February 6, 2014  [MECH360 PRINCIPLES OF MANUFACTURING – HOMEWORK 2] 

Due date: February 11th, 2014 in Class 

Student Name:               ID:         

1. Problems Homework 2 Answer

Your homework must be written in a clear and presentable style. All final answers should be
clearly identified. You should keep the same number of digits after decimal point as those
given in the problem statement. Units must be given with answers. Attach this problem sheet
as the front page of your homework. If the student fails to apply to these requirements, a 5-
point deduction will be given for this homework.

1) A face milling operation removes 6.0 mm from the top surface of a rectangular piece of
aluminum that is 300 mm long by 90 mm wide by 75 mm thick. The cutter follows a path that
is centered over the workpiece. It has four teeth and is 100 mm in diameter. Cutting speed =
2.0 m/s, and chip load = 0.27 mm/tooth. Determine (a) machining time and (b) metal removal
rate during cutting. (10 points)
Solution:
(You can choose the time unit to be per minute or per second. But it should be consistent.
The following solution chooses time unit as second. If your time unit is minute, then the
values of N, v, and MRR time 60. The cutting path follows the center of the part and
cutter diameter is larger than the width of the part; therefore, 0.5 )

a)  (2 points) N = V/πD = 2.0(103) (mm/s)/100 = 6.37 rev/s  

(2 points) v= Nnf = 6.37(4)(0.27) = 6.88 mm/s 

(2 points) 0.5  
=  0.5 100  1002  902  = 0.5(100 – 43.6) = 28.2 mm 

(2 points) t = (l + lc)/v= (300 + 28.2))/6.88 = 47.7 s = 0.80 min 

(b) (2 points) MRR = wdv = 90(6)(6.88) = 3715 mm3/s

2) Peripheral milling is performed on the top surface of a rectangular work part that is 400 mm
long by 50 mm wide. The milling cutter is 70 mm in diameter and has five teeth. It overhangs
the width of the part on both sides. Cutting speed = 60 m/min, chip load = 0.25 mm/tooth, and
depth of cut = 6.5 mm. Determine (a) machining time of the operation and (b) material
removal rate during the cut. (10 points)
Solution:
(a) (2 points)  N = V/πD = 60(103) mm/70π = 273 rev/min 

(2 points)  v = Nnf = 273(5)(0.25) = 341 mm/min 
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(2 points)  l  = (d(D‐d))0.5 = (6.5(70‐6.5)) 0.5  = 20.3 mm 

(2 points)  t = (400 + 20.3)/341 = 1.23 min 

(b) (2 points)  MRR = wdv = 50(6.5)(341) = 110,825 mm3/min 

3) A ductile aluminum part in a turning operation has a specified surface finish of 1.25 µm.
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. (10 points)

Solution:

(2 points) For ductile aluminum at 1.5 m/s or 90 m/min, the ratio rai = 1.25 in the figure.  

(2 points)  Therefore, the theoretical requirement is Ri = Ra /rai = 1.25/1.25 = 1.0 m 

(2 points)  Ri = f2/32NR; 

(4 points)   f = (32 (NR)Ri )0.5 = (32(1.2x10‐3)(1.0x10‐6))0.5 = 1.96x10‐4 m= 0.196 mm  
                      (mm is interpreted mm/rev) 

4) The same grade of cemented carbide tooling is available in two forms for turning operations in
the machine shop: disposable inserts and brazed inserts that must be reground. The Taylor
equation parameters for this grade are n = 0.25 and C = 300 (m/min) under the cutting
conditions here. For the disposable inserts, the price of each insert = $6.00, there are four
cutting edges per insert, and the average tool change time = 1.0 min. For the brazed insert, the
price of the tool = $30.00, and it can be used a total of 15 times before it must be scrapped.
The tool change time for the regrindable tooling = 3.0 min. The standard time to grind or
 February 6, 2014  [MECH360 PRINCIPLES OF MANUFACTURING – HOMEWORK 2] 
 

regrind the cutting edge is 5.0 min, and the grinder is paid at a rate = $20.00/hr. Machine time
on the lathe costs $24.00/hr. The work part to be used in the comparison is 375 mm long and
62.5 mm in average diameter, and it takes 2.0 min to load and unload the work. Feed = 0.30
mm/rev. For the two cases, in order to achieve minimum cost per unit compare (a) cutting
speeds for minimum cost, (b) tool lives, and (c) cycle time and cost per unit of production. (d)
Which tool would you recommend?
(40 points)
Solution:

Disposable inserts: (18 points) 

(a) (7 points) 

(2 points) Co = $24/hr = $0.40/min 

(2 points) Ct = $6/4 = $1.50/edge 

(3 points) vmin = 300[0.40/((1/0.25 ‐ 1)(0.40 x 1.0 + 1.50))].25 = 300[0.40/(3 x 1.9)].25 = 154.4 
m/min 

(b) (2 points) 

Tmin = (1/0.25 ‐ 1)(0.4 + 1.5)/0.4 = 3(1.9/0.4) = 14.25 min 

(c) (9 points) 

(3 points) Tm = (62.5)(375)/(0.30)(10‐3)(154.4) = 1.59 min/pc 

(1 points) np = 14.25/1.59 = 8.96 pc/tool life  Use np = 8 pc/tool 

(1 points) Tc = 2.0 + 1.59 + 1.0/8 = 3.72 min/pc. 

(4 points) Cc = 0.40(3.72) + 1.50/8 = $1.674/pc 

Regrindable tooling: (18 points) 

(a) (7 points) 

(2 points) Co = $24/hr = $0.40/min 

(2 points) Ct = $30/15 + 5($20/60) = $3.67/edge 

(3 points) vmin = 300[0.40/((1/0.25 ‐ 1)(0.40 x 3.0 + 3.67))].25 = 300[0.40/(3 x 4.87)].25 = 
122.0 m/min 

(b) (2 points) 
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Tmin = (1/0.25 ‐ 1)(0.4 x 3 + 3.67)/0.4 = 3(4.87/0.4) = 36.5 min 

(c) (9 points) 

(3 points) Tm = (62.5)(375)/(0.30)(10‐3)(122) = 2.01 min/pc 

(1 points) np = 36.5/2.01 = 18.16 pc/tool life  Use np = 18 pc/tool 

(1 points) Tc = 2.0 + 2.01 + 3.0/18 = 4.18 min/pc 

(4 points) Cc = 0.40(4.18) + 3.67/18 = $1.876/pc 

(d) (4 points) Disposable inserts are recommended. Cycle time and cost per piece are less. 

5) A leadscrew with an 8-mm pitch drives a worktable in an open loop NC positioning system.
The leadscrew is powered by a stepping motor with 180 step angles. Gear reduction ratio is 1.
The worktable is programmed to move a distance of 150 mm from its present position at a
travel speed of 400 mm/min. Determine (a) the number of pulses to move the table the
specified distance, (b) the motor speed, and (c) pulse rate to achieve the desired table speed.
(10 points)
Solution:

(a) (2 points)  = 360/ns = 360/180 = 2.0 

(2 points) np = 360x/p = 360(150)/(8 x 2.0) = 3375 pulses 

(b) (3 points) Nm = v/p = (400 mm/min)/(8 mm/rev) = 50 rev/min 

(c) (3 points) fp = 6Nm / = 150 Hz

6) Referring to Problem 5), the mechanical inaccuracies in the open-loop positioning system can
be described by a normal distribution whose standard deviation = 0.006 mm. The range of the
worktable axis is 750 mm, and there are 12 bits in the binary register used by the digital
controller to store the programmed position. For the positioning system, determine (a) the
control resolution, (b) accuracy, and (c) repeatability.
(10 points)
Solution:

(a) (2 points) CR1 = p/ns = 8 mm/180 = 0.0444 mm 

(2 points) CR2 = L/(2B ‐1)= 750/(212 – 1) = 750/4095 = 0.183 mm 

(2 points) CR = Max{CR1, CR2} = Max{0.0444, 0.183} = 0.183 mm 

(b) (2 points) Accuracy = 0.5 CR + 3 = 0.5(0.183) + 3(0.006) = 0.1096 mm 

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(c) (2 points) Repeatability =  3 =  3(0.006) =  0.018 mm 

7) A CNC machine tool table is powered by a servomotor, leadscrew, and optical encoder. The
leadscrew pitch = 6.0 mm. It is connected to the motor shaft with a gear ratio of 8:1 (8 turns of
the motor for each turn of the leadscrew). The optical encoder connected to the leadscrew and
generates 120 pulses/rev of the leadscrew. The table moves 250 mm at a feed rate = 500
mm/min. Determine (a) the pulse count received by the control system to verify that the table
has moved exactly 250 mm; and (b) the pulse rate and (c) motor speed that correspond to the
feed rate of 500 mm/min. (10 points)
Solution: (a) (4 points) x = pnp/ns ; rearranging, np = xns/p = 250(120)/6 = 5000 pulses 

(b) (3 points) fp = vns/60p = 500(120)/60(6) = 166.67 Hz 

(c) (3 points) Nm = rgv/p = 8 x 500/6 = 666.67 rev/min