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ECONOMIC AND PRODUCT

DESIGN CONSIDERATIONS IN
MACHINING

1. Machinability

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability

 Capability of a material to be easily machined using


appropriate tooling and cutting conditions

 Depends on
 work material
 type of machining operation,
 tooling
 cutting conditions

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Criteria in
Production

Quantification by means of:


 Tool life – longer tool life for the given work material
means better machinability
 Forces and power – lower forces and power mean
better machinability
 Surface finish – better finish means better
machinability
 Ease of chip disposal – easier chip disposal means
better machinability

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Rating

Machinability is expressed as a machinability rating


(MR):

 MR of base material (AISI 1112) = 1.00 (100%)


 MR of test material > 1.00 (100%) means better
machinability

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Rating

AISI 1112 1.00


Medium Carbon steel 0.65
Stainless steel 0.35

Inconel 0.30

Aluminum alloy 2.00

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING

1. Machinability

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Tolerances and Surface Finish

 Tolerances
 Machining can provide high accuracy, but
 Closer tolerances usually mean higher costs

 Surface roughness
 Machining can provide surface finish, but
 Low roughness usually mean higher costs

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Surface Finish

 Surface roughness in machining is determined by:

1. Geometric factors of the operation

2. Work material factors

3. Vibration and machine tool factors

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Geometric Factors

 Machining parameters that determine surface


geometry:
 Nose radius (NR)
 Feed f
 End cutting edge angle

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Geometric Factors Affecting
Surface Finish
 Effect of (a) nose radius, (b) feed, and (c) ECEA

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Ideal Surface Roughness

Ri = f2
32NR

where Ri = theoretical
arithmetic average
surface roughness; f =
feed; and NR = nose
radius

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Ideal Surface Roughness

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Work Material Factors

Other factors increasing surface roughness:


 Built-up edge effects
 Damage to surface caused by chip
 Tearing of surface when machining ductile materials
 Cracks in surface when machining brittle materials
 Friction between tool flank and new work surface

They mainly depend on cutting speed

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Actual Surface Roughness

Ra = rai x Ri

Evaluation of the ratio of


actual to theoretical
roughness according to:

 Workpiece material
 Cutting speed

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Vibration and Machine Tool
Factors

 Chatter (vibration) in machine tool or cutting tool

 Deflections of fixtures

 Backlash in feed mechanism (old machine tools)

These factors can be reduced, then surface roughness


is determined by geometric and work material factors
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING

1. Machinability

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Selection of Cutting Conditions

In the following order:

1. Depth of cut
2. Feed
3. Cutting speed

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Selecting Depth of Cut

 Depth of cut is often predetermined by workpiece


geometry and operation sequence
 In roughing, depth is made as large as possible
to maximize material removal rate, subject to
limitations of horsepower, machine tool and setup
rigidity, and strength of cutting tool
 In finishing, depth is set to achieve final part
dimensions and surface finish

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Determining Feed

Determining feed rate depends on:

 Tooling – harder tool materials require lower


feeds

 Roughing / finishing
 In roughing, 0.5 – 1.25 mm/rev
 In finishing, 0.125 – 0.4 mm/rev

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Determining Feed

Determining feed rate depends on:

 Constraints in roughing: limits on feed are


imposed by forces, setup rigidity and horsepower

 Surface roughness in finishing: select feed to


achieve desired finish

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Optimizing Cutting Speed

 Select cutting speed to achieve a balance between


high metal removal rate and suitably long tool
life
 Mathematical formulas available to determine
optimal speed
 Two alternative objectives in these formulas:
 Maximum production rate
 Minimum unit cost

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Maximum Production Rate

 Maximizing production rate is equivalent to


minimizing cutting time per unit
 In turning, total production cycle time for one part
consists of:
1. Part handling time per part = Th
2. Machining time per part = Tm
3. Tool change time per part = Tt / np, where np =
number of pieces cut in one tool life

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Cycle Time vs. Cutting Speed

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Minimizing Cost per Unit

 In turning, total production cycle cost for one part


consists of:
1. Cost of part handling time = CoTh , where Co =
cost rate for operator and machine
2. Cost of machining time = CoTm
3. Cost of tool change time = CoTt/np
4. Tooling cost = Ct/np , where Ct = cost per cutting
edge

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Unit Cost vs. Cutting Speed

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING

1. Machinability

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design

Design for Manufacturing (DFM)

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

 Select materials with good machinability


 parts made of materials with low machinability
take longer and cost more to produce

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

 Tolerances should be specified to satisfy functional


requirements, but process capabilities should also be
considered
 Very close tolerances add cost but may not add
value to part
 Costs generally increase due to additional
processing, fixturing, inspection, etc.

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

 Surface finish should be specified to meet functional


and/or aesthetic requirements
 However, better surface finish generally
increases processing cost by requiring additional
operations such as grinding or lapping

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

Design rule:

Machined features
such as sharp
corners, edges,
and points should
be avoided

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

Design rule:

Machined parts
should be
designed with
features that can
be achieved with
standard cutting
tools

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

Design rule:
 Design parts that need no machining
 Use net shape processes such as precision
casting, closed die forging, or plastic molding

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

Design rule:

 Avoid undercuts as
in (a)
 Additional setups,
operations, and
often special tooling
are required for
undercuts as in (b)

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines

Design rule:

 Design parts with features that can be produced in a


minimum number of setups

©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014

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