1CM160 – Exercise 4 Solutions

1. An orthogonal cutting operation is performed using a rake angle of 15°, chip thickness
before the cut = 0.012 mm and width of cut = 0.100 mm. The chip thickness ratio is
measured after the cut to be 0.55. Determine

a. the chip thickness after the cut,

b. shear angle,
c. friction angle,
d. coefficient of friction, and
e. shear strain.

2. The orthogonal cutting operation described in Problem 1 involves a work material whose
shear strength is 95 MPa. Based on your answers to the previous problem, compute
a. the shear force,
b. cutting force,
c. thrust force, and
d. friction force.
3. Tool life tests in turning yield the following data: (1) when cutting speed is 120 m/min,
tool life is 7 min; (2) when cutting speed is 80 m/min, tool life is 28 min.
a. Determine the n and C values in the Taylor tool life equation.
b. Based on your equation, compute (i) the tool life for a speed of 110 m/min, and (ii)
the speed corresponding to a tool life of 15 min.

4. Tom Jepperson, the Head of Manufacturing Department at MicroSystems, Inc., knows

that the estimation of tool life as a function of process parameters is important in terms of
calculating machining costs. He knows the Taylor’s tool life equation but he observes
that not only cutting speed but feed also plays an important role on tool life. Tool life test
results obtained after conducting three experiments at different levels are shown below.

𝑉𝑉 (m/min) 𝑓𝑓 (mm/rev) Tool Life (𝑇𝑇, min)

1 100 0.2 80
2 200 0.2 10
3 200 0.1 40

With the addition of feed, he slightly modifies Taylor’s equation as below:

𝑉𝑉 𝑝𝑝 𝑓𝑓 𝑞𝑞 𝑇𝑇 = 𝐶𝐶

(Notice that 𝑝𝑝, 𝑞𝑞, and 𝐶𝐶 are the unknown Taylor equation parameters.)

a) Based on the experimental data, calculate the unknown parameters. Use the given units
while calculating 𝑝𝑝,𝑞𝑞,and 𝐶𝐶.
b) Estimate the tool life for the cutting speed of 150 m/min and the feed of 0.15 mm/rev.
5. Low-Carbon Steel having a shear strength of 220 𝑁𝑁/𝑚𝑚𝑚𝑚2 is cut in a machining operation
with a cutting speed of 3.0 𝑚𝑚/𝑠𝑠. The uncut chip thickness is 0.20 𝑚𝑚𝑚𝑚 and the depth of cut
is 3 𝑚𝑚𝑚𝑚. The rake angle of the tool is 5°. The chip thickness increases by 150% after the
cutting takes place.

a. Determine the following quantities:

• Shear-Plane Angle and Shear Force
• Cutting Force and Thrust Force

b. In lecture videos, the percentage of the total energy that goes into overcoming the friction
at the tool-chip interface is calculated. The rest of the energy can be assumed to be
dissipated in the shear plane to perform the cutting process. In the problem above, calculate
the percentage of the total energy that is dissipated in the shear plane.
6. Disposable and regrindable tooling are to be compared. The same grade of cemented carbide
tooling is available in two forms for turning operations in a certain machine shop: disposable
inserts and brazed inserts. The parameters in the Taylor equation for this grade are: n = 0.25 and
C = 300 (m/min) under the cutting conditions considered here. For the disposable inserts, price of
each insert = $6.00, there are four cutting edges per insert, and the tool change time = 1.0 min
(this is an average of the time to index the insert and the time to replace it when all edges have
been used). For the brazed insert, the price of the tool = $30.00 and it is estimated that it can be
used a total of 15 times before it must be scrapped. The tool change time for the regrindable
tooling = 3.0 min. The standard time to grind or regrind the cutting edge is 5.0 min, and the grinder
is paid at a rate = $20.00/hr. Machine time on the lathe costs $24.00/hr. The workpart to be used
in the comparison is 375 mm long and 62.5 mm in diameter, and it takes 2.0 min to load and
unload the work. The feed = 0.30 mm/rev.

For the two tooling cases, compare (a) cutting speeds for minimum cost, (b) tool lives, (c) cycle
time and cost per unit of production. Which tool would you recommend?
7. The top surface of a rectangular workpart is machined using a peripheral milling operation. The
workpart is 735 mm long by 50 mm wide by 95 mm thick. The milling cutter, which is 60 mm in
diameter and has five teeth, overhangs the width of the part equally on both sides. Cutting speed
= 80 m/min, chip load = 0.30 mm/tooth, and depth of cut = 7.5 mm.

a. Determine the time required to make one pass across the surface, given that the setup
and machine settings provide an approach distance of 5 mm before actual cutting begins
and an overtravel distance of 25 mm after actual cutting has finished.
b. What is the maximum material removal rate during the cut?

8. In this problem, the goal is to compare three tool materials for the same finish turning operation
on a batch of 100 steel parts: High speed steel (HSS), cemented carbide, and ceramic. For the HSS
tool, the Taylor equation parameters are: n = 0.125 and C = 70 (m/min). The price of the HSS tool
is $15.00 and it is estimated that it can be ground and reground 𝑛𝑛𝑔𝑔 = 15 times at a cost of $1.50
per grind. Tool change time is 3 min.
Both carbide and ceramic tools are in insert form and can be held in the same mechanical tool
holder. The Taylor equation parameters for the cemented carbide are: n = 0.25 and 𝐶𝐶 = 500
(m/min); and for the ceramic: n = 0.6 and 𝐶𝐶 = 3,000 (m/min). The purchase price (𝑃𝑃𝑡𝑡 ) for a
carbide insert is $6 and for a ceramic insert is $8. There are 𝑛𝑛𝑒𝑒 = 6 cutting edges per insert in
both cases. Tool change time is 1.0 min for both tools.

The time to change a part is 2 min. The feed is 0.25 mm/rev, and depth of cut is 3 mm. The cost
rate (𝐶𝐶𝑜𝑜 ) for the operator using the machine is $30/hr. The part is 56 mm in diameter and 290 mm
in length. Setup time for the batch is 2 hours. For the three tooling cases, compare: (a) cutting
speeds for minimum cost, (b) tool lives, (c) cost per production unit, (d) total time to complete
the batch. (e) What is the proportion of time spent actually cutting metal for each tooling?
Solution:

For the HSS tool: C0=30/60=0.5 per min; Ct=15/15+1.5=$2.5/min;

a) Vmin=C*((n/(1-n))*(C0/(C0*Tt+Ct)))^n

=70*((0.125/(1-0.125))*(0.5/(0.5*3+2.5)))^0.125≈42.3 m/min

b) From Taylor’s tool life equation; we get Tmin=(70/42.3)^(1/0.125)≈56.24 min

c) Cc=C0*Tc+Ct/np=0.5*7.07+2.5/11≈$3.76 per part

Since Tm=π*56*290/(0.25*42.3*1000)≈4.8 min per part; np=56.24/4.8=11.72 We should take it

11; Tc=2+Tm+3/np=2+4.8+3/11≈7.07 min per part

d) Since we will have 100 parts;

Total time to complete the batch= 2*60+100*(7.07)=827 min

e) The proportion= 480/827≈0.58 which means %58

For the carbide tool: C0=30/60=0.5 per min; Ct=6/6=$1/edge;

a) Vmin=C*((n/(1-n))*(C0/(C0*Tt+Ct)))^n

=500*((0.25/(1-0.25))*(0.5/(0.5*1+1)))^0.25≈289 m/min

b) From Taylor’s tool life equation; we get Tmin=(500/289)^(1/0.25)≈9 min

c) Cc=C0*Tc+Ct/np=0.5*2.79+1/12≈$1.48 per part

Since Tm=π*56*290/(0.25*289*1000)≈0.71 min per part; np=9/0.71=12.7 We should take it 12;

Tc=2+Tm+1/np=2+0.71+1/12≈2.79 min per part

d) Since we will have 100 parts;

Total time to complete the batch= 2*60+100*(2.79)=399 min

e) The proportion= 71/399≈0.178 which means %17.8

For the ceramic tool: C0=30/60=0.5 per min; Ct=8/6=$1.33/edge;

a) Vmin= C*((n/(1-n))*(C0/(C0*Tt+Ct)))^n

=3000*((0.6/(1-0.6))*(0.5/(0.5*1+1.33)))^0.6≈1757 m/min
 b) From Taylor’s tool life equation; we get Tmin=(3000/1757)^(1/0.6)≈2.44 min

c) Cc=C0*Tc+Ct/np=0.5*2.16+1.33/21≈$1.14 per part

Since Tm=π*56*290/(0.25*1757*1000)≈0.116 min per part; np=2.44/0.116=21.03 We should

take it 21; Tc=2+Tm+1/np=2+0.116+1/21≈2.16 min per part

d) Since we will have 100 parts;

Total time to complete the batch= 2*60+100*(2.16)=336 min

e) The proportion= 11.6/336≈0.035 which means %3.5

9. In a production turning operation, the workpart is 125 mm in diameter and 300 mm long. A feed
of 0.225 mm/rev is used in the operation. If cutting speed = 3.0 m/s, the tool must be changed
every 5 workparts; but if cutting speed = 2.0 m/s, the tool can be used to produce 25 pieces
between tool changes. Determine the Taylor tool life equation for this job.
10. The outside diameter of a cylinder made of titanium alloy is to be turned. The starting diameter
is 400 mm and the length is 1100 mm. The feed is 0.35 mm/rev and the depth of cut is 2.5 mm.
The cut will be made with a cemented carbide cutting tool whose Taylor tool life parameters are:
n = 0.24 and C = 450. Units for the Taylor equation are min for tool life and m/min for cutting
speed. Compute the cutting speed that will allow the tool life to be just equal to the cutting time
for this part.

11. A three-axis CNC machining center is used to produce a batch of 150 rectangular steel workparts.
A peripheral (slab) milling operation is performed on the top surface of each workpart which is
400 mm long by 60 mm wide. The milling cutter, which is 80 mm in diameter and has five teeth,
overhangs the width of the part on both sides. The cost of a milling cutter is $15. Cutting speed is
70 m/min, chip load is 0.25 mm/tooth, and depth of cut is 5.0 mm.The CNC machining center is
operated by a worker who takes 2.80 minutes to unload the part just completed and load and
fixture the next part onto the machine worktable. The cost rate for the operator and the machine
is $30/hr. It is known that the worker changes the milling cutter after the completion of every 15
workparts, and it takes 4 minutes to change it. Setup time for the batch is 1.5 hours.

a) A proposal has been made to install an automated pallet shuttle at the machine so that it takes
only 15 seconds to unload the part just completed and load and fixture the next part onto the
machine worktable. What is the proportion of time spent actually cutting the metal before and
after the proposal?
b) Suppose that the proposal has been declined. However, the manufacturing manager finds that
the tool needs to be changed after every 50 parts if the cutting speed is reduced to 50 m/min. If
the objective is to achieve a lower per-part production cost, would you recommend decreasing
the cutting speed? Show all your work.

Yes, decrease the speed. It is ok not to include the setup cost since it is the same for both cases.
12. The diameter of a shaft 𝐷𝐷𝑖𝑖 will be reduced to 𝐷𝐷𝑓𝑓 in a straight turning operation. The value of 𝐷𝐷𝑖𝑖 is
very large compared to 𝐷𝐷𝑓𝑓 . Therefore, it is not possible to perform the turning process in a single
step. A multi step turning operation must be performed.

a. How would you formulate the total machining time calculation? In your formulation, represent
the depth of cut at each pass with 𝑑𝑑. The length of the shaft being turned is 𝐿𝐿, and feed is 𝑓𝑓. The
rotational speed of the shaft is represented with with 𝑁𝑁. The number of passes, which is an
integer number, can be represented with 𝑝𝑝. Assume that cutting speed (𝑉𝑉) and the feed are
constant in this operation. Ignore the tool return time (i.e., the time it takes for the tool to
return to the starting point before each pass). Use your formulation to calculate the total
machining time if 𝐷𝐷𝑖𝑖 =80 mm, 𝐷𝐷𝑓𝑓 =40mm, 𝐿𝐿=100 mm, 𝑉𝑉=50 m/min, 𝑓𝑓=0.1mm/rev, 𝑑𝑑=2 mm.
b. Let us assume that the cutting speed (𝑉𝑉) and feed (𝑓𝑓) are kept constant in this operation and the
tool life equation is expressed as 𝑇𝑇 = 𝐶𝐶𝑑𝑑 𝛼𝛼 where the tool life only depends on depth of cut 𝑑𝑑.
The 𝐶𝐶 and 𝛼𝛼 are tool life constants. This equation implies that as depth of cut increase, tool life
decreases. Let 𝑇𝑇ℎ denote the handling time of the work piece. The tool change time is denoted
with 𝑇𝑇𝑡𝑡 . How would you calculate the optimal depth of cut expression for minimum production
cycle time?