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MP Unit-2

This document describes a machining process called lathe turning and provides numerical problems to calculate machining parameters like material removal rate, cutting speed, and machining time. It defines key lathe parts and explains how to determine spindle speed, depth of cut, feeds and speeds for turning operations. The numerical problems demonstrate calculations for multi-pass turning operations and how to determine machining time for turning and facing steps.

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Parth Maldhure
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92 views113 pages

MP Unit-2

This document describes a machining process called lathe turning and provides numerical problems to calculate machining parameters like material removal rate, cutting speed, and machining time. It defines key lathe parts and explains how to determine spindle speed, depth of cut, feeds and speeds for turning operations. The numerical problems demonstrate calculations for multi-pass turning operations and how to determine machining time for turning and facing steps.

Uploaded by

Parth Maldhure
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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Machining Process

Unit-II

By: Dr. Sourabh Shukla


Lathe
Different parts of Lathe
Numerical problems
Q1. The diameter of a mild steel rod is to be reduced from 70 mm to 65 mm by plain
turning in a single pass at speed of 300 rpm and feed of 0.4 mm/rev. Determine the
material removal rate (MRR) in cubic centimeter (cc)/min that will occur during the
aforesaid machining operation.
Numerical problems
Q2. A mild steel rod having 50 mm diameter and 500 mm length is to be turned on a lathe.
Determine the machining time to reduce the rod to 45 mm in one pass when cutting
speed is 30 m/min and a feed of 0.7 mm/rev is used.

Sol. Given data: D = 50 mm, Lj= 500 mm v = 30 m/min, f = 0.7 mm/rev

Substituting the values of v and D in

calculate the required spindle speed as: N = 191 rpm

Machining time:

t = 500 / (0.7×191) = 3.74 minutes


Numerical problems
Q3. 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.

Sol. Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm (with usual notations)

tan α = (80-50) / 2×80

or α = 10.620

The compound rest should be swiveled at 10.62o


Taper turning

Taper: Conicity:
Numerical problems
Q4. A 150 mm long 12 mm diameter stainless steel rod is to be reduced in diameter to 10
mm by turning on a lathe in one pass. The spindle rotates at 500 rpm, and the tool is
traveling at an axial speed of 200 mm/min. Calculate the cutting speed, material removal
rate and the time required for machining the steel rod.

Sol. Given data: Lj = 150 mm, D1 = 12 mm, D2 = 10 mm, N = 500 rpm

v = π×12×500 / 1000 = 18.85 m/min.

depth of cut = d = (12 – 10)/2 = 1 mm

feed rate = 200 mm/min, we get the feed f in mm/rev by dividing feed rate by spindle rpm.

That is f = 200/500 = 0.4 mm/rev


Metal removal rate:
• When Job makes N revolutions/min
MRR = π D d f N (mm3/min)

• In terms of v MRR is given by


MRR = 1000 v d f (mm3/min)

MRR = 3.142×12×0.4×1×500 = 7538.4 mm3/min

Machining time:

t = 150/(0.4×500) = 0.75 min.


Numerical problems
Q5. 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 .

Sol. Given data: Lj = 170 mm, D1 = 60 mm, D2 = 50 mm, N = 440 rpm, f = 0.3 mm/rev, d= 2 mm,

How to calculate the machining time when there is more than one operation?
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 = (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)
Machining time for one cut = L / (f×N)
Total turning time = [L / (f×N)] × Number of pass
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.
Substituting these value, we get
machining time t = 25/(0.3×440) = 0.18 min.
Total time:
Total time for machining = Time for Turning + Time for Facing = 3.97 + 0.18 = 4.15 min.

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