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Manufacturing Methods
Assignment #2
1- The 302 stainless steel flange shown in figure 1 is to be machined out of a forged
part. Both the central hole and the face of the flange required good surface finish (Ra =
0.8 µm). Determine the process plan to finish the part and then for each operation give
the following details:
a) Sketch the process and determine tool geometry and material,
b) Cutting speed, feed and machining time,
c) Power requirement.
Solution:
Process plan:
1- Rough facing the diameter 120 with 1.5 mm depth of cut.
2- Finish facing the diameter 120 mm with .5 mm depth of cut.
3- Rough boring the part till hole diameter reaches 37 mm.
4- Finish boring the hole to the final demanded surface finish.
b) Select the cutting speed, feed, feed rate and calculate time required,
c) Calculate the power requirement,
d) If the cylinder block is made out of Aluminum alloy instead of cast iron, would the
motor power be less? (Justify your answer).
Solution:
In down milling the feed motion is given in the direction of cutter rotation.
Advantages:
- Cut begins with a well-defined uniform chip thickness
- The surface finish is good
- Cutting direction holds down work piece, which means lower clamping force
Limitations:
- Requires more rigid machine tool
- Machine tool must be free of backlash
Properties for cast Iron:
TS = 500 Mpa
Hardness (HB) = (3 x TS) / (9.81) = (3 x 500) / (9.81) = 153 kg/mm2
From the table for slab milling use Zv = 1.0 and Zf = 0.5/tooth
V = Zv.Vs = 1.0 x 600 = 600 mm/sec
f = Zf.fs = 0.5 x 0.38 x 8 = 1.52 mm/rev
Power requirements:
E = E1(h/href)-a
E1 = 2.14 W.sec/mm3
Power = (E x Vt /η) = 4.4 Kw
If the part were made of aluminum alloy instead of cast iron, would the motor power be
less?
Aluminum is a softer material than cast iron. This hardness (HB) of aluminum alloy
ranges from 30-150 Kg/mm2 while that of cast iron alloy ranges from 110-320 Kg/mm2.
Also the specific energy (E1) of aluminum is lesser than that of cast iron. Hence for the
same cutting speed and feed, power required to machine aluminum alloy be much less
than the power required for machining cast iron. Also in case of aluminum alloys much
higher cutting speed can be used.