Machining Operations

by
Ed Red
ME 482 - Manufacturing Systems

Objectives
Introduce machining operations terminology

Introduce machining efficiency measures

Reconsider cutting parameters as they apply to efficiency

Review a machining efficiency example

Consider modern machine operations (papers)

ME 482 - Manufacturing Systems

Machining terms
Chatter interrupted cutting usually at some frequency Down milling cutting speed in same direction as part feed Up milling cutting speed in opposite direction as part feed Peripheral milling tool parallel to work Face milling tool perpendicular to work Ideal roughness geometrically determined roughness Machinability machining success determined by tool life, surface finish Optimal machining parameter choices that increase machining throughput or reduce operational costs

ME 482 - Manufacturing Systems

Machining operations on lathe

(other than normal turning)
Facing

Taper

Contour

Form

Chamfer

Cutoff

Threading

Boring

Drilling

Knurling

ME 482 - Manufacturing Systems

Two types of milling operations

Peripheral

Face

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Face milling operations

Facing

Partial facing

End milling

Profiling

Pocketing

Surface contouring

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Face milling movements

Peripheral milling cutting positions

Face milling cutting positions

Full face cut

Offset face cut

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Milling cutter time analysis

Spindle rpm related to cutter diameter and speed:

N (rpm) = v/(p D)
Feedrate in in/min: fr = N nt f where f = feed per tooth nt = number of teeth

MRR is
MRR =w d fr
ME 482 - Manufacturing Systems

Milling time analysis

Slab milling: Approach distance, A : A= d (D-d)

Time to mill workpiece, Tm:

Tm = (L + A)/fr
Face milling: Allow for over-travel O where A = O: Full face Partial face Machining time: Tm = (L + 2A)/fr A = O = D/2 A=O= w (D w)

ME 482 - Manufacturing Systems

Milling time analysis - example

Problem statement:

A face milling operation is performed to finish the top surface of a steel rectangular workpiece 12 in. long by 2 in. wide. The milling cutter has 4 teeth (cemented carbide inserts) and is 3 in. in diameter. Cutting conditions are 500 fpm, f = 0.01 in./tooth, and d = 0.150 in. Determine the time to make one pass across the surface and the metal removal rate during the cut.

ME 482 - Manufacturing Systems

Milling time analysis - example

Solution? Numbers?

Full face
Machining time Metal removal rate

A = O = D/2
Tm = (L + 2A)/fr MRR = w d fr

Feedrate in in/min

fr = N nt f
N (rpm) = v/(p D)

ME 482 - Manufacturing Systems

Tolerance by process

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Surface finish by process

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Surface finish by geometry

Ideal roughness,
Ri = f2/(32 NR) where NR = tool nose radius Actual roughness, Ra = rai Ri (about 2 x Ri )

because of edge effects, chip

interactions, surface tearing, etc.
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Machinability

What is a free machining steel?

http://www.sandmeyersteel.com/303.html#1

Machinability is a measure of machining success or ease of machining. Suitable criteria:

tool life or tool speed level of forces surface finish ease of chip disposal
ME 482 - Manufacturing Systems

Machinability - example
Problem statement:
A series of tool life tests is conducted on two work materials under identical cutting conditions, varying only speed in the test procedure. The first material, defined as the base material, yields the Taylor tool life equation v T0.28 = 1050 and the other material (test material) yields the Taylor equation v T0.27 = 1320 Determine the machinability rating of the test material using the cutting speed that provides a 60 min. tool life as the basis of comparison. This speed is denoted by v60.
ME 482 - Manufacturing Systems

Machinability - example
Solution:
The base material has a machinability rating = 1.0. Its v60 value can be determined from the Taylor tool life equation as follows:
v60 = 1050/600.28 = 334 ft/min The cutting speed at a 60 min. tool life for the test material is determined similarly: v60 = 1320/600.27 = 437 ft/min

Accordingly, the machinability rating can be calculated as

MR (for the test material) = 437/374 = 1.31 (or 131%)
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Optimized machining
Cutting speed can be chosen to maximize the production rate or minimize the cost per part (or unit) produced. This is referred to as optimized machining because more than one production variable contributes to the production rate and costs. Variables: Th - part handling time Tm machining time Tt tool change time Co (Cg) operator (grinders) cost rate/min Ch cost of part handling time Cm cost of machining time

np number of parts cut by Ctc cost of tool change time tool during tool life Tc cycle time per part T tool life ME 482 - Manufacturing Systems Ct cost per cutting edge Ctp = Ct/np - tool cost per part

Maximum production rate - turning

Total time per part produced (cycle time):
Tc = Th + Tm + Tt/np where Tt/np is the tool change time per part. Consider a turning operation. The machining time is given by Tm = p D L/(v f)

The number of parts cut per tool is given by

np = T/Tm= f C(1/n)/(p D L v(1/n -1) )
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Maximum production rate - turning

Substituting, we get the total cutting time Tc = Th + p D L/(v f) + Tt[ p D L v(1/n -1)/( f C(1/n) )] Minimizing cycle time (dTc/dv = 0 ) gives optimum (max) cutting speed and tool life:

vmax = C/[(1 - n) Tt/n]n

Tmax = (1 - n) Tt /n
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Minimum cost per unit - turning

Cost of part handling time: Ch = CoTh

Cost of machining time:

Cm = CoTm Cost of tool change time: Ctc = CoTt /np

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Minimum cost per unit - turning

Tool cost per part: Ctp = Ct /np Tooling cost per edge:
Disposable inserts

Ct = Pt /ne

ne = num of edges/insert Pt = original cost of tool

Single point grindable

Ct = Pt /ng + Tg Cg

includes purchase price ng = Num tool lives/tool Tg = time to grind tool

ME 482 - Manufacturing Systems

Minimum cost per unit - turning

Total cost per part: Cc = Co Th + Co Tm + Co Tt /np + Ct /np Substituting for Tm and np: Cc = Co Th + Co p DL/fv + (CoTt + Ct )pDLv(1/n -1)/( f C(1/n) ) Minimizing cost per part (dCc/dv = 0) gives cutting speed and tool life to minimize machining costs per part: vmin = C{n Co/[(1 n)(Ct + CoTt)]}n Tmin = (1 n) (Ct + CoTt)/(n Co)
ME 482 - Manufacturing Systems

Minimum cost per unit - example

Problem statement: Suppose a turning operation is to be performed with HSS tooling on mild steel (n = 0.125, C = 200 from text table). The workpart has length = 20.0 in. and diameter = 4.0 in Feed = 0.010 in./rev. Handling time per piece = 5.0 min and tool change time = 2.0 min. Cost of machine and operator = $30.00/hr, and tooling cost = $3.00 per cutting edge. Find (a) cutting speed for maximum production rate and (b) cutting speed for minimum cost

ME 482 - Manufacturing Systems

Minimum cost per unit - example

Solution: Cutting speed for maximum production rate is vmax = C/[(1 - n) Tt/n]n = 200/[(.875) 2/0.125]0.125 = 144 ft/min

Converting Co from $30/hr to $0.5/min, the cutting speed for minimum cost is given by
vmin = C{n Co/[(1 n)(Ct + CoTt)]}n = = 200{(0.125)(0.5)/[(0.875)(3.00 + (0.5)(2))]}0.125 = 121 ft/min
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Machining operations

What did we learn?

ME 482 - Manufacturing Systems