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by
Ed Red
ME 482 - Manufacturing Systems
Objectives
Introduce machining operations terminology
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
Taper
Contour
Form
Chamfer
Cutoff
Threading
Boring
Drilling
Knurling
Peripheral
Face
Facing
Partial facing
End milling
Profiling
Pocketing
Surface contouring
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
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)
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.
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)
Tolerance by process
Machinability
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
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
Ct = Pt /ne
Ct = Pt /ng + Tg Cg
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
ME 482 - Manufacturing Systems
Machining operations