Escolar Documentos
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Fall 2004
Machinability A measure of the relative ease of a machining operation usually on a work material and type of machining operation, tooling, and cutting conditions.
Longer tool life means better machinability Greater forces and power mean lower machinability Better surface finish means better machinability Easier chip disposal means better machinability Higher MRR means better machinability
Shape
Work Materials Base Steel: B1112 Low Carbon Steels Med. Carbon Steels High Carbon Steels Alloy Steels Cast Iron Ti Alloys Aluminum Aluminum Brinnell Hardness 180-220 130-170 140-210 180-230 170-230 60-230 220-280 (soft) (Hard) Machinability Rating 1.00 0.50 0.65 0.55 0.25-1.5 0.40-0.70 0.2 2.00 1.25
Shape
Rotational parts turning and boring Internal rotational features - drilling Non-rotational parts milling Dependency on the geometry of a tool
Generating Multi-axis milling machine Forming form turning, drilling and broaching Generating/Forming (threading)
MR of base material = 1.00 (100%) MR of test material > 1.00 (100%) means better machinability
3 4
Geometric factor
Surface roughness, R = f i where NR= nose radius 32 NR and Ra = rai Ri because it depends on work material and cutting speed Other expressions of roughness
Ductile metals
1.8
Cast iron
1.2 1
Machining alloys
Cutting speed
Kwon
ME477
Fall 2004
Machining Operations Turning D<25mm 25mm<D<50mm D>50mm Drilling D<2.5mm 2.5mm<D<6mm 6mm<D<12mm 12mm<D<25mm D>25mm Reaming D<12mm 12mm<D<25mm D>25mm Broaching Milling Peripheral Face End Shaping Slotting Planing Sawing
Tolerance (Typical) 0.025 0.05 0.075 0.05 0.075 0.1 0.125 0.20 0.025 0.05 0.075 0.05 0.025 0.025 0.05 0.025 0.075 0.5
Chatter (Vibration)
Vibration and Chatter
Related to machine tool, tooling, and setup:
Chatter (vibration) in machine tool or cutting tool Deflections of fixtures Backlash in feed mechanism
0.8m
0.4m
Without chatter, surface roughness is determined by geometric and work material factors
Add stiffness and/or damping to setup Operate at speeds that avoid natural frequency of machine tool system Reduce feeds and depths to reduce forces Change cutter design to reduce forces Use a cutting fluid
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Cutting Speed
Select speed to achieve a balance between high metal removal rate and suitably long tool life Mathematical formulas are available to determine optimal speed Two alternative objectives:
1. Maximum production rate 2. Minimum unit cost
10
Maximizing production rate = minimizing cutting time per unit In turning, total production cycle time for one part consists of:
Part handling time per part = Th Machining time per part = Tm, For a simple turning, Tm = vf Tool change time per part = Tt/np ,where np = number of pieces cut in one tool life where T fC 1/ n and, from Taylors model, tool life is = np = Tm DLv (1/( n 1) ) 1/ n 1/ n
T =C v
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= Th +
Tool change time Part Handling Time Cutting time vmax
DL Tt (DLv(1/ n1) )
fv + fC1/ n C
Tt np
DL
Cutting speed
Kwon
ME477
Fall 2004
Example
Workpart: L=300mm and D=80mm. C vmax = Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min) n 1 Machining condition: f=0.4mm/rev. n 1Tt Operator and machine cost=$30/hr Tooling cost/edge=$4 2min to load and unload and 3.5min to change tools 1 Tmax = 1Tt (a) Cutting speed for max. production rate n (b) Tool life in min. for max. production rate (c) Cycle time and cost per unit of product for max. production rate
Tm =
DL
vf
(a) Co=$30/hr=$.50/min T vmax=75/[(1/.13-1)(3.5)].13 =49.8m/min np = (b) Tmax=(75/49.8)1/.13 =23.42min Tm (c) Tm=DL/fv=(8)(300)/(.4x49.8x103)=3.787min T np=23.42/3.787~6pc/tool life Tc = Th + Tm + t Tc=Th+Tm+Tt/np=2+3.787+3.5/6=6.37min/pc np Cc=CoTc+Tool cost per edge/np=0.5(6.37)+4/6=$3.85/pc
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Cc = CoTh + CoTm +
CoTt Ct + np np
Ct =
1 n 1
= CoTh +
CoDL + fv
(CoTt + Ct ) DLv
fC
1 n
Example
Workpart: L=300mm and D=80mm. Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min) Machining condition: f=0.4mm/rev. Operator and machine cost=$30/hr Tooling cost/edge=$4 2min to load and unload and 3.5min to change tools (a) Cutting speed for min. cost (b) Tool life in min. for min. cost (c) Cycle time and cost per unit of product for min. cost
Comments
As C and n increase in Taylors equation, optimum cutting speed should be reduced
n Co vmin = C 1 n CoTt + Ct C T + Ct 1 o t Tmin = 1 n Co
n
(a) Co=$30/hr=$.50/min vmin=75/[0.5(1/.13-1)(0.5x3.5+4)].13 =42.6m/min (b) Tmin=(75/42.6)1/.13 =76.96min (c) Tm=DL/fv=(8)(300)/(.4x42.6x103)=4.42min np=76.96/4.42~17pc/tool life Tc=Th+Tm+Tt/np=2+4.42+3.5/17=6.63min/pc Cc=0.5(6.63)+4/17=$3.55/pc
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Cutting speed should be reduced as tool change time Tt and/or tooling cost Ct increase,
Tools should not be changed too often if either tool cost or tool change time is high. An advantage of disposable inserts over regrindable tools due to the lower tool change time.
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Machined parts from standard stock sizes Machining with standard cutting tools
Avoid special form tools Minimize the number of individual cutting tools used
Specify Tolerances to satisfy functional requirements and process capabilities (unnecessary cost from additional
processing, fixturing, inspection, sortation, rework, and scrap)
Specify surface finish to meet functional and/or aesthetic requirements (add processing cost by requiring
additional operations such as grinding or lapping)
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Kwon