine
K N = Nras / nst = 5: 7.5 = 0.65
Nras = Nrez / h = 4: 5 = 0.8
20 Operation automaton 1B 284
Determining the length of stroke
Trim the butt
RH L = 215  105/2 = 55mm
l1 = 5mm
L RH = 55 + 5 = 60 mm
1. Sharpen ? 125
L RH = 10 + 2 = 12 mm
2. Sharpen surface ? 94
RH L = 25mm
3. Sharpen surface ? 125
RH L = 25mm
4. Remove fazku
RH L = 5mm
5. grind surface ? 215
RH L = 55mm
Depth of cut
1. t = 3mm
2. t = 4mm
3. t = 6mm
4. t = 2mm
5. t = 2mm
Assign supply for each transition [8]
S1 = 0,28 mm / rev
S2 = 0,2 mm / rev
S3 = 0,2 mm / rev
S4 = 0,2 mm / rev
S5 = 0,28 mm / rev
Assign speed [8]
V = 148 mm / min
Cutting speed prescribed with correction factors
Knv state correction factor treated surface Knv = 0.5;
Knv correction coefficient for the material of the cutting tool,
Knv = 0.6.
V = 148 x 0.5 x 0.6 = 44 m / min
Find the speed of the spindle
n1 = 1 000 * V / p D = 1000 * 44 / 3.14 = 65.8 * 215 rev / min
Adjust the passport 63 rev / min
1. Vfakt = p D n / 1000 = 3,14 * 215 * 63/1000 = 42.5 m / min.
2. V2 = p D n / 1000 = 3,14 * 115 * 63/1000 = 22.7 m / min.
3. V3 = p D n / 1000 = 3,14 * 124 * 63/1000 = 24.5 m / min.
4. V4 = p D n / 1000 = 3,14 * 124 * 63/1000 = 24.5 m / min.
5. V5 = p D n / 1000 = 3,14 * 215 * 63/1000 = 42.5 m / min.
Determining the total capacity of cutting [8]
Cutter N1 Table. = 2.0 kW.
when t = 3 mm S = 0,28 mm / rev
Cutter N2 Table. = 2.0 kW.
at t = 4 mm, S = 0,2 mm / rev
Cutter N3 Table. = 2.0 kW.
when t = 6 mm S = 0,2 mm / rev
Cutter N4 Table. = 2.0 kW.
when t = 2 mm S = 0,2 mm / rev
Cutter N5 Table. = 2.0 kW.
when t = 2 mm S = 0,28 mm / rev
Determination of the power tool to [8]
S Nrez ? Nshn, Nshn = nst · h,
where: h = 0,8; Nst = 30kW
Nshn = 30 kW 0.8 = 24 kW. <30 kW
10 kW. <24 kW.
Capacity utilization rate of the machine
For N = Nras / nst = 12.5: 30 = 0.41
Nras = Nrez / h = 10: 0.8 = 12.5
30 Operation automaton 1B284
Determine the length of the stroke at each transition [8] c4
1. l = 22mm
l1 = 6mm
L RH = 22 + 6 = 28 mm
2. L RH = 4mm
3. L RH = 14mm
4. L RH = 25mm
5. L RH = 25mm
Depth of cut
1. t = 3mm
2. t = 4mm
3. t = 10mm
4. t = 3mm
5. t = 2mm
Assign supply for each transition [8]
S1 = 0,2 mm / rev
S2 = 0,1 mm / rev
S3 = 0,1 mm / rev
S4 = 0,2 mm / rev
S5 = 0,14 mm / rev
Assign speed [8]
V = 148 mm / min
Cutting speed prescribed with correction factors
Knv correction factor for the surface condition of the treated
Kuv correction coefficient for the material of the cutting tool,
K0v correction factor for the processed material
Knv = 0.5
Kuv = 0.6
K0v = 0.8
V = 148 x 0,5 x 0,6 x 0,8 = 35,52 m / min
Cutting conditions assign respect to the limiting transition
Slim S6
llim l6
n = 1 000 * V / p D = 1000 * 35/100 = 3.14 * 113.1 rev / min
Adjust the passport n = 90 rev / min
V1fakt = p D n / 1000 = 3,14 * 124 * 90/1000 = 31.1 m / min.
V2 = p D n / 1000 = 3,14 * 113 * 80/1000 = 28.4 m / min.
V3 = p D n / 1000 = 3,14 * 120 * 80/1000 = 30.1 m / min.
V4 = p D n / 1000 = 3,14 * 100 * 80/1000 = 25.12 m / min.
V5 = p D n / 1000 = 3,14 * 215 * 63/1000 = 30.1 m / min.
Determination of total capacity on all instruments [8]
N1 = 2,0 kW.
when t = 3 mm S = 0,2 mm / rev
N2 = 2,0 kW.
at t = 4 mm, S = 0,1 mm / rev
N3 = 2,0 kW.
at t = 10 mm S = 0,1 mm / rev
N4 = 2,0 kW.
when t = 3 mm S = 0,2 mm / rev
Cutter N5 = 2,0 kW.
when t = 2 mm S = 0,28 mm / rev
Aggregate capacity
Nrez = N1 + N2 + N3 + N4 = 4 kW
Determination of the adequacy of the power of the machine
S Nrez ? Nshn, Nshn = nst · h,
where: h = 0,8; Nst = 7.5 kW
Nshn = 7.5 kW 0.8 kW = 6. <7.5 kW
4 kW. <6 kW.
Capacity utilization rate of the machine
K N = Nras / nst = 5: 7.5 = 0.65
Nras = Nrez / h = 4: 5 = 0.8
35 Operation aggregate
Determining the length of the stroke at each transition I. / p. = ^  ^
RH L = l + l1 = 28mm
l = 20 mm
l1 = 6mm
RH = L + 20mm = 26mm 6mm
2. L = 31mm RH
3. L RH = 2mm
4. L RH = 31mm
5. L RH = 26mm
Depth of cut
1. t = 7 mm
2. t = 11,5 mm
3. t = 9 mm
4. t = 11,5 mm
5. t = 2 mm
Assign supply for each transition [8]
S1 = 0,14 mm / rev
S2 = 0,23 mm / rev
S3 = 0,25 mm / rev
S4 = 0,23 mm / rev
S5 = 0,2 mm / rev
Assign speed
V1 = 24 m / min
V2 = 32 m / min
V3 = 32m / min
V4 = 32 m / min
V5 = 6 m / min
Cutting speed to take the correction factor
Knv correction factor for the surface condition of the treated
Knv = 0.6
24 * 0.6 = 14,4m / min
n1 = 1 000 * V / p D = 1000 * 14.4 / 14 * 3.14 = 327.6 rev / min
adjust the passport 275 rev / min
V1 = p D n / 1000 = 3.14 * 14 * 275/1000 = 12 m / min
n2 = 1000 * V / p D = 1000 * 14.4 / 23 = 3.14 * 194 rev / min
adjust the passport 180 rev / min
V2 = p D n / 1000 = 3.14 * 23 * 180/1000 = 12.1 m / min
to countersink
n3 = 1 000 * V / p D = 1000 * 14.4 / 18 = 3.14 * 254.8 rev / min
adjust the passport 200 rev / min
V3 = p D n / 1000 = 3.14 * 14 * 200/1000 = 11.3 m / min
n4 = 1 000 * V / p D = 1000 * 14.4 / 23 = 3.14 * 194 rev / min
adjust the passport 180 rev / min
V4 = p D n / 1000 = 3.14 * 23 * 180/1000 = 12.1 m / min
n5 = 1000 * 6/16 * 3.14 = 120 rev / min
Determination of total power cut on all instruments [8]
Drill N1 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N2 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N3 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N4 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N5 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N6 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N7 = 0,28 kW.
when t = 7, S = 0,23 mm
Drill N8 = 0,28 kW.
when t = 7, S = 0,23 mm
Aggregate capacity
Nrez = N1 + N2 + N3 + N4 + N5 + N6 + N7 + N8 = 2,24 kW
Determination of the adequacy of the power of the machine
S Nrez ? Nshn, Nshn = nst · h,
where h = 0,8; Nst = 5.5 kW
Nshn = 5.5 kW  0.8 = 4.4 kW. <5.5 kW
4.4 kW. <5.5 kW.
Capacity utilization rate of the machine
Nras = Nrez / h = 2,24: 0,8 = 2,8
N = Nras / nst = 2.8: 5.5 = 0.5
Determination of total capacity on all instruments
Drill N1 = 0,378 kW.
when t = 11,5 mm S = 0,23
Drill 16 pc.
Aggregate capacity
SNrez = N1 + N2 + N3 + ... + N16 = 6,048 kW
Determination of the adequacy of the power of the machine
S Nrez ? Nshn, Nshn = nst · h,
where h = 0,8; Nst = 17kvt
Nshn = 17 kW  0.8 = 13.6 kW. <17 kW
6,048 kW. <13.6 kW
Nras = Nrez / h = 6,048: 0,8 = 7,56
N = Nras / nst = 7.56 17 = 0.44
5 Spindle speed machine
n = 1 000 * V / p D = 1000 * 14.4 / 23 = 3.14 * 194 rev / min
Adjust the passport 180 rev / min.
10 Operation milling GF 1400
material  steel 25L II  GOST 97775
Choosing a cutting tool  face cutter ? 250 mm with interchangeable plates pentagonal hard metal.
Assign cutting conditions:
1. Depth of cut t = 3 mm.
2. Assign supply S = 0,24 m 1 tooth.
3. Assign tool life table 38 [13] T = 180 min
4. Determine the cutting speed in m / min permissible cutting properties cutters
V = (CV * Dq / Tm * tx * Szyv * Buv * Zpv) * Knv =
= (332 * 2500.2 / 1800.2 * 30.5 * 0,240,4 * 2300.2 * 120) * 0.8 = 96.3
n = 1 000 * V / p D = 1000 * 148.8 / 3.14 = 122.7 * 250 rev / min
Adjust the passport 160 rev / min.
2.13 Analytical calculation of cutting conditions TWO dissimilar OPERATIONS
35 Operation aggregate machine 1AMO 443
material  steel 25L II  GOST 97775
Choosing the cutter drill P18  23mm.
Assign cutting conditions:
1. Depth of cut t = 11,5 mm
2. Assign supply S = 0,23
3. Assign the period of resistance Table 92 T = 50 min
4. Determine the cutting speed in m / min cutting properties permissible drill
V = (CV * Dq / Tm * Sy) * Kv
CV constant cutting conditions for the data;
D  diameter of the drill, mm;
T  the period of resistance, min;
K  correction factor for cutting speed.
x, q, m, y  Exponents
For a given processing conditions find tab. 28 [13]
CV = 7; q = 0,40; m = 0,20;
y = 0,50; Kv = 0,584
V = (7 * 3.62 / 2.19 * 0.479) = 0.584 * 14 m / min
2.15. CALCULATION standard time for all operations. ESTABLISHMENT OF DISCHARGE
10 Operation milling
Set blank fix. Take Off.
TV = 1.8 [9]
Definition of computer time
T1 = Lpx / Smin = 230/160 = 1.43 (min);
T2 = 345/160 = 2.15 (min);
T3 = 230/160 = 1.43 (min);
T2 = 2.15 (min)  limiting;
Tsht = (T0 + TCE) * (1 + (AGBU aotl +) / 100)
where: K  universal equipment and semiautomatic (1.1)
aobs. time service workplace
AGBU. = 4% of the operational time
aotl.  Time to rest, and personal need
aotl. = 4% of the operational time [9]
Tsht = (2,15 + 1,8 * 1,1) + (I + (4 + 4) / 100) = 4.56 min.
Tshk = Tsht * 0.8 * 0.8 = 4.56 = 0.36 min.
Tshk = Tsht + QST = 4.56 + 0.36 = 4.92 min
Assign IV discharge papers.
15 Operation Turning
Set blank fix. Take Off.
TV = 1.8 [9]
Definition of computer time
T1 = Lpx / Smin = 67 / 20.7 = 1.78 (min);
T2 = 28 / 20.7 = 1.35 (min);
T3 = 37 / 20.7 = 1.78 (min);
T4 = 28 / 20.7 = 1.35 (min);
T2 = 1.35 (min)  limiting;
Tsht = (T0 + TCE) * (1 + (AGBU aotl +) / 100)
where: K = 1,1 be the universal and semiautomatic equipment
aobs. time service workplace
AGBU. = 6.5% of the operational time
aotl.  Time to rest, and personal need
aotl. = 4% of the operational time
Tsht = 3.79 min.
Tshk = 0.3 min.
Tshk = 4.09 min
Assign IV discharge papers.
20 Operation automaton 1B284
Set blank fix. Take Off. [9]
TB = 1,2 [9]
Definition of computer time
T1 = Lpx / Smin = 67 / 17.64 = 3.4 (min);
T2 = 25 / 12.6 = 1.98 (min);
T3 = 25 / 12.6 = 1.98 (min);
T4 = 5 / 12.6 = 0.39 (min);
T5 = 55 / 3.11 = 14.49 (min);
T1 = 3.4 (min)  limiting;
Tsht = (T0 + TCE) * (1 + (AGBU aotl +) / 100)
where: K = 1,1 be the universal and semiautomatic equipment
aobs. time service workplace
AGBU. = 6.5% of the operational time
aotl.  Time to rest, and personal need
aotl. = 4% of the operational time
Tsht = 5.21 min.
Tshk = 0.41 min.
Tshk = 5.62 min
Assign IV discharge papers.
30 Operation automaton 1B284
Set blank fix. Take Off. [9]
TB = 1,2 [9]
Definition of computer time
T1 = Lpx / Smin = 28/16 = 1.75 (min);
T2 = 4/8 = 0.5 (m);
T3 = 10/8 = 1.25 (m);
T4 = 25/16 = 1.56 (min);
T5 = 35 / 11.2 = 3.12 (min);
T5 = 3.12 (min)  limiting;
Tsht = (T0 + TCE) * (1 + (AGBU aotl +) / 100)
where: K = 1,1 be the universal and semiautomatic equipment
aobs. time service workplace
AGBU. = 6.5% of the operational time
aotl.  Time to rest, and personal need
aotl. = 4% of the operational time
Tsht = 4.9 min.
Tshk = 0.39 min.
Tshk = 5.29 min
Assign IV discharge papers.
35 Operation aggregate 1.AMO 443
Set blank fix. Take Off. [9]
TV = 1.8 [9]
Definition of computer time
T1 = Lpx / Smin = 26 / 38.5 = 0.67 (min);
T2 = 60 / 41.4 = 1.45 (min);
T3 = 2 / 62.5 = 0.03 (min);
T4 = 31 / 41.4 = 0.75 (min);
T5 = 26/240 = 0.11 (min);
T5 = 1.45 (min)  limiting;
Tsht = (T0 + TCE) * (1 + (AGBU aotl +) / 100)
where: K = 1,1 be the universal and semiautomatic equipment
aobs. time service workplace
AGBU. = 6.5% of the operational time
aotl.  Time to rest, and personal need
aotl. = 4% of the operational time
Tsht = 3.79 min.
Tshk = 0,39min.
Tshk = 4.09 min
Assign IV discharge papers.
40 Operation locksmith
Set the item. Take Off. [9]
TB = 0.52 = 3.48 Tshk (min)
T0 = ??2.96
Assign IV discharge papers.
2.16 ECONOMIC studies of the selected treatment option
In the thesis project for turning operation piece machined 1B284, in the factory version  on 4 machines 1512. [15]
Compare rates: 1512 1B284
The cost of the machine to rub .; 370000tenge (4 pcs) 23086
Motor power, kW; 880.kvt (4 pcs) 30
Piece time, hour; 0.86 0.993
Computer time, hour; 0.67 0.081
Cost per minute
Operating instruments. 0.111 0.42
PART 3 Design
3.1.PROEKTIROVANIE special cutting tools
The main structural elements are the tap cutting l calibrating part number; profile and direction of the grooves, the corners cut, thinning of the gauge, thread elements, completeness [11,12]
In accordance with GOST specifies the nominal dimensions of the threaded connection: D, D1, D2, R, H, H1, R.
Outer diameter D = 16mm
The inner diameter D1 = 13,8350,3mm
The average diameter D2 = 14,7010,132mm
Step 2 P = ± 0.03 mm
H = 0.87 P = 1.74 mm
H1 = 0.54 mm F = 1.08
R = 0,14 F = 0.28 mm
Limit size diameter nuts
D2max = D2 + ES, where the upper deviation ES
D1max = D1 + ES,
D2max = 14.701 + 0.132 = 14,833mm
D1max = 13.835 + 0.3 = 14,135mm
The diameter of the tap on the front end
dT = D1 (0,1: 0,35) = 13.835  0.1 = 13,735mm
The length of the cutting part of the tap
lp1, = 6, P = 12mm
Diameters for the tap
d = D = 16 mm
d2 = D2 = 14,701mm
d2 = D1 + 0.055 P = 13.835 + 0.055 * 2 = 13,945mm
Rear angle a = 100
The value zatylovaniya
K = tga (p D / n) = 3.14 * 10 * 16/3 = 2.95
tgax (K n / p D) = 295 * 3/16 * 3.14
tgaN = tgax * sin 300 = 0.088;
tgaN3 = tgax * sin 900 5,4 = 0,175;
The calculations angles These curves were plotted graphs of their changes. Good quality thread turns provided the optimum cutting conditions, the geometry of the tap, coolant composition and method of attachment of the tap.
The machine used two methods of threading taps:
samozatyagivanie without forced feeding and feeding on the copier.
3.2 Design of the measuring instrument
Calculated the size of the executive caliber  plugs M16  7H STP 074219284 for holes M 16 2H7 [6]
1) Determine the largest value of the average diameter of the hole, as it coincides with the nominal, then the table we find A2 = 14,701mm
According to Table 5 for step 2 and ? 16mm find adopted the line number  26.
According to Table 6, we find the line number of the top 26 new caliber deviation is + 23mkm.
Lower deviation of the new caliber is + 9mkm;
maximum deviation worn equal caliber  5 microns.
The size of the new gauge plugs on the average diameter is 14.701 + 0.023 = 14.724 mm
Admission is (23)  (0.9) = 14mkm
Therefore, the tube size PR executive for the average diameter is equal to 14.724  0.014
The size limit is worn caliber
14.701  0.005 = 14.696 mm.
2) Determine the size of the plug PR executive from the outside diameter; need to know the greatest deviation limit of the inner diameter of the holes D. It coincides with the nominal, then D = 16mm.
Then on Table II for. line 26, we find the upper deviation caliber, it is + 30MKM.
Lower deviation gauge on the outer ? = + 2mkm.
Maximum deviation worn caliber =  5 microns.
Admission is (30)  (2) = 28mkm
Consequently, the size of the PR executive from the outside diameter is equal to 16.030  0,028mkm.
Size limit worn gauge on the outside diameter 16.0  0.005 = 15,995mm.
3) To determine the size of the PR executive of the inner diameter is necessary to know the value of the limit of the smallest inner diameter of the hole D1 = 13.835 In Table 15
Upper deviation of the new caliber is 0, the lower deviation of the new caliber equal to 26 microns.
Admission is 26mkm, executive tube size PR on the inner diameter is equal to 13.835  0.026 (mm)
Bushing threaded plugs with the full makeup with the details set that error Da / 2 and DPn offset error of the mean diameter, and that the size of A is not less than the set limit size. The through traffic jams, so check the thread complex.
Impassable plugs checks average diameters of the holes! and set the size DZne more to limits.
Find the greatest value of the average diameter of the hole as it coincides with the nominal, then the table we find A2 = 14,966mm, according to Table 5 for step 2 and diameter of 16 find the line number, it is equal to 26.
According to [6] to find the top 26 rows of the new gauge deviation is + 14mkm.
Lower deviation cork is not 0, the limit deviation worn the same caliber  8mkm.
The size of the new executive caliber plug on the average diameter is 14.966 + 0.014 = 14,980mm
Size extremely worncaliber equal to 14,980  0,008 = 14.973
4) Determine the executive tube size is not on the outside diameter. Need the most extreme deviation of the internal diameter of the hole D = 15.387. According to Table II, line number 26, we find the upper deviation caliber, it is + 21mkm.
Marginalworn U = 7 mm
Admission is (+ 21mkm)  (7 mm) = 28mkm
Consequently, the size of the executive on the outside diameter is equal to 15.387  0.028 = 15,359mm
5) To determine the size of the PR executive of the inner diameter is necessary to know the value of the smallest hole diameter DR = 13.835
According to Table 15, the lower deviation of 7 mm, executive tube size 13.835  0.007 = 13,828mm
3.3 DESIGN FOR Machinetool milling operations
Develop a single device with pneumatic clamping parts for milling and casting profits with flanges.
Selecting the method of installation (based) components and placing positioning elements in the adaptation, determine the amount, location and direction of application of forces to clamp.
Define the cutting force in milling by the formula [18]
PZ = [(10 * CP * tx * Syz * Vi * Z) / dq * nw] * CMR [13]
where: Sp constant cutting conditions for the data;
t  milling depth, mm;
S  feed per tooth cutter, mm;
B  milling width, mm;
Z  the number of teeth of the cutter;
K  a correction factor for the quality of the material being processed
n  spindle speed, rev / min.
tx = 30,85 = 2,54; CP = 12.5; Syz = 0,240,75 = 0,342; Bu = 150; Dq = 1600.78 = 40.64;
nw = 1600,13 = 0,516; CMR = 1.12; Z = 10.
PZ1 = 8699kg
Define the cutting force to handle the end of the casting ?215 profits:
tx = 30,85 = 2,54; CP = 12.5; Syz = 0,240,75 = 0,342; Bu = 215; Dq = 2500.73 = 56.29;
nw = 1600,13 = 0,516.
PZ2 = 10,802kg
Determine PZ3
tx = 30,85 = 2,54; CP = 12.5; Syz = 0,240,75 = 0,342; Bu = 150; Dq = 1600.78 = 40.64;
nw = 1600,13 = 0,516; Z = 10.
PZ3 = 8699kg
PZ1i PZ3 resultant forces.
Determine the torque for PZ3po formula [13]
KM = W f1r + W f2r [1 / sin (a / 2)]
where: W  cutting force
f1i f2 coefficients of friction force
a  the installation angle prisms
KM = 10802 * 0,16 * 107,5 + I0802 * 0, I6 * I07,5 [1 / sin (90/2)] = 545426,56
Determine the clamping force according to the formula
W = KM / (f1r + f2r sin (a / 2)) = 545426.56 * 56/17 + 17,2 * sin (a / 2)
For double acting cylinder at a pressure of rodless cavity
[18]
W = 0,785 * D2R h,
where: D  diameter of the cylinder, mm
P  air pressure in kg / cm2
h = 0,85 ? 0,90 efficiency cylinder
From the formula can determine the diameter of the cylinder, if known W and P W = 17896n; == P 0,4 MPa
From the formula W = 0,785 * D2R h,
You can determine the diameter of the cylinder going to simplify the calculation, and the creation of the reserve force of the rule formula h efficiency, but what he saw requirement calculation force on the rod W is increased by 1.5 times and doubleacting cylinder diameter is found from the equation
1,5W = 0,785 D2R,
where D == 292,4mm
Choosing an air cylinder to directory
? cylinder = 300 mm
? = 65 mm rod
Determines the validity of the clamping force
W = 0,785 D2R / 1.5 = 18840 H
Determine the response time of the pneumatic cylinder according to the formula:
Tc = (A ^ * lx) / (d20 * Vc),
where: lx length moves the piston design accessories
d0 diameter vozduhoprivoda
Vc speed of the compressed air
Tc = (300 * 60) / (82180) = 1.5 sec
4 CALCULATION AND PRODUCTION PLAN AREA
4.1 Calculation of the number of production equipment and load it.
Exhaust stroke  6,88min.
Release program 35000sht
In mass production of the estimated amount of equipment is determined by the formula [7]
Cp = Tsht * N / 60 Gd,
where: Tsht total processing time details
N  release program details
Gd effective annual fund production time (4015chas).
Think of Operations:
10 Operation milling
Cp = 4.92 * 35000/60 * 4015 = 0.71, accept one machine.
Determine the load factor K = 71%.
15 Operation Turning
Cp = 4.09 * 35000/60 * 4015 = 0.59, accept one machine.
The load factor K = 59%.
20 Operation automaton
Cp = 5.62 * 35000/60 * 4015 = 0.81, accept one machine.
The load factor K = 81%.
30 Operation automaton
Cp = 5.29 * 35000/60 * 4015 = 0.76, accept one machine.
The load factor K = 76%.
35 Operation aggregate
Cp = 4.09 * 35000/60 * 4015 = 0.59, accept one machine.
The load factor K = 59%.
40 Operation locksmith
Cp = 3.48 * 35000/60 * 4015 = 0.5, take a sander.
The load factor K = 50%.
Average% loading equipment  69%.
All estimates are tabulated.
Table 3 Estimates.
Name of the operation time of the part number of machine utilization rate,%
Rated A received
10 Milling 4.92 0.71 1 71
Turning 15 4.09 0.59 1 59
20 submachine 5.62 0.81 1 81
30 submachine 5.29 0.76 1 76
35 aggregate 4.09 0.59 1 59
Locksmith 40 3.48 0.5 1 50
The average load factor of equipment is determined by the formula
DAC = (Sras / Sprinim) * 100% = 69%.
4.2 Selecting the required amount of conveyor technology
In the shops and highvolume mass production are widely used electric lifting kranbalki controlled pushbutton remote control with sex shops, traveling cranes.
For mechanization of technological processes used ropfgangi and conveyors for transport of intra and interdepartmental parts or pieces used transport and motorized vehicles, electric vehicles.
To take the projected area mechanized forklift CH63, in the amount of 4 pieces, mechanized trolley on rails, load capacity of 1.5 t and bridge crane lifting capacity of 5t.
4.3 Calculation of the number of main and auxiliary workers, engineers and employees
The calculation of the number of workers by category. For this mode to be determined (T) at each operation according to the formula: [7]
T = Tper * * Ref DRG,
where T  period of service jobs (8.2 hours)
Spr taken jobs
Kzg load factor jobs for this operation.
T1 = 1 * 8.2 * 0.71 = 5.82
T2 = 8.2 * 1 * 0.59 = 4.83
T3 = 1 * 8.2 * 0.81 = 6.64
T4 = 1 * 8.2 * 0.76 = 6.23
T5 = 8.2 * 1 * 0.59 = 4.83
T6 = 8.2 * 1 * 0.5 = 4.2
The number of production workers is given by:
PCT = Tshk * N / 60 * GDR
PCT where the number of workers of the profession and discharge
Tshk singlepiececalculation time for an operation;
Gdr actual annual fund of working time machine operator
GDR = [(3651048) * 8.2  6.1] * KH,
where 365  the number of calendar days in the year;
104  the number of days off per year, with a 5day week;
8  the number of public holidays;
8.2  working hours;
6  the number of preholiday days with a reduction of 1 hour working days
Princefactor considering the use of nominal fund of time due to absenteeism.
Kn = (100  CH) / 100
where CH losses due to absenteeism, leave 15 days
Kn = (100  18) / 100 = 0.82
T = (365  104 8) * 8.2 * 6.1 * 0.82 = 1930 (h)
Think of Operations:
10 Operation milling
PCT = 4.02 * 35000/80 * 1930 = 1.48, take two Milling
15 Operation Turning
PCT = 4.02 * 35000/80 * 1930 = 1.23, take two turner
20 Operation automaton
PCT = 4.02 * 35000/80 * 1930 = 1.7, take two turner.
30 Operation automaton
PCT = 4.02 * 35000/80 * 1930 = 1.6, take two turners
35 Operation aggregate
PCT = 4.02 * 35000/80 * 1930 = 1.23, take two driller.
40 Operation locksmith
PCT = 4.02 * 35000/80 * 1930 = 1.05, machine operators perform locksmith
work
Basic operating accept 8.
Adjuster  1 person  5 category;
Transport Workers 1chelovek  3razryad;
Controller 1 people  3 digit.
Total received: 8 + 3 = 11 people.
When mnogostanochnoy calculation of production workers work done with respect to a given number of machines, which can run one operating the profession. [1, 15]
PCT = FdSpKz / GdrSm,
where Fd effective annual fund operating time of the production machine Cn taken the number of machines
Kz load factor machines
Gdr actual annual fund operating time machine operator
Cm number of machines, which can work at the same time a worker
The number of machines that can be operated by one worker equals
See tma = tvp + / + tvn tvp + tper,
wherein tma continuous automatic machine and the time during which the machine can be operated without working
tvn support nonoverlapping time
tvp support overlapping time on a single machine
tper time to move the worker from one machine to another.
Cm = 3.4 + 0.95 / 0.95 + 0.42 + 0.5 = 2.15
Take 2 machine
Then
PCT = FdSpKz / GdrSm,
PCT = 4015 * 2 * 0.59 * 0.81 / 1930 * 2 = 1.02, accept one person.
For the operation  15 machine gun  machine MK112
and operation  20 machine gun  machine 1B284 take one working machine operator,
for the operation  30 machine gun  machine 1B284,
for the operation  35 aggregate  machine .1AM0443
Cm = 3.12 + 0.95 / 0.95 + 0.42 + 0.5 = 2.13 takes 2 machine.
PCT = 4015 * 2 * 0.59 * 0.76 / 1930 * 2 = 1.01 accept one working machine operator.
Total basic working on all transactions take 8 vspomogatelnyh 3, adopted on 8 + 3 = 11chelovek.
4.4 CALCULATION production areas, Disposition sites.
Total land area (Rob) consists of production (RPR) and auxiliary (RVSP) area.
Rob RPR + = RVSP,
Production area occupied by the main jobs, walkways, driveways.
It is defined by
RPR = S (P1 + P2) * Ref.
where P1 specific area on a piece of equipment, m2
P2 specific area on the walkways and driveways;
P2 = 6 m2 + 8 m2;
Spr number of similar machines;
n  number of items.
Secondary area, occupied by warehouses, determined
RVSP = MLR + + Rkontr Rbyt.,
Rskl where the area under the blank 15% of the production
Rkontr area checkpoint, 6% of the production
Rbyt. area of ??residential, office space
The area of ??the checkpoint and the area of ??household, office space provided on the area of ??the shop.
P = 14.69 + 5.29 + 6 + 6 + 6 + 9.81 + 30.86 + 6 = 100m2
Warehouse space blank
RSK. zag. = Q * N * td / Tr * q * K
where Q is the weight of the workpiece, kg
N  number of items, pieces;
TKstock quantity (6days)
Tpworking days (253)
q  permissible load (load capacity of 1 M2 1.5 m);
RSK. zag. = 37.7 * 35000 * 6/253 * 1.5 * 0.4 = 47 m2
RSK. children. = 27.4 * 35000 * 6/253 * 1.5 * 0.4 = 35m2
Total land area
Rob. = 100 + 47 + 35 = 182
Vuch = 182 * 6 = 1092 m3
5 ORGANIZATIONAL PART
5.1 Organization of jobs and system maintenance.
For each worker must be provided a convenient place, feel free to his actions during operation. The workplace should be secured area to accommodate tooling blanks.
Shelves for storage of parts and workpieces to be such a height that the working comfortably and safely stow blanks and parts. Do not store the tool in the machine frame.
Cupboards for tools and equipment must match the number of jobs and the shape of things to store which they are intended.
Cleaning chips from machine tools and automatic transfer lines should be as mechanized.
In the process map and commissioning etc. must be specified devices, cutting tools and measuring safety devices, transport, lifting means and methods to ensure safe operations.
5.2 Measures for the protection of health and safety
Under the OSH should understand complex technical, sanitary and legal measures aimed at creating a safe and healthy working conditions.
Safety industrial sanitation define such conditions in a production environment, which can not directly or indirectly lead to accidents, occupational diseases. Therefore, workers are required to strictly comply with all applicable safety regulations and industrial hygiene.
The development and implementation of measures to create a safe and healthy working conditions is important to follow the sequence and complexity. You must first remove the factors harmful effects on the human body  the noise, unfavorable climate, air pollution in industrial premises, etc., and then proceed to the aestheticization of the production environment.
To comply with the permissible mikrokliamticheskih conditions in the work area must be room in summer  natural ventilation, air conditioning; winter  hot air curtains and locks in the doorway of industrial premises. For the purity of the air at the site should be used forcedair ventilation.
Measures to combat noise and vibration  the use of sound insulation for walls, the use of personal protective equipment, etc.
To avoid injury when working on machine tools must be strictly adhered to the rules of TB. Moving and rotating parts of the machine must be closed reliable guards. Provide protective equipment (plastic screens, glasses) of the emitted chips. Workpiece and the tool must be secured.
Organizational measures: quality and timely briefings on TB, the organization of social labor inspection, strengthening billboards, hanging posters on TB, TB corner of creation, the appointment of duty (in turn) safety on each shift.
5.3 Measures for fire protection
Fire hazard plant belongs to the category "D"  processing incombustible substances and materials in the cold condition.
To avoid fires must comply with the rules of fire safety. On the territory of the shop aisles, driveways, hatches wells should be free and not cluttered with materials, blanks, parts and production waste. Oily rags should be collected in a certain place constantly get out of the shop.
Must be a fire escape plan, a sand box, firefighting equipment on the boards in the right amount and shall be easily accessible. You must have an emergency exit in case of fire. Must also be blocking electrical equipment.
5.4 Determination of annual need of materials, tools, energy and water
Planning and accounting of balance of energy produced by the method. Energy balances of the plant divided by the nature and purpose (planning, reporting), by type of energy and facilities. Balances are developed on the basis of the relevant expenditure norms.
Annual energy consumption in kWh is given by:
Er = (Fs * Must * C * h * CWR) / KpsKm = 120 * 4015 * 2 * 0.5 / 0.96 * 0.85 = 59044 kW / h
where: Must installed capacity of electric equipment stock kW;
Fd valid fund operating time per shift in hours;
C  the number of shifts per day of the equipment;
h  equipment load factor of 0.75;
Kvr coefficient of simultaneous operation of the equipment (0.4  0.6);
Kp.s. coefficient taking into account losses in the network (0.95  0.97);
KM efficiency motor (0.8  0.85).
Need of the materials specified in the annual, quarterly and remarks sections and calculated on the basis of a given production program (taking into account the timing margin products in production) and progressive consumption rates of materials.
The value of delivery (delivery) of each type of material is determined on annual basis according to the formula
H = + By + Ilb He Oak,
where: Therefore the need for the main production plants in the material of this kind and size in t;
Pv need service shops in the material of this kind and size in t;
Oak remainder of this kind of material at the end of the planning period t;
Onthe remainder of this kind of material at the beginning of the planning period in t;
determined by adding to it. The actual availability at the time of the plan expected receipt of materials to the end of the reporting period preceding the planned;
of this amount shall be deducted the planned material consumption for the same period;
shall be equal to the difference between the expected balance at the beginning of the planning period.
When calculating the annual needs of the enterprise in the tool using one of three methods, namely:
a) at application rates of the tool;
b) the coefficients of the average equipment jobs;
c) for the reporting and static data.
In determining the need for instrument The consumption is necessary to determine the service life of the tool in hours Tsrpo the following formula:
Toff = (L / l +1) * Tcm (1b),
where: L  value of the allowable wetting the cutting part of the tool, in mm;
l  the value of the layer is removed in one regrinding, in mm;
Tcm resistant tool, ie the work it between two regrinds in hours;
b  coefficient of random loss tool (b = 0,05 ? 0,10).
Toff = (15/3 + 1) 0.5 * (1  0.05) = 2.85 (h)
Number of cutting tools required to perform the annual program n  determined by the formula
n = S (N * tm / Toff * 60)
where: kDa number of types of parts to be processed by the tool;
N  number of specific parts of the name, to be processed by the tool on the annual production program pcs .;
tm machining time specified name, which is used for the treatment of this instrument in min .;
Tsr tool life up to full deterioration in hours.
Drills ? 23
n = S (35000 * 1.45 / 2.85 * 60) = 296 pcs
Drills ? 14
n = S (35000 * 0.68 / 2.85 * 60) = 137 pcs
Cutter
n = S (35000 * 0.5 / 60 * 2.85) = 102 pcs
Tap
n = S (35000 * 0.11 / 60 * 2.85) = 23 units
Mills
n = S (35000 * 1.43 / 2.85 * 60) = 292 pcs
6. The economic part
6.1 VALUATION OF FIXED ASSETS
The cost of building is determined by the formula
RCH = Fo * 1.1 NS,
where: Fo total internal area of ??the plot [2]
RCH = 180 1.1 6 35 = 41580 (rub.) / 2,079,000 tenge
Calculating the cost of production equipment (take out of the consolidated statement of equipment) 113499 rubles. / 5674950 tenge
Calculating the cost of Conveyor (take from the consolidated statement of equipment) 9410 rub. / 470,500 tenge
Cost quickly wear out tools and equipment to accept the standard cost for one machine. The estimates take 50% wear.
Machine GF 1400 560 50/100 = 280 rubles.
MK 112 350 50/100 = 175 rubles.
1B284 350 50/100 = 175 rubles.
1AM0443 230 50/100 = 115rub
Total cost:
280 + 175 + 175 + 175 + 115 = 920rub / 46000 tenge
Cost of production equipment. Take 20rub per worker
20 * 8 = 160 rub. / 8000 tenge
The cost of household equipment
20 * 8 = 160 rub. / 8000 tenge
Table 4  Summary of fixed assets
Name of fixed assets
The cost of fixed assets
RUB / KZT
Depreciation rate
%
Depreciation deductionsWIDE,
RUB / KZT
Building
Basic equipment
Handling equipment
Tools and accessories
Production equipment
Household equipment
Expensive tool
41580/2079000
383419/19170950
9410/470500
920/46000
160/8000
160/8000
1500/75000
3.0
14
16
20
12
12
50
1247/62350
54828/2741400
1562/78100
184/9200
20/1000
20/1000
750/37500
Total: 437 149 rubles. / 58612/2930600 23657450 tenge tenge
6.2. VALUATION OF MATERIAL
This calculation is made on the basis of norms of material consumption per part to the cost of returnable waste, prices for transportation and procurement costs and programs.
Determine the cost of the basic material for the annual [2];
M = (Pm Qm * * Ktz q0 * P0) * N,
wherein: the flow rate Qm material preform kg;
Pm wholesale price for 1kg material RUB / KZT;
Ktz factor ordering costs;
q0 mass return of waste to the workpiece, kg;
P0 price for 1kg of returnable waste, kg;
N  annual program, pc;
M = (37.7 * 0.47 * 1.05  10 * 0.024) * 39 000 = 659572,79rub / 32978600 tenge
6.3. VALUATION low value of tools and accessories
Costs associated with wear and repair of low value tools and equipment accounted for 40 rubles per 1 machine.
Determine the cost of 5 machines:
40 x 5 = 200 rub. / 10000 tenge
6.4. VALUATION OF ALL KINDS OF ENERGY AND WATER
The cost of electricity power:
3c = ClSNu Fs * * * By Ks / EC * Tg
where: C1 cost of 1 kW / h (0.0051 rubles / 0,255tenge);
Fd total power of the engines on equipment kW;
Fsefficient fund operating time, hour;
Ksaverage load factor of equipment (0.88);
K  coefficient of simultaneous operation of the equipment (0.74 0.75);
es efficiency of the machine (the average efficiency of electrical equipment (0.85);
Tg loss rate in the network (0,95);
3c = 0,0051 * 120 * 4015 * 0.88 * 0.7 / 0.85 * 0.95 = 1874.45 rubles / 93722.5 tenge.
Costs for compressed air [3];
REM = * Qczh CSF,
where: Tsszh cost 1m3szhatogo air (0,002 rubles / 0,1tenge);
Qszh annual consumption of compressed air, m3;
Qszh = Fs * Ks * Sob * q ',
where: Sob = 5 using blasting;
q = 1 m3 / h  compressed air consumption for 1 machine.
Qszh = 0.88 * 4015 * 5 * 1 = 17766 m3;
VSL = 0.002 * 17,766 = 35.33 rub. / 1248,21tenge
Consumption of energy and fuel for household needs.
The cost of electricity for lighting [2]
SEA = C1 * W,
where: C1 cost of 1 kW / h (0,0051rub / 0,26tenge);
W Annual need Kilowatt [2];
W = dcp * F * T / 1000?
where: dcp Medium electricity consumption for lighting 1m2;
F  land area (182 m2);
T  duration of light per year, with twoshift operation (2630 hours);
1.05 coefficient takes into account the 5% loss at daylight
W = 25 * 1.05 * 182 * 2630/1000 = 11966.5 kW
SEA = 0.0051 * 11 * 966.5 = 61.02 rub. / 3051tenge
Expenditure on steam for heating [2];
Sn = C * Wp,
where: Cn value of 1 ton of steam (4,66rub / 233tenge);
Wp annual demand of steam on the machine;
Wp = qn * V * TGI / g * 1000
where: qn fuel consumption by 1 m3zdaniya (25,435 kcal / h);
\ /  Internal volume of the building;
Tot duration of the heating season (4320chas);
g  heat of vaporization (540 kcal / h).
Wp = 25 * 1092 * 4320/540 * 1000 = 218 tonnes
Sn = 4.66 * 218 = 1016 rubles / 50800 tenge.
Water consumption for household needs:
Sre households. = St. * Qhoz,
where: Sv. cost of 1 m2vody (10 kopecks);
Qhoz annual demand for water for domestic and economic needs;
Qhoz = qv * TV * Cr / 1000
where: QBrate of water flow per employee (75 l);
TV number of working days 1 working (253 days);
Kp number of employees at the site (10).
Qhoz = 75 * 253 * 10/1000 = 189.75 m3;
Sre. host = 0.1 * 189.75 = 18.97 rubles / 948.5 m.
Water consumption for industrial needs:
St. Flowers * QB = Ks * * Z,
where: C  1 m3vodoprovodnoy cost of water (0.10 rubles / 5tenge);
QBannual water consumption for 1 machine (25 m3);
Z number of shifts;
Kz equipment load factor
St. = 0.10 * 25 * 5 * 0.85 * 2 = 21.25 rubles / 1062,5tenge.
6.5. Determination of the wage fund
Definition of the payroll of all categories of workers:
1. Calculation of payroll basic working [2]
RSD = Tg tshk * * N / 60,
where: tshk singlepiececalculation time
T  flat rate according to the category
Machinists work in a team and perform locksmith work. Total machinists 8 people, they substitute for each other when dvusmennoy work the first shift 4 people and the second shift 4 people.
Determining the wage, pay, consider mnogostanochnoe service:
The calculation of Operations:
10 Milling operation
Tg = 0.67 rubles.
RSD = 0.67 * 4.92 * 35000/60 = 1992.9 rubles / 99645tenge.
tshk = 4.92 min
1. The calculation of premiums payroll
ZPpr ZPst * = 30/100 = 1992.9 * 30/100 = 597.87 rubles / 29893tenge
2. The main fund s / n with the payment of bonuses
1992.9 + 597.87 = 2590.77 rubles / 129538,5tenge
3. Supplementary Fund CLP = 10%
ZPdop = 2590.77 * 10/100 = 259.07 rubles / 12953,5tenge
4. The main fund plus an additional fund
ZPosn = 2590.77 + 259.07 = 2849.84 rubles / 142492tenge
5. The waist ratio 15%
R = 2849.84 * 15/100 = 427.476 rubles / 21374tenge
6. The total payroll for the year
ZPgod = 2849.84 + 427.476 = 3277.31 rubles / 163865.5 tenge
40 operation locksmith
Tg = 0.67 = 3.48 rubles tshk min
RSD = about 67 x  3.48 * 35000/60 = 2030 rubles / 101500 tenge
I. Calculation of premiums from payroll
ZPpr = 2030 * 30/100 = 609 rubles / 30450 tenge
2.Core payroll, taking into account payment of premiums
2030 + 609 = 2639 rubles / 131950 tenge
3. Supplementary Fund K = 10%
ZPdop = 2639 * 10/100 = 263 rubles / 13150 tenge
4. Supplementary Fund plus the main fund
2639 + 263 = 2902 rubles / 145,100 tenge
5. The waist ratio 15%
R = 2902 * 15/100 = 435.30 rubles / 21765 tenge
The total payroll for the year ZPgod = 2902.15 + 435.30 = 3337.45 rubles / 166872.5 tenge
The calculation of basic operating fund at mnogostanochnom service.
Step 15 and 20 turning machine gun performs one work in the first shift, 4 bits, 4 bits and machine operator
the second shift. Payroll apply a factor of 0.7
mnogostanochnogo for maintenance.
15 Operation Turning 20 machine gun operation
He = 0.67 rubles / 33,5tenge He = 0.67 rubles / 33.5 tenge
RSD = 0.67 * 4.09 * 35000/60 = 1598.5 rubles / 79925 tenge;
RSD = 0.67 * 5.62 * 35000/60 = 2196.48 RUB / KZT 109,824;
RSD = (1598.5 + 2196.48) * 70/100 = 2655.08 rubles / 132754 tenge
1.Raschet premium payroll
ZPpr = 2655.08 * 30/100 = 796.52 rubles / 39826 tenge;
2. The main fund s / n with the payment of bonuses
ZP0 = 2655.08 + 796.52 = 3451.6 rubles / 172,580 tenge;
3. Supplementary Fund CLP = 10%
ZPdop. = 345.16 * 10/100 = 345.16 rubles / 17258 tenge
4. The main fund plus an additional fund
CP = 3451.6 + 345.16 = 3796.76 rubles / 189,838 tenge
5. The waist ratio 15%
R = 3796.76 * 15/100 = 569.51 rubles / 28475.5 tenge
6. The total payroll for the year
ZPgod = 3736.76 + 569.51 = 4366.27 rubles / 218313.5 tenge
30machine operation and 35 aggregate operation
He = 0.67 rubles / 33.5 = 0.67 tenge That RUB / KZT 33.5
wk = wk = 5.29 m 4.09 m
RSD = 2067.5 rubles / RSD = 103375 KZT 1,598.5 rubles / 79925 tenge
RSD = (2067.5 + 1598.5) * 70/100 = 2566.2 rubles / 128,310 tenge
1. Calculation of the Prize Fund RFP
Zppr = 2566.2 * 30/100 = 769.86 rubles / 38493 tenge
2. The main fund with the payment of bonuses
2566.2 + 769.86 = 3336.06 rubles / 166,803 tenge
3. Supplementary Fund CLP = 10%
ZPdop. = 3336.06 * 10/100 = 333.6 rubles / 16680 tenge
4. Supplementary Fund plus the main fund
3336.06 + 333.6 = 3669.66 rubles / 183,483 tenge
5.Poyasnoy coefficient of 15%
R = 3669 * 15/100 = 550.44 rubles / 27522 tenge
6. The total payroll for the year
ZPgod = 3669.66 + 550.44 = 4220.10 rubles / 211,005 tenge
The total payroll for all transactions:
CP = 3277.31 + 3337.45 + 4366.27 + 4220.10 = 15201.13 rub / 760056.5 tenge
RFP one machinist average
ZPmest.st. = 15,201.13: 8: 12 = 158.34 rubles / 7917 tenge
Calculating payroll auxiliary workers:
I. Calculation of premiums from the total wage bill
ZPpr = 1287 * 30/100 = 389.36 rubles / 19468 tenge for the adjuster
ZPpr = 1041.21 * 30/100 = 312.36 rubles / 15618 tenge for the controller and transport workers.
2.0snovnoy payroll, taking into account the payment of premiums
1287 + 389.36 = 1676.36 rubles / 83 818 tenge for the adjuster.
1041.21 + 312.36 = 1353.57 rubles / 67678 tenge for the controller and transport workers.
Z. Supplementary Fund CLP = 10%
1676.36 * 10/100 = 167.63 rubles / 8381.5 tenge for the adjuster.
1353.57 * 10/100 = 135.35 rubles / 6767.5 tenge for the controller and transport workers.
4. Main Fund plus an additional fund
1676.36 + 167.63 = 1843.99 rub. / 92199.5 tenge for the adjuster
1353.57 + 135.35 = 1488.92 rub. / 74 446 tenge for the controller and transport workers.
5. The waist ratio 15%
1843.997 * 15/100 = 276.59 rub. / 13829.5 tenge for the adjuster. 100
1488.92 * 15/100 = 223.33 rub. / 11166.5 tenge for the controller and transport workers.
6. The total payroll for the year
1843.99 + 276.59 = 2120.59 rub. / 106,029 tenge for the adjuster.
1488.92 + 223.33 = 1712.25 rub. / 85612.5 tenge for the controller and transport workers.
7 .Srednemesyachnaya salary:
one working 2120.59 12 = 176.71 rubles. / 8835 tenge
adjuster. 1712.25: 12 = 142.68 rub. / 7134 tenge Comptroller and transport workers.
Annual payroll on site
Zpgod = ZPosn. slave. + ZPvsp.,
ZPgod = 15201.13 2120.59 2 '= 1712.25 20746.22 rub / 1,037,311 tenge.
6.6. Estimated shop expenses
Items of expenditure
The amount of KZT.
1. The basic wage
A) support workers
2. Social security contributions 14% of the total wages
3. The cost of maintenance of buildings, structures
A) electricity for lighting
B) steam for heating
B) water for domestic use
4. The cost of maintenance and operation of equipment
A) power electricity
B) compressed air
5. Depreciation of equipment, vehicles and expensive tooling
6. The costs of repairs and maintenance of equipment
7. The costs of depreciation and maintenance of lowvalue tools and equipment
8. The cost of auxiliary materials
9. Depreciation of production areas (3%)
10. Costs for the protection of health and safety
11. Costs of invention and rationalization
277254.5
145223.5
3051
50800
948.5
93722.5
1766.5
765900
397250
212500
20000
58830
16500
11000
Total: 2053246tenge
6.7. Calculation of economic efficiency of projects and the level of profitability
Shop cost was (on an annual program):
659572 + 56266 + 2128 = 717794.21 rub. / 35889710.5 tenge
Works general expenses accounted for 80% of the basic salary of workers
15201.13 * 80/100 = 12160.90 rub. / 608,045 tenge
Production cost is the sum of the cost of parts and works general expenses
Ref = 729,955.11 rubles / 36497755.5 tenge.
Nonproduction costs amount to 5% of the production cost  36497,75rub / 1824887.5 m.
Total cost is the sum of cost of production and nonproductive costs
Cn = 766,452.86 rubles / 38,322,643 tenge.
The company's profit is 15% of the total cost
P = 114967,92rub / 5748396. tenge
The wholesale price of the company is the sum of the total cost and profit of the enterprise
Tsopt. 881420,78rub = / 44071000 tenge.
Level of profitability:
P / Ep = 114,967.92 / 766,452.86 * 100 = 15%
Output in rubles 881,420.78 rubles / 44,071,000 tenge.
Capital productivity = TP / Stand. osn.f = 881,420.78 / 437,149 = 2.01
= Capitalstoim.osn.f. / Number of the slave. in Naib. cm. = 437149/7 =
= 62450 rubles / 3,122,500 tenge
Shift factor = number of slave. Ouch. / number of the slave. in Naib. cm.
KSM = 11/7 = 1.6
Output per worker 1 = TP / Crab = 881,420.78 / 11 =
= 80129 rubles / 4,006,450 tenge.
6.8.TEHNIKOECONOMIC INDICATORS OF SITE
The name of indicators
Unit
measurement
Indicators
The annual program of manufacture of the product
Same
The total number of employees, including:
mainly workers
auxiliary workers
The average wage group main working
Payroll on site
Number of equipment
Total cost of equipment
The total capacity of the equipment
Average loading equipment
The production area of ??the site
Unit cost of manufactured products
Profit
Level of profitability
Capital productivity
Fondovooruzhennsot
Pcs.
Rub.
Pers
Pers
Pers

rub.
Pcs.
rub.
kw
%
m 2
rub.
rub.
%
rub.
35000
881,420.78
11
8
3
4
20746.22
5
383419
120
69
182
20.50
114,967.92
15
2.01
62450
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