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23-1
Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
23.9 The unit cost in a machining operation is the sum of four cost terms. The first three terms are: (1)
part load/unload cost, (2) cost of time the tool is actually cutting the work, and (3) cost of the time
to change the tool. What is the fourth term?
Answer. The fourth term is the cost of the tool itself (purchasing the tool and grinding it, if
applicable).
23.10 Which cutting speed is always lower for a given machining operation, cutting speed for minimum
cost or cutting speed for maximum production rate? Why?
Answer. Cutting speed for minimum cost is always lower because of the fourth term in the unit cost
equation, which deals with the actual cost of the cutting edge. This term tends to push the U-shaped
function toward a lower value in the case of cutting speed for minimum cost.
Problems
Answers to problems labeled (A) are listed in an Appendix at the back of the book.
Machinability
23.1 (SI units) Machinability ratings are to be determined for a new work material using the cutting
speed for a specified tool life as the basis of comparison. For the base material (B1112 steel), test
data resulted in Taylor equation parameter values of n = 0.24 and C = 450, where speed is m/min
and tool life is min. For the new material, the parameter values were n = 0.28 and C = 490.
Cemented carbide tools were used. Compute machinability ratings for the new material using as the
tool life criterion (a) 60 min, (b) 10-min, and (c) 1.0 min. (d) What do the results show about the
difficulties in machinability measurement?
Solution: (a) Base material: v60 = 450/600.24 = 168.4 m/min
New material: v60 = 490/600.28 = 155.7 m/min
MR = 155.7/168.4 = 0.925 = 92.5%
(b) Base material: v10 = 450/100.24 = 259.0 m/min
New material: v10 = 490/100.28 = 257.2 m/min
MR = 257.2/259.0 = 0.993 = 93.3%
(c) Base material: v1 = 450/10.24 = 450 m/min
New material: v1 = 490/10.28 = 490 m/min
MR = 490/450 = 1.089 = 108.9%
(d) Different test conditions often result in different machinability results.
23.2 (USCS units) A small company uses a band saw to cut through 2-in metal bar stock. A material
supplier is proposing a new material that is supposed to be more machinable while providing
similar mechanical properties. The company does not have access to sophisticated measuring
devices, but they do have a stopwatch. They have acquired a sample of the new material and cut
both the present material and the new material with the same band saw settings. In the process, they
measured how long it took to cut through each material. To cut through the present material, it took
an average of 2 min, 20 sec. To cut through the new material, it took an average of 2 min, 6 sec. (a)
Develop a machinability rating system based on time to cut through the 2.0-in bar stock, using the
present material as the base material. (b) Using your rating system, determine the machinability
rating for the new material.
Solution: (a) Since a material with a shorter cutting time is more machinable, it should have a
higher machinability rating. To achieve this the cutting time of the base material needs to be in the
numerator and the time of the tested material needs to be in the denominator. Therefore, if the test
material has a shorter cutting time, the rating will be greater than 100%. The appropriate MR
equation is the following: MR = Tm(base material)/Tm(test material) x 100%
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Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
23.8 (A) (SI units) A part turned in an engine lathe must have a surface finish of 1.6 m. The part is
made of a free-machining aluminum. Cutting speed = 200 m/min, and depth of cut = 4.0 mm. The
nose radius on the tool = 1.5 mm. Determine the feed that will achieve the specified surface finish.
Solution: For free-machining aluminum at 200 m/min, the ratio rai = 1.0 in Figure 23.2 so Ra = Ri.
Ra = Ri = f2/32NR
Rearranging, f2 = Ri(32NR) = 1.6(10-6)(32)(1.5)(10-3) = 76.8(10-9) = 7.68(10-8) m2
f = (7.68(10-8) m2)0.5 = 2.77(10-4) m = 0.277 mm (mm is interpreted mm/rev)
23.9 (SI units) Solve previous Problem 23.8 except that the part is made of cast iron instead of aluminum
and the cutting speed is reduced to 100 m/min.
Solution: For cast iron at 100 m/min, the ratio rai = 1.3 in Figure 23.2 so Ra = 1.3Ri.
Ra = 1.3f2/32NR
Rearranging, f2 = Ri(32NR)/1.3 = 1.6(10-6)(32)(1.5)(10-3)/1.3 = 59.08(10-9) = 5.908(10-8) m2
f = 5.908(10-8) m2)0.5 = 2.43(10-4) m = 0.243 mm (mm is interpreted mm/rev)
23.10 (SI units) A ductile aluminum part in a turning operation has a specified surface finish of 1.25 m.
Cutting speed = 1.5 m/s, and depth of cut = 3.0 mm. The tool nose radius = 1.2 mm. Determine the
feed that will achieve this surface finish.
Solution: For ductile aluminum at 1.5 m/s or 90 m/min, the ratio rai = 1.25 in Figure 23.2.
Therefore, the theoretical requirement is Ri = Ra /rai = 1.5/1.25 = 1.2 m
Ri = f2/32NR; f = (32 (NR)Ri )0.5 = (32(1.2x10-3)(1.25x10-6))0.5 = 48x10-9 = 4.8x10-8 m2
f = (4.8(10-8) m2)0.5 = 2.19(10-4) m = 0.219 mm (mm is interpreted mm/rev)
23.11 (SI units) The surface finish specification on a cast iron part in a turning job is 0.8 m. Cutting
speed = 75 m/min, feed = 0.5 mm/rev, and depth of cut = 4.0 mm. Determine the minimum nose
radius that will obtain the specified finish in this operation.
Solution: For cast iron at 75 m/min, the ratio rai = 1.35 in Figure 23.2.
so Ra = 1.35Ri = 1.35f2/32NR
Rearranging, NR = 1.35f2/(32Ra)
NR = 1.35(0.5 x 10-3)2/(32)(0.8)(10-6) = 0.0132 m = 13.2 mm
Comment: This is a very large nose radius, suggesting that the specified surface roughness would
be readily achieved. However, cast iron tends to produce discontinuous chips which cause problems
with surface finish.
23.12 (A) (USCS units) A face milling operation will be performed on a cast iron part to finish the surface
to 32 -in. The cutter uses six inserts, and its diameter is 3.0 in. The cutter rotates at 500 rev/min. A
carbide insert with 4/64 in nose radius will be used. Determine the required feed rate (in/min) that
will achieve the 32 -in finish.
Solution: v = DN = (3/12)(500) = 393 ft/min
For cast iron at 393 ft/min, the ratio rai = 1.25 in Figure 23.2, so Ra = 1.25 Ri
Ri = Ra/1.25 = 32/1.25 = 25.6 in
Ri = f2/32 NR
Rearranging, f2 = 32Ra(NR) = 32(25.6 x 10-6)(4/64) = 51.2 x 10-6 in2
f = (51.2 x 10-6).5 = 7.16 x 10-3 = 0.00716 in/tooth.
fr = Nntf = 500(6)(0.00716) = 21.5 in/min
23.13 A face milling operation is not yielding the required surface finish on the work. The cutter is a
four-tooth insert type face milling cutter. The machine shop foreman thinks the problem is that the
work material is too ductile for the job, but this property tests well within the ductility range for the
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23-4
Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
material specified by the designer. Without knowing any more about the job, what changes in (a)
cutting conditions and (b) tooling would you suggest to improve the surface finish?
Solution: (a) Changes in cutting conditions: (1) decrease chip load f, (2) increase cutting speed v,
(3) use cutting fluid.
(b) Changes in tooling: (1) increase nose radius NR, (2) increase rake angle, and (3) increase relief
angle. Items (2) and (3) will have a marginal effect.
23.14 (USCS units) A turning operation is to be performed on C1010 steel, which is a ductile grade. It is
desired to achieve a surface finish of 64 -in, while at the same time maximizing the metal removal
rate. It has been decided that the speed should be in the range 200 ft/min to 400 ft/min, and that the
depth of cut will be 0.080 in. The tool nose radius = 3/64 in. Determine the speed and feed
combination that meets these criteria.
Solution: Increasing feed will increase both RMR and Ra. Increasing speed will increase RMR and
reduce Ra. Therefore, it stands to reason that we should operate at the highest possible v.
Try v = 400 ft/min. From Fig. 25.45, rai = 1.15.
Ra = 1.15 Ri
Ri = Ra/1.15 = 64/1.15 = 55.6 in
Ri = f2/32NR
f2 = 32Ra(NR) = 32(55.6 x 10-6)(3/64) = 83.4 x 10-6 in2
f = (83.4 x 10-6).5 = 0.0091 in/rev
RMR = 3.51 in3/min
Compare at v = 300 ft/min. From Fig. 25.45, rai = 1.26.
Ra = 1.26 Ri
Ri = Ra/1.26 = 64/1.26 = 50.8 in
Ri = f2/32NR
f2 = 32Ra(NR) = 32(50.8)(10-6)(3/64) = 76.2(10-6)in2
f = (76.2 x 10-6).5 = 0.0087 in/rev
RMR = 2.51 in3/min
Optimum cutting conditions are: v = 400 ft/min and f = 0.0091 in/rev, which maximizes RMR = 3.51
in3/min
Machining Economics
23.15 (A) (SI units) A high-speed steel tool is used to turn a steel work part that is 350 mm long and 75
mm in diameter. The parameters in the Taylor equation are: n = 0.13 and C = 75 (m/min) for a feed
of 0.4 mm/rev. The operator and machine tool rate = $36.00/hr, and the tooling cost per cutting edge
= $4.25. It takes 3.0 min to load and unload the work part and 4.0 min to change tools. Determine
(a) cutting speed for maximum production rate, (b) tool life, and (c) cycle time and cost per unit of
product.
Solution: (a) Co = $36/hr = $0.60/min
vmax = 75/[(1/0.13 - 1)(4.0)].13 = 75/[6.692 x 4.0].13 = 48.9 m/min
(b) Tmax = (75/48.9)1/.13 = (1.534)7.692 = 26.85 min
(c) Tm = DL/fv = (75)(350)/(.4 x 48.9 x 103) = 4.216 min
np = 26.85/4.216 = 6.37 pc/tool life Use np = 6 pc/tool life
Tc = Th + Tm + Tt/np = 3.0 + 4.216 + 4.0/6 = 7.88 min/pc
Cc = 0.60(7.88) + 4.25/6 = $5.44/pc
23.16 (SI units) Solve Problem 23.15 except that in part (a), determine cutting speed for minimum cost.
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Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
(e) total time to complete the batch and production rate. (f) What is the proportion of time spent
actually cutting metal for each tool material? Use of a spreadsheet calculator is recommended.
Solution: HSS tooling: (a) Ct = $20/15 + 2.00 = $3.33/edge. Co = $40/hr = $0.667/min
vmin = 80[0.667/((1/.13 - 1)(0.667 x 3.0 + 3.33))].130 = 47.7 m/min
(b) Tmin = (1/.13 - 1)(0.667 x 3 + 3.33)/0.667 = 6.69(5.33/.667) = 53.4 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)47.7) = 4.01min/pc
np = 53.4/4.01 = 13.3 pc/tool life Use np = 13 pc/tool life
Tc = 2.5 + 4.01 + 3.0/13 = 6.74 min/pc.
(d) Cc = 0.667(6.74) + 3.33/13 = $4.75/pc
(e) Time to complete batch = 2.5(60) + 50(6.74) = 487 min = 8.12 hr.
Production rate Rp = 50 pc/8.12 hr = 6.16 pc/hr.
(f) Proportion of time spent cutting = 50(4.01)/487 = 0.412 = 41.2%
Cemented carbide tooling: (a) Ct = $8/6 = $1.33/edge. Co = $40/hr = $0.667/min
vmin = 650[0.667/((1/.30 - 1)(0.667 x 1.0 + 1.333))].30 = 363 m/min
(b) Tmin = (1/.30 - 1)(0.667 x 1 + 1.333)/0.667 = 2.333(2.0/0.667) = 7 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)363) = 0.53 min/pc
np = 7/0.53 = 13.2 pc/tool life Use np = 13 pc/tool life
Tc = 2.5 + 0.53 + 1.0/13 = 3.11 min/pc.
(d) Cc = 0.667(3.11) + 1.333/13 = $2.18/pc
(e) Time to complete batch = 2.5(60) + 50(3.11) = 305.5 min = 5.09 hr.
Production rate Rp = 50 pc/5.09 hr = 9.82 pc/hr.
(f) Proportion of time spent cutting = 50(0.53)/305.5 = 0.087 = 8.7%
Ceramic tooling: (a) Ct = $10/6 = $1.67/edge. Co = $40/hr = $0.667/min
vmin = 3,500[0.667/((1/.6 - 1)(0.667 x 1.0 + 1.67))].6 = 2105 m/min
(b) Tmin = (1/0.6 - 1)(0.667 x 1 + 1.67)/0.667 = 0.667(2.33/0.667) = 2.33 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)2105) = 0.091 min/pc
np = 2.33/0.091 = 25.6 pc/tool life Use np = 25 pc/tool life
Tc = 2.5 + 0.091 + 1.0/25 = 2.63 min/pc.
(d) Cc = 0.667(2.63) + 1.67/25 = $1.82/pc
(e) Time to complete batch = 2.5(60) + 50(2.63) = 281.5 min = 4.69 hr.
Production rate Rp = 50 pc/4.69 hr = 10.66 pc/hr.
(f) Proportion of time spent cutting = 50(0.091)/281.5 = 0.016 = 1.6%
Comment: One might conclude that such a low proportion of time spent cutting for ceramic tooling
would argue against the use of the calculated cutting speed. However, note that ceramic tooling
provides a significant advantage in terms of unit cost, batch time, and production rate compared to
HSS tooling and even carbide tooling. The very small cutting time Tm and resulting low proportion
of time spent cutting for ceramic tooling focuses attention on the nonproductive work elements in
the batch time, specifically, setup time and work part handling time; and this puts pressure on
management to seek ways to reduce these nonproductive elements.
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23-8
Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
23.22 (SI units) Solve Problem 23.21 except that in parts (a) and (b) determine the cutting speeds and tool
lives for maximum production rate. Use of a spreadsheet calculator is recommended.
Solution: HSS tooling: (a) Ct = $20/15 + 2.00 = $3.33/edge. Co = $40/hr = $0.667/min
vmax = 80/[(1/.13 - 1)(3.0)].130 = 80/[6.69 x 3)].130 = 54 m/min
(b) Tmax = (1/0.13 - 1)(3) = 6.69(3) = 20.0 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)54) = 3.53 min/pc
np = 20.0/3.53 = 5.66 pc/tool life Use np = 5 pc/tool life
Tc = 2.5 + 3.53 + 3.0/5 = 6.63 min/pc.
(d) Cc = 0.667(6.63) + 3.33/5 = $5.09/pc
(e) Time to complete batch = 2.5(60) + 50(6.63) = 481.5 min = 8.03 hr.
Production rate Rp = 50 pc/8.03 hr = 6.23 pc/hr.
(f) Proportion of time spent cutting = 50(3.53)/481.5 = 0.367 = 36.7%
Cemented carbide tooling: (a) Ct = $8/6 = $1.33/edge. Co = $40/hr = $0.667/min
vmax = 650/[(1/.30 - 1)(1.0)].30 = 650/[(2.33 x 1.0)].30 = 504 m/min
(b) Tmax = (1/0.30 - 1)(1.0) = 2.33(1.0) = 2.33 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)504) = 0.38 min/pc
np = 2.33/0.38 = 6.13 pc/tool life Use np = 6 pc/tool life
Tc = 2.5 + 0.38 + 1.0/6 = 3.05 min/pc.
(d) Cc = 0.667(3.05) + 1.33/6 = $2.25/pc
(e) Time to complete batch = 2.5(60) + 50(3.05) = 302.5 min = 5.04 hr.
Production rate Rp = 50 pc/5.04 hr = 9.92 pc/hr.
(f) Proportion of time spent cutting = 50(0.38)/302.5 = 0.063 = 6.3%
Ceramic tooling: (a) Ct = $10/6 = $1.67/edge. Co = $40/hr = $0.667/min
vmax = 3,500/[(1/.6 - 1)(1.0)].6 = 3,500/[.667 x 1.0].6 = 4464 m/min
(b) Tmax = (1/0.6 - 1)(1) = 0.667(1) = .667 min
(c) Tm = (73)(250(10-6))/(0.30(10-3)4464) = 0.043 min/pc
np = 0.667/0.043 = 15.58 pc/tool life Use np = 15 pc/tool life
Tc = 2.5 + 0.043 + 1.0/15 = 2.61 min/pc.
(d) Cc = 0.667(2.61) + 1.67/15 = $1.85/pc
(e) Time to complete batch = 2.5(60) + 50(2.61) = 280.5 min = 4.68 hr.
Production rate Rp = 50 pc/4.68 hr = 10.70 pc/hr.
(f) Proportion of time spent cutting = 50(0.043)/280.5 = 0.0077 = 0.77%
Comment: One might conclude that such a low proportion of time spent cutting for ceramic tooling
would argue against the use of the calculated cutting speed. However, note that ceramic tooling
provides a significant advantage in terms of unit cost, batch time, and production rate compared to
HSS tooling and even carbide tooling. The very small cutting time Tm and resulting low proportion
of time spent cutting for ceramic tooling focuses attention on the nonproductive work elements in
the batch time, specifically, setup time and work part handling time; and puts pressure on
management to seek ways to reduce these nonproductive elements.
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23-9
Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
23.23 (USCS units) A vertical boring mill is used to bore the inside diameter of a large batch of
tube-shaped parts. The diameter = 28.0 in, and the length of the bore = 14.0 in. Cutting speed = 150
ft/min, feed = 0.015 in/rev, and depth of cut = 0.125 in. The parameters of the Taylor equation for
the cutting tool in the operation are n = 0.25 and C = 1100 (ft/min). Tool change time = 3.0 min and
tooling cost = $3.50 per cutting edge. Time to load and unload the parts = 14.0 min, and the cost of
machine time = $42.00/hr. Management wants to increase production rate by 50%. Is that possible?
Assume that feed is unchanged to achieve the required surface finish. What is the current
production rate and the maximum possible production rate for this job?
Solution: At the current operating speed v = 150 ft/min:
T = (1100/150)1/.25 = 2892 min
Tm = (28)(14)/(150 x 12 x 0.015) = 45.6 min/pc
np = 2892/45.6 = 63.4 pc/tool life Use np = 63 pc/tool
Tc = 14 + 45.6 + 3/63 = 59.6 min
Rc = 60/59.6 = 1.006 pc/hr
Find vmax to compare with current operating speed.
vmax = 1100/[(1/.25 - 1)(3.0)].25 = 850/[(3 x 3.0)].25 = 491 ft/min
Tmax = (1/.25 - 1)(3.0) = 3(3.0) = 9.0 min
Tm = (28)(14)/(491 x 12 x 0.015) = 13.93 min/pc
np = 9/13.93 = 0.65 pc/tool life
This would mean that the tool would have to be changed during the machining of the workpiece,
which is undesirable. A reasonable decision would be to operate at a cutting speed slightly lower
than vmax so that the tool would last for at least one workpiece. However, we will complete the
calculations using the value of np = 0.65.
Tc = 14 + 13.93 + 3/.65 = 32.5 min
Rc = 60/32.5 = 1.84 pc/hr
Comment: This is an 83% increase in production rate relative to the current 150 ft/min cutting
speed. It should be possible to increase production rate by at least 50% and still use a cutting speed
that will last at least one workpiece.
23.24 (A) (USCS units) A CNC lathe cuts two passes across a cylindrical workpiece under automatic
cycle. The operator loads and unloads the machine. The starting diameter of the work = 3.00 in and
length = 10 in. The work cycle consists of the following steps (with element times given in
parentheses where applicable): 1. Operator loads part into machine, starts cycle (1.00 min); 2. CNC
lathe positions tool for first pass (0.10 min); 3. CNC lathe turns first pass (time depends on cutting
speed); 4. NC lathe repositions tool for second pass (0.4 min); 5. CNC lathe turns second pass (time
depends on cutting speed); and 6. Operator unloads part and places in tote pan (1.00 min). In
addition, the cutting tool must be periodically changed. Tool change time = 1.00 min. Feed rate =
0.007 in/rev and depth of cut for each pass = 0.100 in. The cost of the operator and machine =
$48/hr and the tool cost = $2.00/cutting edge. The applicable Taylor Tool Life parameters are n =
0.26 and C = 900 (ft/min). Determine (a) cutting speed for minimum cost per piece, (b) time to
complete one production cycle, and (c) cost of the production cycle. (d) If the setup time for this job
is 3.0 hours and the batch size = 125 parts, how long will it take to complete the batch?
Solution: (a) Co = $48/hr = $0.80/min
vmin = 900[.80/((1/.26 - 1)(.80 x 1.0 + 2.00))].26 = 900[.80/(2.846 x 2.80)].26 = 495 ft/min
(b) Tmin = (1/.26 - 1)(.65 x 1 + 2.0)/.80 = 2.846(2.80/.80) = 9.96 min
First pass: Tm = (3)(10)/(495 x 12 x 0.007) = 2.27 min/pc
Second pass: Tm = (3.0 - 2x0.100)(10)/(495 x 12 x 0.007) = 2.12 min/pc
np = 9.96/0.5(2.27+2.12) = 4.5 passes/tool life
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23-10
Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
Since there are two passes/workpiece, np = 2.25 pc/tool life. Use np = 2 pc/tool
Tc = 1.0 + 0.1 + 2.27 + 0.4 + 2.12 + 1.0 + 1.0/2 = 7.39 min/pc
(c) Cc = 0.80(7.39) + 2.00/2 = $6.91/pc
(d) Time to complete batch Tb = 3.0(60) + 125(7.39) = 1103.75 min = 18.40 hr
23.25 (USCS units) As indicated in Section 23.4, the effect of a cutting fluid is to increase the value of C
in the Taylor Tool Life equation. In a certain machining situation using HSS tooling, the C value
increases from 200 to 225 due to the use of the cutting fluid. The n value = 0.125 with or without
fluid. Cutting speed = 125 ft/min, feed = 0.010 in/rev, and depth of cut = 0.100 in. The effect of the
cutting fluid can be to either increase cutting speed (at the same tool life) or increase tool life (at the
same cutting speed). (a) What is the cutting speed that would result from using the cutting fluid if
tool life remains the same as with no fluid? (b) What is the tool life that would result if the cutting
speed remained at 125 ft/min? (c) Economically, which effect is better, given that tooling cost =
$2.00 per cutting edge, tool change time = 2.5 min, and operator and machine rate = $30/hr? Justify
your answer with calculations, using cost per cubic in of metal machined as the criterion of
comparison. Ignore effects of work part handling time.
Solution: Cutting dry, the Taylor tool life equation parameters are n = 0.125 and C = 200.
At v = 125 ft/min, tool life T = (200/125)1/.125 = (1.6)8 = 43 min
With a cutting fluid, the Taylor tool life equation parameters are n = 0.125 and C = 225.
The corresponding cutting speed for a 43 min tool life v = 225/430.125 = 140.6 ft/min
(b) Cutting at v = 125 ft/min with a cutting fluid gives a tool life T = (225/125)8.0 = 110 min
(c) Which is better, (1) cutting at a speed of 140.6 ft/min to give a 43 min tool life, or (2) cutting at
125 ft/min to give a 110 min tool life. Use time to cut 1.0 in3 of metal cut as the basis of
comparison, with cost and time parameters as follows: Ct = $2.00/cutting edge, Tt = 2.5 min, and Co
= $30/hr = $0.50/min
(1) At v =140.6 ft/min, Tm = 1.0 in3/RMR = 1.0/(140.6 x 12 x 0.010 x 0.100) = 0.5927 min
For T = 43 min, volume cut per tool life = 43/0.5927 = 72.5 in3 between tool changes.
Ignoring work handling time, cost/in3 = 0.50(.5927) + (0.50 x 2.5 + 2.00)/72.5 = $0.341/in3
(2) At 125 ft/min, Tm = 1.0 in3/RMR = 1.0/(125 x 12 x 0.010 x 0.100) = 0.6667 min
For T = 110 min, volume cut per tool life = 110/0.6667 = 164.9 in3 between tool changes.
Ignoring work handling time, cost/in3 = 0.50(.6667) + (0.50 x 2.5 + 2.00)/164.9 = $0.353/in3
Conclusion: it is better to take the benefit of a cutting fluid in the form of increased cutting speed.
23.26 (USCS units) In a turning operation on ductile steel, it is desired to obtain an actual surface
roughness of 63 -in with a 2/64 in nose radius tool. The ideal roughness is given by Equation
(23.1), and an adjustment will have to be made using Figure 23.2 to convert the 63 -in actual
roughness to an ideal roughness, taking into account the material and cutting speed. Disposable
inserts are used at a cost of $1.75 per cutting edge (each insert costs $7.00, and there are four edges
per insert). Average time to change each insert = 1.0 min. Workpiece length = 30.0 in and diameter
= 3.5 in. The machine and operators rate = $39.00 per hour, including applicable overheads. The
Taylor Tool Life equation for this tool and work combination is given by: vT0.23 f0.55 = 40.75, where
T = tool life, min; v = cutting speed, ft/min; and f = feed, in/rev. Solve for (a) the feed in in/rev that
will achieve the desired actual finish, (b) cutting speed for minimum cost per piece at the feed
determined in (a). Hint: To solve (a) and (b) requires an iterative computational procedure. Use of a
spreadsheet calculator is recommended for this iterative procedure.
Solution: Cost and time parameters: Co = $39/hr = $0.65/min, Ct = $1.75/cutting edge,
Tt = 1.0 min
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Solutions for Fundamentals of Modern Manufacturing, 5/e (published by Wiley) MPGroover 2012
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23-13