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Tutorial 2

The document provides solutions to 4 turning problems involving calculations of machining time. 1) The machining time to turn down a 170mm long, 60mm diameter workpiece to 165mm long, 50mm diameter is 3.97 minutes, assuming a spindle speed of 440 rpm, feed of 0.3 mm/rev, and maximum 2mm depth of cut taken in 3 passes. 2) The compound rest angle to cut an 80mm taper over 80mm length on a 150mm long, 80mm diameter workpiece is 10.62 degrees. 3) The machining time to reduce a 200mm long, 20mm diameter workpiece to 10mm diameter, with a material removal rate of 8000

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76 views

Tutorial 2

The document provides solutions to 4 turning problems involving calculations of machining time. 1) The machining time to turn down a 170mm long, 60mm diameter workpiece to 165mm long, 50mm diameter is 3.97 minutes, assuming a spindle speed of 440 rpm, feed of 0.3 mm/rev, and maximum 2mm depth of cut taken in 3 passes. 2) The compound rest angle to cut an 80mm taper over 80mm length on a 150mm long, 80mm diameter workpiece is 10.62 degrees. 3) The machining time to reduce a 200mm long, 20mm diameter workpiece to 10mm diameter, with a material removal rate of 8000

Uploaded by

omar salah
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 PDF, TXT or read online on Scribd
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Engineering Production

Tutorial 2
Turning Problems
(1) Calculate the time required to machine a workpiece 170 mm long, 60
mm diameter to 165 mm long 50 mm diameter. The workpiece rotates at
440 rpm, feed is 0.3 mm/rev and maximum depth of cut is 2 mm. Assume
total approach and overtravel distance as 5 mm for turning operation.
Solution
Time for Turning:

• Total length of tool travel = job length + length of approach and overtravel

 L = 170 + 5 = 175 mm

• Required depth to be cut (d) = (60 – 50)/2 = 5 mm

• Since maximum depth of cut is 2 mm, 5 mm cannot be cut in one pass. Therefore, we calculate number

of cuts or passes required.


• Number of cuts required = 5/2 = 2.5 or 3 (since cuts cannot be a fraction)
𝑳
• Machining time for one cut  𝒕 =
𝒇×𝑵
𝑳
• Total turning time = [ ] × Number of cuts
𝒇×𝑵
𝟏𝟕𝟓
 tturning = [ )] × 3= 3.97 min.
𝟎.𝟑×𝟒𝟒𝟎
Solution
Time for Facing:

• Now, the diameter of the job is reduced to 50 mm. Recall that in case of facing
operations, length of tool travel is equal to half the diameter of the job. That is, L = 25
mm.

𝟐𝟓
tfacing = 𝟎.𝟑×𝟒𝟒𝟎 = 0.18 min.

Assignment: What is the machining time if facing was carried out


first?
(2) Determine the angle at which the compound rest would be swiveled for
cutting a taper on a workpiece having a length of 150 mm and outside
diameter 80 mm. The smallest diameter on the tapered end of the rod
should be 50 mm and the required length of the tapered portion is 80 mm.
(2) Determine the angle at which the compound rest would be swiveled for
cutting a taper on a workpiece having a length of 150 mm and outside
diameter 80 mm. The smallest diameter on the tapered end of the rod
should be 50 mm and the required length of the tapered portion is 80 mm.
Solution
𝑫𝟏 −𝑫𝟐 𝟖𝟎 −𝟓𝟎
tan a = =
𝟐𝑳 𝟐×𝟖𝟎

 a = 10.620

The compound rest should be swiveled at 10.62°


(3) It has been determined to use a Material Removal Rate of 8000
mm3/min to reduce the diameter (20 mm) of a 200 mm long workpiece
that rotates with a spindle speed of 200 rpm to 10 mm. Calculate the time
required to complete that process.
Solution
MRR = π D d f N

 8000 = π × 20 × 5 × f × 200

 f = 0.127 mm/rev

π𝑫𝑵 π×𝟐𝟎×𝟐𝟎𝟎
OR v = 𝟏𝟎𝟎𝟎
= 𝟏𝟎𝟎𝟎
= 12.566 m/min

𝟖𝟎𝟎𝟎
MRR = 1000 v d f  f = 𝟏𝟎𝟎𝟎×𝟏𝟐.𝟓𝟔𝟔 ×𝟓 = 0.127
𝑳 𝟐𝟎𝟎
t= 𝒇×𝑵 = = 7.874 min
𝟎.𝟏𝟐𝟕×𝟐𝟎𝟎
(4) A cylindrical workpiece of 40 mm diameter and 120 mm length is to be
produced from 60 mm diameter bar on a centre lathe. Rough cutting is
used with a maximum depth of cut of 3 mm, cutting velocity of 20 m/min
and a feed of 0.5 mm/rev and finish cut is used with a maximum depth of
cut of 1 mm, a cutting velocity of 35 m/min and a feed of 0.2 mm/rev
Determine the machining time required for that process. (Assignment)

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