ME477

Fall 2004

1. Machinability Economics and Product Design Considerations

1. Machinability 2. Tolerance and Surface Finish 3. Selection of Cutting Conditions 4. Product Design Considerations
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Machinability A measure of the relative ease of a machining operation usually on a work material and type of machining operation, tooling, and cutting conditions.
Longer tool life means better machinability Greater forces and power mean lower machinability Better surface finish means better machinability Easier chip disposal means better machinability Higher MRR means better machinability

Mechanical properties and Machinability

High hardness of work materials means abrasive wear resistance High strength of work materials means cutting forces, specific energy, and cutting temperature increase High ductility of work materials means tearing of metal as chip is formed, causing chip disposal problems and poor surface finish

Shape
Work Materials Base Steel: B1112 Low Carbon Steels Med. Carbon Steels High Carbon Steels Alloy Steels Cast Iron Ti Alloys Aluminum Aluminum Brinnell Hardness 180-220 130-170 140-210 180-230 170-230 60-230 220-280 (soft) (Hard) Machinability Rating 1.00 0.50 0.65 0.55 0.25-1.5 0.40-0.70 0.2 2.00 1.25

Shape
Rotational parts turning and boring Internal rotational features - drilling Non-rotational parts milling Dependency on the geometry of a tool
Generating Multi-axis milling machine Forming form turning, drilling and broaching Generating/Forming (threading)

MR of base material = 1.00 (100%) MR of test material > 1.00 (100%) means better machinability
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2. Tolerances & Surface Finish

Tolerances
Machining provides high accuracy relative to most other processes Closer tolerances usually mean higher costs

Tolerance and Surface finish

Types of Operations Cutting tool geometry
Ratio, rai
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Geometric factor
Surface roughness, R = f i where NR= nose radius 32 NR and Ra = rai Ri because it depends on work material and cutting speed Other expressions of roughness

Ductile metals

Surface roughness in machining is determined by:

Work material factors Geometric factors of the operation Vibration and machine tool factors

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Cast iron

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Machining alloys

Work Material Factors

Built-up edge effects Damage to surface caused by chip Tearing of surface for ductile materials Cracks in surface for brittle materials Friction between tool flank and new surface
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Nose Radius, Feed and End Cutting Edge Angle

Zero Nose Radius

Cutting speed

Zero End Cutting Edge Angle Small feed

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Kwon

ME477

Fall 2004

Machining Operations Turning D<25mm 25mm<D<50mm D>50mm Drilling D<2.5mm 2.5mm<D<6mm 6mm<D<12mm 12mm<D<25mm D>25mm Reaming D<12mm 12mm<D<25mm D>25mm Broaching Milling Peripheral Face End Shaping Slotting Planing Sawing

Tolerance (Typical) 0.025 0.05 0.075 0.05 0.075 0.1 0.125 0.20 0.025 0.05 0.075 0.05 0.025 0.025 0.05 0.025 0.075 0.5

Surface Finish (Typical best) 0.8m

Chatter (Vibration)
Vibration and Chatter
Related to machine tool, tooling, and setup:
Chatter (vibration) in machine tool or cutting tool Deflections of fixtures Backlash in feed mechanism

Typical Tolerance Surface Finish

0.8m

0.4m

Without chatter, surface roughness is determined by geometric and work material factors

How to avoid Chatter

0.4m

1.6m 1.6m 6.0m 7

Add stiffness and/or damping to setup Operate at speeds that avoid natural frequency of machine tool system Reduce feeds and depths to reduce forces Change cutter design to reduce forces Use a cutting fluid
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3. Selection of Cutting Conditions

One of the tasks in process planning For each operation, decisions on machine tool, cutting tool(s), and cutting conditions based on workpart machinability, part geometry, surface finish, and so forth Cutting Tool Manufacturers Recommendation Cutting conditions: speed, feed, depth of cut, and cutting fluid
Depth of cut predetermined by workpiece geometry and operation sequence.
In roughing, high depth to maximize material removal rate, but limited by horsepower, machine tool and rigidity, and strength of cutting tool. In finishing, depth to achieve final part dimensions

Selecting Feed and Speed

Feed: In general: feed first, speed second
Tooling Harder tool materials require lower feeds Roughing or finishing - Roughing means high feeds, finishing means low feeds Constraints on feed in roughing: cutting forces, setup rigidity, and sometimes horsepower Surface finish requirements in finishing Select feed to produce desired finish

Cutting Speed
Select speed to achieve a balance between high metal removal rate and suitably long tool life Mathematical formulas are available to determine optimal speed Two alternative objectives:
1. Maximum production rate 2. Minimum unit cost

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Maximum Production Rate

Time per workpart

Maximum Production Rate

Tc = Th + Tm +
Total time per piece

Maximizing production rate = minimizing cutting time per unit In turning, total production cycle time for one part consists of:
Part handling time per part = Th Machining time per part = Tm, For a simple turning, Tm = vf Tool change time per part = Tt/np ,where np = number of pieces cut in one tool life where T fC 1/ n and, from Taylors model, tool life is = np = Tm DLv (1/( n 1) ) 1/ n 1/ n
T =C v
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= Th +
Tool change time Part Handling Time Cutting time vmax

DL Tt (DLv(1/ n1) )
fv + fC1/ n C

Tt np

DL

Cutting speed

dTc = 0 vmax = n dv 1 n 1Tt The tool life: 1 Tmax = 1Tt n

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ME477

Fall 2004

Example
Workpart: L=300mm and D=80mm. C vmax = Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min) n 1 Machining condition: f=0.4mm/rev. n 1Tt Operator and machine cost=$30/hr Tooling cost/edge=$4 2min to load and unload and 3.5min to change tools 1 Tmax = 1Tt (a) Cutting speed for max. production rate n (b) Tool life in min. for max. production rate (c) Cycle time and cost per unit of product for max. production rate

Minimum Cost Per Part

Cost of part handling CoTh Cost of machine time CoTm Cost of tool change CoTt n p P Tooling cost Ct n p C = n
t t e

Tm =

DL
vf

for disposable inserts

(a) Co=$30/hr=$.50/min T vmax=75/[(1/.13-1)(3.5)].13 =49.8m/min np = (b) Tmax=(75/49.8)1/.13 =23.42min Tm (c) Tm=DL/fv=(8)(300)/(.4x49.8x103)=3.787min T np=23.42/3.787~6pc/tool life Tc = Th + Tm + t Tc=Th+Tm+Tt/np=2+3.787+3.5/6=6.37min/pc np Cc=CoTc+Tool cost per edge/np=0.5(6.37)+4/6=$3.85/pc
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Cc = CoTh + CoTm +

CoTt Ct + np np

Ct =
1 n 1

= CoTh +

CoDL + fv

(CoTt + Ct ) DLv
fC
1 n

n dCc Co = 0 vmin = C 1 n C T + C dv o t t 1 CoTt + Ct Tmin = 1 n Co

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Pt + T g C g for regrindable inserts ng n

Example
Workpart: L=300mm and D=80mm. Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min) Machining condition: f=0.4mm/rev. Operator and machine cost=$30/hr Tooling cost/edge=$4 2min to load and unload and 3.5min to change tools (a) Cutting speed for min. cost (b) Tool life in min. for min. cost (c) Cycle time and cost per unit of product for min. cost

Comments
As C and n increase in Taylors equation, optimum cutting speed should be reduced
n Co vmin = C 1 n CoTt + Ct C T + Ct 1 o t Tmin = 1 n Co
n

Cemented carbides & ceramic tools at higher speeds.

vmax is always greater than vmin.

Reason: Ct/np term in unit cost equation pushes optimum speed to left in the plot of Cc vs. v.

(a) Co=$30/hr=$.50/min vmin=75/[0.5(1/.13-1)(0.5x3.5+4)].13 =42.6m/min (b) Tmin=(75/42.6)1/.13 =76.96min (c) Tm=DL/fv=(8)(300)/(.4x42.6x103)=4.42min np=76.96/4.42~17pc/tool life Tc=Th+Tm+Tt/np=2+4.42+3.5/17=6.63min/pc Cc=0.5(6.63)+4/17=$3.55/pc
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Cutting speed should be reduced as tool change time Tt and/or tooling cost Ct increase,
Tools should not be changed too often if either tool cost or tool change time is high. An advantage of disposable inserts over regrindable tools due to the lower tool change time.
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Product Design Guidelines I

Design parts to minimize machining
by using net shape (precision casting, closed die forging, or plastic molding) or near net shape processes (impression die forging)

Product Design Guidelines II

Avoid features such as sharp corners, edges, and points
They are difficult to machine Sharp cutting tools tend to break and create burrs

Essential Reasons for machining

Close tolerances Good surface finish Flexibility Special features such as threads, precision holes, cylindrical sections with high degree of roundness

Machined parts from standard stock sizes Machining with standard cutting tools
Avoid special form tools Minimize the number of individual cutting tools used

Specify Tolerances to satisfy functional requirements and process capabilities (unnecessary cost from additional
processing, fixturing, inspection, sortation, rework, and scrap)

Select materials with good machinability

Materials with low machinability take longer and cost more. Minimize the number of setups

Specify surface finish to meet functional and/or aesthetic requirements (add processing cost by requiring
additional operations such as grinding or lapping)
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