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Sample - Solution Manual Fundamentals of Metal Machining and Machine Tools 3rd Edition Boothroyd & Knight

This document summarizes machining operations and calculations for manufacturing components. It includes: 1) Calculations to determine the total production time for rough cutting a volume of 256 x 10^3 m3 would be 1698 ks. 2) Calculations of volume removed and machining times for rough and finish cuts of a specific component. 3) Calculations of number of passes, production time, and power requirements for milling a flat surface on a workpiece.

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Farhan Tanvir
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2K views4 pages

Sample - Solution Manual Fundamentals of Metal Machining and Machine Tools 3rd Edition Boothroyd & Knight

This document summarizes machining operations and calculations for manufacturing components. It includes: 1) Calculations to determine the total production time for rough cutting a volume of 256 x 10^3 m3 would be 1698 ks. 2) Calculations of volume removed and machining times for rough and finish cuts of a specific component. 3) Calculations of number of passes, production time, and power requirements for milling a flat surface on a workpiece.

Uploaded by

Farhan Tanvir
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Chapter 1 Machine Tools and Machining Operations

1. Power available, Pm = P,qm= 2000x 0.5 = lOOOW


1000
Also Pm = psZwand therefore Z , = Pm/ps = = 3.66 X 1o - ~m3/s
2.73 X 109
For finish cut

Volume V to be removed in rough cut:

Total production time = 2000(120 + 2 X 15 + 699) = 1698 ks

Alternatively:

Total volume removed = 256 X 10a m3

v01
Therefore tm = -= 699 S
zw
2. (a) Rough cut:
Volume to be removed = - .-[(-)'
50 n
103 4
100
103
-(')1] = 0.17x10-' m'

(b) Finish cut:

f=0.1mm,ap=3mrn,v=1.5m/s

(c) t,, =20+2~30+190+76.5=347 s

3.

-
(a) Total tool feed normal to cutting edge = 2.5 cos 30' = 2.165 mm

Number of passes = 2.1651 0.13 17

(b) Production time = 17(2.f:-8 + 20) = 2.465 S


(a) Radial distance moved by tool = 750 - 300 =450 mm

Therefore number of revolutions of workpiece = 4501 0.25

(b) Pm = psZw = 3 . 5 109z, ~ W


P,, = 3 . 5 x l 0 ' ~ , = 3 . 5 ~ 1 0 ~ f a , n , 2 m ,
= 3.5 X 10' X 0.25 X 1 0 - ~X 6 x 1 0 - ~ X 0 . 5 1.5n
~ = 12.37kW

(c) Pm,=3.5x109x0.25x10-3x6x10-3x0.5x0.6z=4.95kW
Region (a) maximum power: P, = p,Z,

When the rotational frequency rises to critical value:


Zw = fa,n, X 2%

Combining (1) and (2)

V, volume removed in period (a):


V =?(l2
-0.48')~ 5 X 1 0 - ~
4

Machining time in period (a):


A7
-(l2 -0.48')~ 5 x 1 0 - ~
v - 4 = 2.285 ks
~m',- -
A

Wz (300012.27 xlo-°)

Machining time in period (b):

t, = t, + t,, + 600 = 4.03 ks


For 50 components t,, = 50 X 4.03 = 201.5 ks

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