Site planning and production calculations - Building Science

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 low-value 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 cost-effectiveness 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 "Kazakhstan-2030" for raising the economy of the Republic of Kazakhstan much attention is paid to raising and development of agriculture, as well as shut-off valve is an integral part of the equipment of agriculture, there is a need to create specialized repair shops shut-off 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 21003-100ASB 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 self-braking, 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 shut-off 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 078I-084-77

2) For valves with electric smelting to produce electrode

CM-6L-5,0-2.

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 4666-75 mark of the manufacturer.

1.3 part material and its characteristics.

Detail - GL21003-100ASV body is made of steel castings 25JI GOST 977-75 of the first group.

For the manufacture of castings used basic or acid open-hearth 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 1050-74 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,

High-volume production.

In large-scale 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, in-line 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 two-shift 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, custom-molding 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 I855-55 and AINO 2009-55:

?238 + 2 = 240 mm + 358 mm l 2 = 360 mm

?107 - 2 == 105 mm

?92-2 = 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 plus-tolerances, which divide the figure by 8 elementary geometric solids:

F1 = (P2 r2) p = (107,52-572) 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 = (P2-r2) p = (8I2- 502) p = 12 758;

V3 = F h = 12 758 x 8 = I23 432,1;

F4 = (P2-r2) p = (65 ^ 45 ^) p = 6 911.5;

V4 = F h == 6 911,5 x 23. 168 = 964.5;

F5 = (P2-r2) p = (87,52- 52,52) p = 15393, 82;

\ / 5 = F h = 15 393,82 x 40 = 636 753.3; _

F6 = (P2-r2) p = (602- 502) x 0,7854 = 3455,76;

V6 = F h = 3455,76 x 110 = 401,345, 2;

F7 = (P2-r2) p = 0,7854 (I302- 1202) = 1963,5 x. 4 = 7854;

V7 = F h = 7854 x 120 = 973,860;

F8 = (P2-r2) 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 machine-gun - machine 1B284

Soblyudat- instructions T B.

1.Set, removing.

2.Podrezat end ? 215 mm.

3.Tochit ? 115 mm. t = ZMM-blank.

? 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 machine-gun - 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 251-11 977-75.

Basic data of the machine GF 1400:

Table working surface dimensions according to GOST 6955-70:

width 500mm

length 1250mm

Maximum table travel 1250mm

Number of table feeds 18

Limits table feeds 20-1000 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 30-550 mm

Number of spindle speed:

1 spindle 19

2 spindle 19

3 spindle 19

Limits of spindle speeds:

1 spindle 25-1600 rev / min

2shpindel 25 - I600 / min

3 spindle 25-1600 / 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 12,5-2000vb / min

Limits of working feeds:

7-4,16 longitudinal 0.0 mm / rev

cross 0,04-2,08mm / 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 semi-automatic 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 20-224

Feed per revolution of the spindle 0,08-5,00mm

Duration table rotation 3.4 seconds

Power LP kW

25 Operation surfacing BKCM-IOOO RB-301

30 Operation automaton 1B284

35 Operation aggregate

On an aggregate operation offer to take a three-pronged horizontal drilling and threading spindle 40 with four-position 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 UM2464-011 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 UM2474-012 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 21003-100ASB

"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 self-aligning,

Finished part is removed from the device.

Cutting tool:

Face cutter ? 160mm Standard

Face cutter ? 250mm Standard

The tool measuring:

Caliper 11-250-01 GOST 166-80

15 Operation Lathe MK 112

Fitting: Insert PRK320

Cutting tool:

Cutter GOST 18877-73 2102-0059 T5K10

Cutter Criminal 2I30-40I5

Measuring tools:

Caliper 11-250-01 GOST 166-80

Bracket 230mm ? n 14 STP 1742 163-83

? 230mm bracket Criminal 8II3-4003 / 2

20 Operation automaton 1B284

Fitting: chuck model 425P

Cutting tools:

1.Rezets 10C2573 (20h32h100)

2.Rezets 1032100-0226-IOO T5K10 STP 21004-74

3.Rezets 1032101-0894-65T5K10 STP 21013-74

4.Rezets 12C-C2573 (16h16h65)

5.Rezets 11-S2573 (16h16h75)

GOST 18877-73 6.Rezets 2102-0060

7.Rezets 10-S2573 (20h32h100)

8.Rezets 1032100-0226-100 T5K10 STP 21004-74

Measuring tools:

Caliper ShTs-11-250-0,1 GOST 166-80

Caliper ShTs -1-125-0.1 GOST 166-80

Cork ?115mm N14PR STP 0742.172-83

Cork ?115mm N14NE STP 0742.173-83

Cork ? 94mm N14PR STP 0742.172-83

Cork ? 94mm H14 NOT STP 0742.173-83

25 Operation surfacing BKSM- 1000 RB-301

30 Operation automaton 1B284

Fitting: chuck model 425P

Cutting tools:

Criminal 1.Rezets 2102-4010 (16h16h70)

Criminal 2.Rezets 2102-4010 0 (16h16h70)

Criminal 3.Rezets 2102-4011 (16h16h75)

Criminal 4.Rezets 2102-4009 (16h16h70)

5.Rezets 5S2808 (16h16h70)

6.Rezets 13C2573 (16h16h85)

7.3enker 2329 Criminal Code 4005-01

Measuring tools:

Caliper ShTs-11-250-0.1 GOST 166-80

Cork ? 140mm STF N12PR 0742-172-83

Cork ? 140mm STF N12NE 0742-173-83

Caliper ShTs 1-125-01-GOST 166-80

Cork 0 N14PR 100mm STF 0742-172-83

Cork 0 H14HE 100mm STF 0742-173-83

Template Criminal 8424-4199

Template Criminal 8424-4200-01

35 Operation Machine 1AM0443

Device when the machine IAM0443-050

Cutting tools:

? 14mm drill GOST 12121-77 2301-3439

? 23mm drill GOST 10903-77 2301-0079

Tap M1b 2620-1619N2 GOST 3266-71

Measuring tools:

Cork ? 14mm HI2 STP 0742.169-83

Cork ? 23mm HI5 STF 0742.169-3

Cork GOST 17756-72 8221-0068 7H

Cork 822I-1068-7H GOST 17757-72

40 Operation locksmith

Grinding machines IP2013

Grinding PP 60h25h20 GOST 2424-75

GOST 71465-69 Files 2822-0024

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 Zi-1 + Ti-1 + r2i-e2u + 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 20-0,84

r and e tezhe data

Ziminposle finishing = R Zi-1 + Ti-1 + ri-1 + 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 inter-operational 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 zi-1

T i-1

r i-1

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 977-75

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 977-75

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 semi-automatic (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 semi-automatic 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 semi-automatic 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 semi-automatic 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 semi-automatic 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 0742-192-84 for holes M 16 -2-H7 [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 make-up 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 worn-caliber 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.

Marginal-worn 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 Machine-tool 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 = 160-0,13 = 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 = 160-0,13 = 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 = 160-0,13 = 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 double-acting 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) / (82-180) = 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 high-volume mass production are widely used electric lifting kranbalki controlled push-button 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 CH-63, 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- single-piece-calculation time for an operation;

Gdr- actual annual fund of working time machine operator

GDR = [(365-104-8) * 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 5-day week;

8 - the number of public holidays;

8.2 - working hours;

6 - the number of pre-holiday days with a reduction of 1 hour working days

Prince-factor 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 non-overlapping 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;

TK-stock quantity (6days)

Tp-working 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 forced-air 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, fire-fighting 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;

On-the 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 (1-b),

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 deductions-WIDE,

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;

Fs-efficient fund operating time, hour;

Ks-average 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 two-shift 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: QB-rate 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);

QB-annual 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- single-piece-calculation 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

30-machine 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 low-value 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.

Non-production costs amount to 5% of the production cost - 36497,75rub / 1824887.5 m.

Total cost is the sum of cost of production and non-productive 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

= Capital-stoim.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.TEHNIKO-ECONOMIC 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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2. Resurrection BV, Palamarchuk AS Directory Economist engineering enterprise. M..Mashinostroenie, 1971.

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11.Semenchenko II Matyushin V.M7 Sakharov GN Design of cutting tools. M.'Mashgiz, 1962.

12.Spravochnik technologist Machinist in 2 volumes / Ed. AG Kosimova M. Machinery, 1985,496s.

13.Spravochnik technologist Machinist / Ed. AN Malov. Ed.

Third, the slave pen. M .: Machine structure t.2,1972, 720c.

14. Gamrat Kurek-LI The economic rationale for graduation projects. M .: Higher School, 1974,19Ss.

15.Shatin VP Shatin Yu Directory --..:,1975.456.

16.Ekonomika, organization and planning of engineering production. M .: Higher School, 1973.

17. MA Anserov tools for machine tools Mechanical Engineering, 1966


  












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