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Operations
by
Ed Red
Peripheral Face
movements
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
Approach distance, A :
A= d (D-d)
Tm = (L + A)/fr
Face milling:
Machining time:
Tm = (L + 2A)/fr
Problem statement:
Feedrate in in/min fr = N nt f
N (rpm) = v/(p D)
Ri = f2/(32 NR)
where
NR = tool nose radius
Actual roughness,
Ra = rai Ri (about 2 x Ri )
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
Variables:
Th - part handling time Co (Cg) operator (grinders) cost rate/min
Tc = Th + Tm + Tt/np
Tm = p D L/(v f)
Tmax = (1 - n) Tt /n
Ch = CoTh
Cm = CoTm
Ctp = Ct /np
Cc = Co Th + Co Tm + Co Tt /np + Ct /np