Part Print Analysis

UNIT 5 PART PRINT ANALYSIS

Structure
5.1 Introduction
Objectives

5.2 Problems Encountered in Reading and Interpreting Part Prints

5.3 Establishing the General Characteristics of the Workpiece
5.3.1 General Description of the Part
5.3.2 General Configuration of the Part
5.3.3 Material Specifications
5.3.4 The Originating Operation
5.3.5 Recorded Changes in Design
5.3.6 Resistance to Damage in Process

5.4 Alternate Process

5.5 Functional Surfaces of the Workpiece
5.5.1 Surface Finish
5.5.2 Basic Geometry
5.5.3 Tolerances

5.6 Determining Areas Used for Processing

5.7 Specifications
5.8 Nature of the Work to be Performed
5.9 Summary
5.10 Answers to SAQs

5.1 INTRODUCTION
The ideas of product designer are conveyed to those concerned with transforming them
into the physical product using part drawings/blueprints/Part Prints. Part prints offer
greater information in manufacturing.
The process engineer must study the part print to understand what is wanted in the final
product. A detail study of Part drawings for the manufacturing of the part is called as Part
Print Analysis. The process engineer must consider the following two important
questions in making his preliminary part print analysis :
(a) What does the product designer want?
(b) What must be done with the information disclosed by the part print to get
what is wanted?
Objectives
After studying this unit, you should be able to
• provide the detailed information from the part print,
• identify the functional surfaces of the workpiece,
• determine the areas best qualified for locating, supporting and holding, and
• decide the sequence of operations to be performed on the workpiece.
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Elements of CAPP
5.2 PROBLEMS ENCOUNTERED IN READING AND
INTERPRETING PART PRINTS
The designers and draftsmen maintain a considerable degree of individualism in their
work, though efforts are continuously made to standardize the design and drawing
techniques. In fact companies themselves frequently setup their own standards for the
drafting room, establish their own codes and notations, all of which are meant to satisfy
the needs peculiar to that individual industry. However, due to these non-standardization
practices, the process engineers may confuse with the notations and other details on the
part drawings from an outside firm. Hence it is obviously tempting for the process
engineer to substitute his own interpretation of the part print which may be quite different
from those of the product designer. Such assumptions can be extremely dangerous.
It is necessary that the process engineer and product engineer effect a meeting of minds
to avoid hazards involved in having more than one interpretation of the part print. Any
revision in the part print resulting from such a meeting should be recorded on the part
print. Oral agreements should not be made under any conditions.

5.3 ESTABLISHING THE GENERAL CHARACTERISTICS

OF THE WORKPIECE
This step is preliminary to extract more detailed information from the part print.
Essentially, the process engineer seeks to determine six things at this stage.
(a) The general description of the part.
(b) The general configuration of the part.
(c) The material from which the part is made.
(d) How the part originated?
(e) Recorded changes in design.
(f) Resistance to damage in process.
5.3.1 General Description of the Part
The part description is acquired from the title block on the print. Because space is usually
limited, the description occasionally is abbreviated or contracted to a point where
interpretation is difficult. The designer should be consulted when it is felt that further
clarification is needed. Other information important to the general description is the part
number and the numbers of the sub assembly or assembly of which it is a part.
5.3.2 General Configuration of the Part
The general size and shape of the part is referred by configuration. To avoid
misinterpreting the parts size, the scale of drawing should be observed. The scale is
usually included in the title block. Size and shape relate themselves to many
manufacturing problems, some of which are discussed below.
Handling
The methods adopted for moving heavy and bulky parts are different from those
for small parts. As the workpiece must be moved from operation to operation, the
process engineer is naturally concerned with how to take hold of it and how it must
be moved. For example, large castings may require special lugs cast on them so
that they may be picked up by a crane. In other cases they may be moved on skids
or on a heavy duty roller conveyor. In contrast, small lightweight part may be
moved by a tote pan, chute or belt conveyor.
The general shape of the workpiece is important in respect of the manner in which
it must be handled. For example, coil springs tangle badly when thrown together
and cause difficulty when they must be separated. Round and cylindrical parts
frequently can be moved by gravity because they roll freely. Rectangular parts or
parts with flat surfaces can frequently be slid down chutes.
Type of Tooling
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 Type of tooling required is based on the size and shape of the workpiece. Consider Part Print Analysis
an example of flange shown in Figure 5.1. Almost all work performed can be done
between machine centres. Whereas the lever shown in Figure 5.2 is more complex
in shape and would require several types of jigs and fixtures for milling, drilling
and trapping, etc. Tooling for small parts can be designed to be turned over or
moved about by hand on a machine table. Tooling for large parts is less mobile
because of weight.

1 2 3 4 5 6
X-X

A
A φ 0.12 A C

12.5
3 HOLES, φ 6 x // 0.05 A
φ 3
EQUI-SP
ο 0.08 B ⊥ 0.02 A
M30 x 2.5
C B

+ 0.15
φ20 − 0.02
B
ο 0.1 B

+ 0.15
− 0.00
φ 75 ± 0.5

φ 25
32
φ 60

6.3 3

16
+ 0.12
20
− 0.02
0 0.2 − 0.02 32 C
A
x 40 + 0.00
− 0.12

Name Date Finish

Matl Tolerance
CI 25

D Title
D
Flange

Scale Drg. No.

1 2 3 4 5 6

Figure 5.1 : Flange

R 17.5
X

Oil Hole, φ 3
CSK φ 5

R5
32

R 60
X
22

14

0
35
2

R 14
R 30

R 48 X-X
16
φ 40
25

20

17

φ 48 φ 22

Figure 5.2 : Lever

Type of Machines
21
Elements of CAPP In general, very large parts are produced by slower methods because of difficulty
in handling. Hence they must be produced on the larger and slower machines
mainly on a tool room basis. Smaller parts whose shape is easy to handle can be
produced on faster machines and are more readily adapted to mass production.
There are exceptions, of course. For example, in the pressed metal industry
production techniques have been developed to the point where large sheet metal
parts can be produced at relatively high speeds. Hence in general, the size and
shape of the workpiece associates itself closely with the size and type of machine
required to produce it.
Sequence of Operations
The shape of the workpiece does influence which of its surfaces must be machined
first and method of location necessary for maintaining maximum dimensional
control over its geometry.
Rate of Production
The size of the workpiece influences its mobility and thus affects its rate of
production. It also affects the number of operations which can be combined at one
setting of the workpiece. The ease with which the workpiece can be handled
probably has more influence on production rate than any other single factor.
5.3.3 Material Specifications
In part prints the information regarding the material from which the part is made is
generally found in one of two places. In most cases, material specifications are presented
in the title block close to the general description. However, some designers show this
information in general notes. Different materials present different manufacturing
problems as well as different manufacturing costs. It is necessary to know the material of
the workpiece in order to cope with both of these important problems.
5.3.4 The Originating Operation
The general configuration of the workpiece is created by the originating operation. There
is actually no fixed rule to find how the workpiece is originated from part print. In some
cases, only the material specification is presented and the process engineer is left to
determine whether the piece will be cast, forged, or made from bar stock. But in most of
the cases the decision is not left to the process engineer but is either spelled out with the
material specifications or in the general notes.
5.3.5 Recorded Changes in Design
The revisions made in the part print must be carefully studied. Any failure in checking
the revisions can cause costly manufacturing mistakes. Quite often revisions are made at
the request of process engineer. The reason for revising drawings may be to correct
errors, reduce cost, improve manufacturing methods, improve the existing design,
facilitate inspection, improve quality and many others.
Any change in the design must be checked out completely before the process can be
planned because of the effect they may have on the operational sequence, tooling,
locating system and overall manufacturing economy.
Majority of components are either made up from an assembly of individual parts or
become a part of another assembly. Hence, it should be standard practice in seeking out
revisions to check all other drawings related to the given part to determine how the
revisions tie in.
5.3.6 Resistance to Damage in Process
The preliminary examination of a part print provides the general conception about the
care required in protecting the workpiece. However, certain characteristics can be
determined from the material specifications and part’s general configuration. For
example, castings and forgings are less susceptible to damage than certain fragile parts or
parts having thin sections such as parts of electrical controls. Usually, as the workpiece
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progresses through its manufacturing sequence, it becomes more susceptible to damage, Part Print Analysis
because more finished surfaces are exposed. Protecting a part being processed becomes
an important consideration, as the objective is to produce a good part.

5.4 ALTERNATE PROCESS

The only best method for manufacturing a product has not yet been discovered, nor can it
be said that a job can be performed in only one way. The process engineer is
continuously facing alternative solutions to manufacturing problems and no doubt always
will be. Possibility, alternate process operations come from a combination of information
gleaned from the part print, imagination, and the process engineer’s knowledge of known
processes.
The assumption that the design engineer, through the part print, maintains absolute
control over the process of manufacture is not always true. The product designer’s
interest is – and should be – in the physical specification of the workpiece, material-wise,
functionally, and from the standpoint of acceptable appearance. How the part is
manufactured to these specifications is the job of the process engineer. Economy of
manufacture is a factor that frequently upsets the best laid plans; it calls for coordinating
the efforts of both the design and manufacturing activities. Only a careful manufacturing
cost study will reveal, for example, whether a part should be produced from a casting, a
forging, or bar stock. The general configuration of the part will often reveal these
alternatives. This does not imply that the process engineer or any other person except the
designer has the right to change the part print or its specifications. This would be
unrealistic for certain characteristics desired in the part may not be fully apparent from
the study of the print. The direction of the fibre flow lines in a certain forged part, for
instance, might produce a stronger and more desirable part than one produced from a
casting of the same material.

5.5 FUNCTIONAL SURFACES OF THE WORKPIECE

The surfaces which must be developed on the workpiece in the process of manufacturing
are known as the functional surfaces. Consider a workpiece to be machined. Practically,
the machined surfaces must mate with other machined surfaces. The areas which must be
machined are identified from the part prints in three major ways.
(a) Surface finish
(b) Basic geometry
(c) Tolerances
5.5.1 Surface Finish
The standards for surface finish and their symbols shown on the product drawings are
extremely useful to the process engineer in determining which surfaces must be
machined. To some extent, they also limit the choice of how these surfaces must be
accomplished.
5.5.2 Basic Geometry
The need for machining is identified by the basic shape of the part. A particular degree of
roundness, squareness, flatness, parallelism or other specific descriptions of shape aid in
recognizing machined surfaces. The process employed in originating the workpiece will
often dictate how well these basic characteristics can be maintained. For example, shell
mould casting may require little or no machining compared to the same part produced as
a sand casting.
5.5.3 Tolerances
The preliminary part print analysis gives the general idea of dimensional limitations. As
far as the functional requirements of the workpiece are concerned, tolerances indicate the 23
Elements of CAPP margin of error that can be tolerated in manufacturing and still considered as the
acceptable part. The basic configuration of the workpiece and the general notes and
dimensions indicate to what degree these characteristics are needed.

5.6 DETERMINING AREAS USED FOR PROCESSING

In contrast to those surfaces on the workpiece which affect its function, other surfaces
may be equally important in their effect on its manufacture. These surfaces influence the
ease or difficulty with which the part can be located, supported, and held throughout the
manufacturing sequence.
Some surfaces or areas have greater importance than other and are called critical areas.
These are the ones which have a critical relationship with other areas on the workpiece
and, as such, serve as registering points for the location system and can be identified
from the part print. Identification can be made by looking for baselines from which
dimensions are measured, close dimensional tolerances, and natural centerlines. The
order of establishing processing areas is as follows :
(a) Determine those areas best qualified for locating the workpiece during
processing.
(b) Determine those areas best qualified for supporting the workpiece during
processing.
(c) Determine those areas best qualified for holding the workpiece during
processing
Areas Suitable for Location
When the workpiece is received from its basic or originating process in a rough
cast or forged state, surface conditions create problems in maintaining adequate
dimensional control in the machining operations which follow. A knowledge of
how the workpiece originated aids the process engineer in determining the
variations which he must control. The process engineer is interested in getting the
best workpiece out of the process by maintaining control over those variations
inherent in both the workpiece and the process. To this end, he must be concerned
with selecting the surfaces most ideally suited for location.
Obviously, the first locating surface on a casting or forging will be a rough surface.
Getting the workpiece out of the rough in the shortest possible time aids in
establishing control sooner in the operation sequence. Thus, the first surface
machined should be one that can qualify as best for location in a subsequent
operations. Such established surface are said to be geometrically, dimensionally,
and mechanically qualified for locating the workpiece. These areas can only be
determined from information provided by the part print.
Areas Suitable for Support
When the print reveals the possibility that the workpiece will require additional
support even when properly located, the process engineer must decide what
additional areas can be best provide it. No workpiece is completely rigid. Forces
created by the cutting action deflect the unsupported workpiece causing the tool to
chatter. The result is poor surface finish and loss of dimensional control. The
addition of supporting elements to the workpiece should take place after the
locating surfaces have been established. Some important guides for selecting
supporting areas are as follows :
(a) Select supporting areas on the workpiece where maximum deflection
is likely to occur.
(b) Check the part print and select support areas which will not interfere
with the location of the workpiece or displace locating areas.
(c) Make certain that support areas are not the same as those that are to be
machined.
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 (d) Select supporting areas which will allow the mechanical elements of Part Print Analysis
support without interfering with the loading and unloading of the
workpiece from the tooling.
Areas Suitable for Holding
Establishing areas suitable for holding or clamping the workpiece, while it is being
machined, can be as difficult and as important as in case of locating and supporting
it. Because the order for establishing the processing areas leaves holding until last,
the choice of qualified surfaces may be limited. The ideal surfaces for holding or
champing are those directly opposite the locating points. Because those surfaces
are the ones which are also most likely to be the ones requiring the machining, the
process engineer often must effect a compromise. In this case, a resultant holding
force must be obtained on other surfaces equivalent to the ideal holding force. This
is not always a simple task and without the aid of the part print, it would be almost
impossible to determine in advance.
Some fundamental guidelines for selecting surfaces for holding the workpiece are
as follows :
(a) Check the print to identify areas that are to be machined. Avoid using
these areas for clamping unless the machining does not include the
entire surface.
(b) Check surfaces chosen for location. When possible, choose surface for
clamping opposite those for location.
(c) When the surface opposite the locators must be machined, choose
alternate surfaces in such a way that a resultant force can be
established that acts against the locators.
(d) Choose surfaces which will not cause the clamping action to distort
the workpiece.
(e) Choose surface areas large enough to distribute the clamping forces.
Holding forces concentrated in small areas often mutilate the
workpiece. Remember, enough force must be applied to prevent the
workpiece from shifting during machining.
(f) When possible, avoid using previously machined areas for clamping
when there is the possibility that they might become damaged when
applying the holding force.

5.7 SPECIFICATIONS
Specifications on the part print provide information relating to both general and specific
characteristics of the workpiece that are not provided within the conventional
dimensioning system. Specifications usually pertain to the material, its heat treatment or
finish, general tolerance level to be attained, references to other drawings, notations that
cannot be included as part of the dimensions, and other instructions. Specifications are
either explicit or implied.
Explicit specifications are stated on the part print in sufficient detail to meet fully and
completely the instructions required to produce the part. They are the specifications that
are actually needed before the part can be made. A specific surface hardness wanted on
the part when completed, for example, to be explicit must indicate how hard the surface
must be, the depth of the hardness, and the instructions for producing the specification. A
few other examples of instructions that must be stated explicitly are :
(a) the location of the part number on the workpiece and whether it is to be
stamped or produced in the basic process,
(b) surface finish notations, 25
Elements of CAPP (c) general notes indicating the size of fillets and redii,
(d) treatment of sharp edges, and
(e) areas where treatment of the workpiece is localized, and many others.
Implied specifications are those which are not always stated on the part print but are
correctly assumed either by general knowledge or convention to be in effect. Generally
speaking, such specifications are met in the normal course of manufacturing and are left
to the good judgment of the process engineers and the manufacturing people. For
example, if a rectangular workpiece 20 × 40 × 60 mm were to be machined, it would be
assumed, unless otherwise specified, that the corners would all be square and that it
would be unnecessary to specify a 90o angle on each corner. Some specifications are
implied from other more specific ones. A hole may have a diameter clearly specified;
however, it may not be stated that the hole must be round; this is implied. Although it
may not be perfectly round after it is produced, it is assumed that it will be within normal
machining tolerances and, therefore, acceptable.
One major danger is created by the implied specification. One can never be certain that
the specification is actually implied or has been unintentionally omitted. Because errors
of omission are not uncommon, it is always good judgment to check with the product
engineer before making a questionable assumption.

5.8 NATURE OF THE WORK TO BE PERFORMED

Ultimately, an examination of the part print leads to the nature of the work to be
performed. This, in turn, points to the sequence of operations that must be performed on
the workpiece to produce the part to its print specifications. The characteristics of the
workpiece affect economy of production. At this stage of the part print analysis, the
process engineer must seek out these characteristics and relate them to the job to be done.
In this regard, answering the following questions offer some help :
(a) What is the degree of symmetry found in the workpiece?
(b) How many machined surfaces are related to each other?
(c) What is the relationship between these surfaces?
(d) Can the related surfaces or areas be combined or grouped to reduce the
number of machining setups?
(e) How many operations must be performed on each surface?
Degree of Symmetry
Symmetry implies that several surfaces may share a common axis or centre line. It
can also mean that a number of surfaces might share a common locating system.
This being the case, symmetrical parts can usually be machined with fewer setups
and in such a way that each setup can produce more than one machined surface.
The resulting advantages are : increased accuracy, economy, and ease of handling,
especially when the workpiece is made up from basic cylindrical shapes generated
about the same center line, as in a turning operation.
Because the purpose of dimensioning on the part drawing is to relate surfaces, it
becomes obvious that the dimensioning system itself is the best method of
determining the number of surfaces that can be related in one setting of the
workpiece. As in the case of the symmetrical part, related surfaces often share the
same seat of registry. The example in Figure 5.3 shows several surfaces located
with respect to each other in such a way that they can be gang milled in a single
pass.
3
26 1
2
8 4
3/4 3/4
 Part Print Analysis

Figure 5.3 : Surface of this Part are Related in such a way that those Shaded may be Machined in One
Combined Operation such as Gang Milling

Degree of Relationship Between Surfaces

The primary reasons for relating surfaces on the part print are to guarantee
accuracy in the workpiece and economy in manufacture. A competent process
engineer realizes that unless he can fully establish the relationship between
surfaces, he cannot hope to achieve the accuracy specified. Economy can only
result when good part are produced.
Actually, on a given workpiece all surfaces are related to one another either
directly or indirectly. The dimensioning system will generally indicate how closely
the relationship exists. Each dimension presented on the part print indicates a
direct relationship between two surfaces or lines. The object shown in Figure 5.4
indicates varying degree of dimensional relationships. For example, surface A is
directly related to surfaces B, D, and F. Surface A is related to surface E indirectly
since it is connected dimensionally only through surface D. The relationship
between surface B and surface C is even more indirect since they can only be
related through surfaces A and D. The number of direct dimensional relationship
connecting dimensional links that must be considered in relating one surface to
another indicates their degree of relationship.

A B C D E F

Figure 5.4 : Sketch to Illustrate Degrees of Relationship Between Surfaces

Thus, surfaces A and D have a first degree relationship, surfaces A and E have a
second degree relationship, and surfaces B and C have a third degree relationship.
Because dimensional tolerances must also be considered when relating surfaces, it
follows that the degree to which surfaces are related is tied in closely with the
tolerances which must be held. If it is felt that a certain tolerance must be held
between two surfaces not directly related, the tolerances on the interconnecting
dimensions must be tightened to make certain that their collective variations do not
exceed those desired in the direct dimension.
Grouping Related Surfaces or Areas
When several areas or surfaces are related in such a way that they can be
accomplished in one setting of the workpiece, considerable savings can usually be
attained. For this reason, when the process engineer attempts to establish the
relationship between surfaces, he should also be concerned with grouping them for
economy.
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Elements of CAPP Some surfaces, though closely related dimensionally, cannot be combined readily
for machining because of differences in surface position. Two surfaces bearing an
angular relationship to each other may be difficult to combine because they cannot
be matched with the geometry the machine was built to produce. For example, in
Figure 5.5 each of the three surfaces bear a specific relationship to the base of the
object. Surface B is parallel to the base of the object, but surfaces A and C are at
angles to the base and at opposite angles to each other. It is obvious that all three
surfaces could not be gang milled at one pass. The object in Figure 5.5 would not
present such a problem, for all surfaces were parallel.
B

Figure 5.5 : Sketch Showing Surfaces, which are not Related to can be Conveniently
Combined the Degree, Those Operations on Them

SAQ 1
(a) What are the problems encountered in Reading and Interpreting the Part
Prints?
(b) How does the shape of the Part affect its processing?
(c) How can changes in product design affect processing? What can the process
engineer do to minimize these affects?
(d) Why is the originating operation important to the process engineer as he
plans the process?
(e) How the functional surfaces on the workpiece can be identified?
SAQ 2
(a) List out the machine tools used to machine the part shown in Figure 5.6.
(b) Give a detailed tooling layout for the part prints shown in Figures 5.6(a), (b)
and (c).
Planed Surface

φ 20

150

(a)

Gear to DP 21 Teeth
2

200
φ Spline
50 20 Teeth

(b)
28
 Part Print Analysis

φ 20

40

(c)
Figure 5.6

(c) Explain how Part Print leads to the selection of nature of the work to be
performed?
(d) Explain the role of specifications on the Part Prints.
(e) Explain how are Part Prints prepared?
(f) How does the shape of the part affect its processing?
(g) How may functional surfaces on the workpiece be identified?

5.9 SUMMARY
This unit discusses about the importance of part print analysis and the problems
associated in understanding the part drawings. A detail study of Part drawings for the
manufacturing of the part is called as Part Print Analysis. Part print analysis leads to
nature of work to be performed. This, in turns, points to the sequence of operations that
must be performed onto the workpiece to produce the part to its print specifications and
cost effective. However, due to these non-standardization practices, the process engineers
may confuse with the notations and other details on the part drawings from an outside
firm.
The preliminary step to extract more detailed information from the part print is to
establish the general characteristics of the workpiece. The best method for manufacturing
a product has not yet been discovered, nor can it be said that a job can be performed in
only one way. The possibility of generating alternate process operations come as a result
of combination of information gleaned from the part print, imagination, and the process
engineer’s knowledge of known processes.
This unit also discusses about the functional surfaces. The surfaces, which must be
developed on the workpiece in the process of manufacturing, are known as the functional
surfaces. The areas, which must be machined, are identified from the part prints in three
major ways like Surface finish, Basic geometry and Tolerances.
Specifications on the part print provide information relating to both general and specific
characteristics of the workpiece that are not provided within the conventional
dimensioning system. Specifications usually pertain to the material, its heat treatment or
finish, general tolerance level to be attained, references to other drawings, notations that
cannot be included as part of the dimensions, and other instructions. Specifications are
either explicit or implied.
Ultimately, an examination of the part print leads to the nature of the work to be
performed. This, in turn, points to the sequence of operations that must be performed on
the workpiece to produce the part to its print specifications.

29
Elements of CAPP

BIBLIOGRAPHY
Donald F. Eary and Gerald E. Johnson (1962), Process Engineering for Manufacturing,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey.
(1982), HMT Handbook on Production Technology, TMH, New Delhi.
S. K. Bogoyubov (1975), Exercises in Machine Drawing, MIR Publishers, Moscow.
Hirm E. Grant (1971), Jigs and Fixtures, TMH, New Delhi.
P. N. Rao (2000), Manufacturing Technology – Metal Cutting and Machine Tools, TMH,
New Delhi.
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Tien-Chien Chang, Richard A. Wysk and Hsu-Pin Wang (1991), Computer-Aided Part Print Analysis
Manufacturing, Prentice-Hall, Englewood Cliffs, New Jersey.

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