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
Peripheral milling cutting positions

movements

Face milling cutting positions

Full face cut Offset face cut

ME 482 - Manufacturing Systems

 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 A = O = D/2

Partial face A=O= w (D w)

Machining time:

Tm = (L + 2A)/fr

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 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/(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.

ME 482 - Manufacturing Systems

 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%)

ME 482 - Manufacturing Systems

 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 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 Ct cost per cutting edge

T tool life Ctp = Ct/np - tool cost per part

ME 482 - Manufacturing Systems

 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) )

ME 482 - Manufacturing Systems

 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

ME 482 - Manufacturing Systems

 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
ME 482 - Manufacturing Systems
 Machining operations

What did we learn?

ME 482 - Manufacturing Systems