Machining

Operations
by
PARAS KAUSHIK
A50105414047
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

Machiningterms
Chatterinterruptedcuttingusuallyatsomefrequency
Downmillingcuttingspeedinsamedirectionaspartfeed
Upmillingcuttingspeedinoppositedirectionaspartfeed
Peripheralmillingtoolparalleltowork
Facemillingtoolperpendiculartowork
Idealroughnessgeometricallydeterminedroughness
Machinabilitymachiningsuccessdeterminedbytoollife,surface
finish
Optimalmachiningparameterchoicesthatincreasemachining
throughputorreduceoperationalcosts
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Machiningoperationsonlathe
(otherthannormal
turning)

Facing

Chamfe
r

Boring

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Taper

Conto
ur

Cutof

Drillin
g

Form

Threadin
g

Knurli
ng

Twotypesofmillingoperations

Peripheral

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Face

Facemillingoperations

ME 482 - Manufacturing Systems

Facing

Partial
facing

Profili
ng

Pocketing

End
milling

Surface
contouring

Facemilling
movements

Peripheral milling cutting

positions

Face milling cutting

positions

Full face
cut

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Ofset face
cut

Millingcuttertimeanalysis
Spindle rpm related to cutter diameter and speed:
N (rpm) = v/( 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

Millingtimeanalysis
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

A = O = D/2

Partial face

A= O =

w (D w)

Machining time:
Tm = (L + 2A)/fr

ME 482 - Manufacturing Systems

Millingtimeanalysisexample
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

Millingtimeanalysisexample
Solution?

Numbers?

Full face

A = O = D/2

Machining time

Tm = (L + 2A)/fr

Metal removal rate

MRR = w d fr

Feedrate in in/min

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

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Tolerancebyprocess

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Surfacefinishbyprocess

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Surfacefinishbygeometry
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

ME 482 - Manufacturing Systems

ease of chip
disposal

Machinabilityexample
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.
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Machinabilityexample
Solution:
The base material has a machinability rating = 1.0. Its v 60 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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Optimizedmachining
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

Co (Cg) operator (grinders) cost rate/min

Tm machining time

Ch cost of part handling time

Tt tool change 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
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Ct cost per cutting edge

Ctp = Ct/np - tool cost per part

Maximumproductionrateturning
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 = D L/(v f)
The number of parts cut per tool is given by
np = T/Tm= f C(1/n)/( D L v(1/n -1) )
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Maximumproductionrateturning
Substituting, we get the total cutting time
Tc = Th + D L/(v f) + Tt[ 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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Minimumcostperunitturning
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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Minimumcostperunitturning
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

Minimumcostperunitturning
Total cost per part:
Cc = Co Th + Co Tm + Co Tt /np + Ct /np
Substituting for Tm and np:
Cc = Co Th + Co DL/fv + (CoTt + Ct )DLv(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 Systems
= (1
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n) (Ct + CoTt)/(n Co)

Minimumcostperunitexample
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

Minimumcostperunitexample
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
ME 482 - Manufacturing Systems

Machiningoperations

What did we learn?

ME 482 - Manufacturing Systems