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Homework of Lecture 4 Manufacturing

1) The document contains calculations for turning and milling operations including feed rate, surface speed, spindle speed, material removal rate, and required machining power. 2) For a turning operation, the calculated material removal rate was 15.699 in^3/min and required machining power was 4.70 hp. 3) For a milling operation using the given parameters, the material removal rate was 3 in^3/min and required machining power was 0.9 hp.

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Hassan Younas
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120 views7 pages

Homework of Lecture 4 Manufacturing

1) The document contains calculations for turning and milling operations including feed rate, surface speed, spindle speed, material removal rate, and required machining power. 2) For a turning operation, the calculated material removal rate was 15.699 in^3/min and required machining power was 4.70 hp. 3) For a milling operation using the given parameters, the material removal rate was 3 in^3/min and required machining power was 0.9 hp.

Uploaded by

Hassan Younas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Name Rakan Alnasser

Assignment No.3 Manufacturing


Question No.1:
Consider turning at feed rate = 10 in/min and speed =1000rpm.Workpiece diameter=5in

1) Calculate f(feed)
2) Calculate V (Surface speed)

Solution

a)

Feed rate = 10in/min

Speed =1000 rpm

Diameter=D=5 in

Feed= Feed rate/N

10∈¿ min
=
1000 rpm
Feed = 0.01 in/rev

b)

λND 3.14∗1000∗5
V= =
12 12

Surface Speed =V= 1308.33 feet per mint

Question N0.2:
A piece of Aluminum will be milled using a 1.5in Diameter HSS tool that has 4 teeth.

1. Choose appropriate surface speed using table 4.2 (from feller Book)
2. Calculate the required spindle speed
3. Choose appropriate feed rate using Table 4.2 From Feller Book
4. Calculate the feed and feed per tooth.
Solution:
1):
For HSS tool in Milling for aluminum work piece material

Appropriate surface speed = 750 feet per minute (From table of feller Book)

2):
λND
V=
12
V= surface speed = 750 feet per minute.
N=spindle speed

12∗V 12∗750
N= =
λ∗D 3.14∗1.5

N= 1910.82 rpm

3):
Feed rate = 20 in/min from table of feller book

4):
Feed rate = Feed*Spindle speed
Feed = feed rate/spindle speed
Feed = 20/1910.82
Feed =0.0104 in/rev

Feed per tooth = Feed /Number of tooth


= 0.0104/4
= 2.616x 10−3 in/rev/tooth

Question N0.3
If the depth of cut in example 1 and 2 is 0.1in.What is the MRR? What is the required
machining power?

Solution:
For Example 1: using data of example 1
Feed = 0.01 in/rev
Surface Speed =V= 1308.33 feet per mint = 12*1308.33= 15699.96 inch per mint
d= 0.1 inch
1):
Calculation of Example 1 MRR and Required Machining power:
MRR for Turing (Example 1 related to turning) = feed*d*V
=0.01*0.1*15699.96
MRR (for example 1) =15.699 ¿3 /min

Required Machining Power =MRR*Unit Power


Assuming the material is Aluminum= unit power= 0.3hp/ ¿3 /min
Required Machining Power (for example 1) =15.699 ¿)* 0.3(hp/¿3 /min )
Required Machining Power (for example 1) = 4.70hp

2):
Calculation of Example 2 MRR and Required Machining power:

MRR for Milling (Example 2 Related to milling) = feed rate * depth of cut*width

Assume Diameter = Width=w


Feed rate = 20 in/min from table of feller book
Diameter=Width=1.5in
Depth of cut =d=0.1inch

MRR for Milling (Example 2 Related to milling) = feed rate * depth of cut*width
= 20*0.1*1.5
MRR (For example 2) = 3 ¿3 /mint

Workman specimen material is Aluminum so unit power of Aluminum is = 0.3hp/¿3 /min

Required Machining Power =MRR*Unit Power

Required Machining Power (for example 2) = 3 ¿)* 0.3(hp/¿3 /min )

Required Machining Power (for example 2) = 0.9hp

Question No.4
Suppose a turning operation to be performed with HSS tooling on mild steel
With Taylor tool life parameters n=0.125, C = 70m/min. Work part length = 500mm and
diameter = 100 mm. Feed = 0.25 mm/rev. Handling time per piece = 5.0 min, and tool change
time = 2.0min. Cost of machine and operator = $30/hr, and tooling cost = $3 per cutting edge.
Find:
(a)Cutting speed for maximum production rate.
(b)Cutting speed for minimum cost.

Solution:
a):
Cutting speed for maximum production rate

n=0.125
C = 70m/min
T (t) =2min

Putting value in this equation for cutting speed for maximum production rate:

C
n
V (max) = 1
[ ( )
n
−1 ∗Tt ]

70
0.125
= 1
[ ( 0.125
−1 ∗2] )
Cutting speed for maximum production rate= V (max) = 50 m/min

b):
Cutting speed for minimum cost.
Converting $30/hr to $0.5/min. Minimum cost cutting speed is given By:

Cutting speed for minimum cost = V (min) = 42m/mim

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