Bannari Amman Institute of Technology

Sathyamangalam

Department of Mechanical Engineering

Welcomes You
18ME605 - COMPUTER AIDED MANUFACTURING II
Unit II
ECONOMICS AND TESTING OF
MACHINE TOOLS
Topic -1
Factors influencing Selection of CNC
Machines
Cost of operation of CNC
 COST OF HOUSE BUILDING
• Thus, manufacturing department must be in close relation with all other departments in a company:
- Design dept. - Purchase dept.
- Quality dept. - Sales dept.
- Etc.
• When manufacturing a component, there is a strong relation among COST and:

• Material analysis and optimization

of these interrelations
• Process DFMA
• Design Design For Manufacturing and Assembly
• Assembly

Material Process

Design Assembly

COST
 CNC Machines- How do they look like?

Servo Motors

Display Console Coolant

control
Slides Automated
Tool changer
Controller Controller

Chip collection and

removal
Process
 Design

Assembly

PROPOSED DESIGN

Looks OK,
right?
 Design

Assembly

FINAL DESIGN

After DFMA
what a difference!
Do You Know ...

1. Machine tools
2. Machining methods
3. Process parameters
 TOPICS:

1.
1. Indicate
Indicatevariousvarious
operations operations
performed performed
in
in CNC
CNCmachine
machine
2.
2. Select
Selectthe appropriate
the appropriate
factors factors
influencing
influencing machine
machine
selection. selection.
3.
3. Compute
Computethe operation
the operation
cost of CNC cost of CNC
machine
machine
 Operations in CNC
CNC Milling

CNC Plasma Cutter CNC Electric Discharge Machining

Axes of CNC Machine Tool
Five Axis CNC
 From 3-axis to 5-axis machining

• dozens of views need to be defined

• not sufficient for the complete • more tool movements
finishing process for very • programming is quite difficult
deep part and having narrow cavities • sum of all views does not cover the
whole geometry
• results in a bad surface quality and • overlapping views lead to surface
long machining times in Case of quality problems
harder material • More number of lead-in and out
movements
 Configurations for 5-axis machining

Swivel Head with Traveling Column

Rotary Table Integrated Trunnion Table
 Specification
• TARUS TPGM5X1083 SPECIFICATIONS
Parameters
X Axis Travel 3048 mm
Y Axis Travel 2540 mm
Z Axis Travel 1117 mm
Space between columns 3886 mm
Workable size,L*W 3568 mm*2235 mm
X , Y and Z axis maximum feed rate 30m/min
A axes tip +/-100 degrees
C axis tip Continuous
A and C axis positioning peak torque 4073 NM
A and C axis positioning Feed 30 degrees per second
Milling Spindle HSK 63A, 0-20,000 RPM
(3 axis and 5 axis milling)
4,000 RPM base speed
70 NM constant torque,160 NM peak torque
29 KW rated power
Linear Accuracy (X,Yand Z) ± .013 mm , ± 0.006 mm, ± 0.005 mm
 CNC machines

• Programming

• CAD/CAM

• Programming Software
 CNC Programming
Programming consists of a series
Important things to know: of instructions in form of letter codes

•Preparatory Codes:
• Coordinate System G codes- Initial machining setup and
establishing operating conditions
• Units, incremental or absolute N codes- specify program line number
positioning to executed by the MCU

•Axis Codes: X,Y,Z

• Coordinates: X,Y,Z, RX,RY,RZ Used to specify motion of the slide along
X, Y, Z direction
• Feed rate and spindle speed
•Feed and Speed Codes: F and S
Specify feed and spindle speed
• Coolant Control: On/Off, Flood,
Mist •Tool codes: T – specify tool number

•Miscellaneous codes – M codes

• Tool Control: Tool and tool
For coolant control and other activities
parameters
 Common Format of a Block

Sequence Preparatory Dimension Feed Spindle Tool Misc.

# Function Words Rate Function Function Function

N50 G90 G01 X1.40Y2.25 F10 S1500 T01 M03

Individual Words
 Selection of CNC machines
• Main factors
RELIABILITY
It is very important in order to get a good CNC machining,
must operate consistently over time and operate with only routine
maintenance.

PRECISION
The components of the machine must be designed and constructed
with excellent structural stability and carefully selected materials to
achieve cutting precision and good CNC machining.
 Selection of CNC machines
• Main factors
EASE
Cost per piece also depends on the hours that the worker devotes to each piece.
Perform CNC machining with minimal operator involvement.

CONTROLS
CNC machines operated through numerical controls, easy to control, to program
and to operate. This allows the operator perform the job more quickly, avoiding to
accumulate hours of production in the price or even delay deliveries to
customers.

MAINTENANCE
Machines that perform CNC machining
 Choosing CNC Machine
• Major factors

Current Machine Tool Set-

Up And Operator
Experience

Part Difficulty And Complexity

Materials To Be Machined
Choosing CNC Machine
• Major factors

Linear Motion (LM) Guide

Ways Or Box Guide Ways

Types Of CNC
Control System
 Choosing CNC Machine
• Major factors
Cost Per Part

Available Space At Factory

 Choosing CNC Machine
• Major factors
Naturally, this varies from industry to industry, and
may include the following factors:
 Maximize utilization of available floor space
 Minimize the movement of workers from machine
to machine
 Material flow and space for movement of materials
from point to point
 Increase productivity
 Chip disposal
 Safety conditions for workers
 Space for future expansion
 Available power points
 MACHINING OPERATIONS
Classification of Machined Parts
1.Rotational - cylindrical or disk-like shape
2.Nonrotational (also called prismatic) - block-like or plate-like

Figure - Machined parts are classified as: (a) rotational, or (b)

nonrotational, shown here by block and flat parts
 Machining Operations and Part Geometry
Each machining operation produces a characteristic part geometry due
to two factors:
1. Relative motions between the tool and the workpart
• Generating – part geometry is determined by the feed
trajectory of the cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by the shape of the cutting
tool
Figure - Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling
Figure - Forming to create shape: (a) form turning, (b) drilling, and
(c) broaching
Figure - Combination of forming and generating to create shape:
(a) thread cutting on a lathe, and (b) slot milling
Operations Performed on Lathe
(Other than Turning)
Machining Time and Cost
 Machining Time and Cost
BASIS:
• Analyze machinability METHODOLOGY:
• Apply recommended standards
• Select process and optimize • Consider work material and
tool combinations.
• Obtain optimal results • Utilize modern tools, analyze
Higher material removal rate, the machinability
surface finish, quality, •Compare the results and
Lessor power consumption recommend optimal results
Better economy
 Machining Time and Cost
Selected data / Input information: Analysis / Calculations using
• Work piece material app / web s /w

• Operations sequence and tool a) Machining time

• Tool material b) Material removal rate MRR
• Selected speed, feed, depthof cut,
c) Power required
• Operation length / tool or work travel
• Number of cutting passes d) Surface finish obtained
• Others if any e) Others if any
EXAMPLE
 MACHINING TIME
MACHINING TIME ESTIMATION METHODS

• The TOTAL MACHINING TIME (TT) calculus is very important to determine:

• Manufacturing costs: Machine rate [€/h] * TT [h]
• Machine work loads
• Personnel needs.
• Delivery time

• The cutting time (TCUTTING) is the only one that can be accurately
calculated. Rest of the times need to be estimated.

• Most commonly used TIME ESTIMATION methods are:

1. By estimation.
2. By comparison.
3. By timing.
4. By the sum of elementary predefined times.
 MACHINING TIME
MACHINING TIME ESTIMATION METHODS

− : Set-up time MANUAL OPERATION : Manual operation time

• Time necessary to prepare the machine-tool to be • It is difficult to calculate properly because it varies depending
ready to start machining: on part’s dimensions and weight, machine tool, etc.
• Workholding device set-up • In general, manual operation time > cutting time.
• Toolholding device set-up • Workpiece clamping and un-clamping
• Material procurement • Non-cutting movements
• Tool procurement • Tool changes
• Taking references
CUTTING : Cutting time UNFORESEEN : Unforeseen time
• Measurements
• It is the time consumed in movements that remove • It covers all the time gone in unforeseeable events during the
material. machining process (unexpected times).
• Non-cutting movements, such as fast approximations • Machine-tool breakdown.
or retracts, are not considered.
L: tool or workpiece • Tool wear or breakage
displacement. • Lack of raw material.
V: displacement speed.
• Blackout
 MACHINING TIME
MACHINING TIME ESTIMATION METHODS
By estimation
• It consists in breaking down the operation in different smaller phases, so that a rough estimation can
be made based on the experience of the technicians.
• It is commonly used when:
• unitary parts or small batches are required.
• not enough data is available.
• delivery time is short.
• As it is a estimation method, it is not very accurate.

BASED ON THE TECHNICIAN EXPERIENCE

 MACHINING TIME
MACHINING TIME ESTIMATION METHODS
By comparison
• It consists in determining the time of a specific operation by
comparing it with the time consumed a previously machined
• similar operation.

As it is a estimation method, it is not very accurate.

However, it is more accurate than the estimation method.

BASED ON OTHER PARTS EXPERIENCE

 MACHINING TIME
MACHINING TIME ESTIMATION METHODS
By timing
• It consists in measuring the time needed to manufacture
the part.
• Thus, it is a very time consuming and expensive method.
• It is commonly used when:
• Very stable & automatized processes are required.
• Large series are required.
1ª OPERACIÓN
HABLAR
Los operarios antes de comenzar el proceso comentan entre ellos sobre el
trabajo que habrán de desempeñar

DURACIÓN= 30 Seg.
¿Qué haremos
ahora? Bueno, empezaremos a
preparar la máquina

TOTAL = 38 MIN 50 SEG

BASED ON THE TIMING

 MACHINING TIME
MACHINING TIME ESTIMATION METHODS
By the sum of elementary predefined times
• It consists in breaking down the execution of a part in elementary phases. The time needed to be
accomplish these elementary phases are predefined in tables (machine notebooks).
• It is commonly used when a fast and economic decision need to be taken.
• It is an accurate time estimation method.

Technical specifications Predefined elementary times

Speeds, Feeds, & DOC
• Turning
– RPM vs. Surface footage
• Definition
• How to calculate
• When and Why to use
• Material machinability ratings
– Feed rate
• Under or Over feeding and its effect
• Feed rate on materials
• Effect on tools
• Calculating material removal
• Revolutions per minute (RPM)
– It is a measure of the frequency of a rotation.
– It represents the number of turns completed in one minute
around a fixed axis. It is used as a measure of rotational
speed of a mechanical component.

• Surface Speed (sfm or m/min)

– It is the speed difference (relative velocity) between the cutting
tool and the surface of the workpiece it is operating on. It is
expressed in units of distance along the workpiece surface per
unit of time, typically surface feet per minute (sfm)
or meters per minute(m/min).
MPH vs. SFM
Questions
• How many of you have specific RPM’s you always use to
perform certain tasks?

– I always run my part-off tool at 1000RPM

– We run this spot drill at 1500RPM.
– ½” end mills should be run at 750RPM

• WHY?
Questions
• Examples
– I always run my part-off tool at 1000RPM
• On ½” Ø material this is 130 SFM
• ¾” Ø it’s 200 SFM
• 1” Ø it’s 260 SFM
– We run this 90o spot drill at 1500RPM
• Depth controls SFM
• 1/4” deep for 1/2” Ø chamfer is 200 SFM
• 3/8” deep for 3/4” Ø chamfer is 300 SFM
– ½” end mills should be run at 2000RPM
• This is 260 SFM – material controls if this proper speed

• Where did these numbers come from?

FORCES AND POWER
FORCES AND POWER
COOLENTS
COOLENTS
CUTTING TOOLS

(HSS)

VIDEO
CUTTING TOOLS
 CUTTING TOOLS
Temperature
ºC [ºC]

1550 Ceramic
1400 CBN
1300 Carbide
(Hard
metal)

Hardness
900 Diamond

[HRC]
800 HSS
CUTTING TOOLS
Feed [mm/rev]

Cutting speed
[m/min]
50
TURNING PARAMETERS
TURNING CUTTING TIME
TURNING CUTTING TIME
TURNING CUTTING TIME
TURNING CUTTING TIME
TURNING CUTTING TIME
TURNING CUTTING TIME
DRILLING PARAMETERS
DRILLING PARAMETERS
DRILLING CUTTING TIME
DRILLING CUTTING TIME
MILLING PARAMETERS
CUTTING TIME
CUTTING TIME
CUTTING TIME
 Process Planning for A Component
Example part to be made on a mill-turn center

Sequence of operations
Selection of Cutting Conditions
 One of the tasks in process planning
 For each operation, decisions must be made about machine
tool, cutting tool(s), and cutting conditions
 These decisions must give due consideration to workpart
machinability, part geometry, surface finish, and so forth
 Cutting conditions: speed, feed, depth of cut, and cutting
fluid
 Selecting Depth of Cut
 Depth of cut is often predetermined by workpiece geometry
and operation sequence
 In roughing, depth is made as large as possible to
maximize material removal rate, subject to limitations of
horsepower, machine tool and setup rigidity, and strength
of cutting tool

 In finishing, depth is set to achieve final part dimensions

 Determining Feed
 In general: feed first, speed second
 Determining feed rate depends on:
 Tooling – harder tool materials require lower feeds
 Roughing or finishing - Roughing means high feeds,
finishing means low feeds
 Constraints on feed in roughing - Limits imposed by
cutting forces, setup rigidity, and sometimes horsepower
 Surface finish requirements in finishing – select feed to
produce desired finish
 Optimizing Cutting Speed
 Select speed to achieve a balance between high metal
removal rate and suitably long tool life
 Mathematical formulas are available to determine
optimal speed
 Two alternative objectives in these formulas:
1. Maximum production rate
2. Minimum unit cost
 Maximum Production Rate
 Maximizing production rate = minimizing cutting time per
unit
 In turning, total production cycle time for one part consists
of:
1. Part handling time per part = Th
2. Machining time per part = Tm
3. Tool change time per part = Tt/np , where np = number of
pieces cut in one tool life
Total time per unit product for operation:

Tc = Th + Tm + Tt/np

Cycle time Tc is a function of cutting speed

Cycle Time vs. Cutting Speed
 Minimizing Cost per Unit
 In turning, total production cycle cost for one part consists of:
1. Cost of part handling time = CoTh , where Co = cost rate for
operator and machine
2. Cost of machining time = CoTm
3. Cost of tool change time = CoTt/np
4. Tooling cost = Ct/np , where Ct = cost per cutting edge
Total cost per unit product for operation:
Cc = CoTh + CoTm + CoTt/np + Ct/np
Again, unit cost is a function of cutting speed, just as Tc is a function
of v
Unit Cost vs. Cutting Speed
 Machining Economics
 As C and n increase in Taylor tool life equation, optimum
cutting speed should be reduced
 Cemented carbides and ceramic tools should be used at
speeds significantly higher than for HSS

 As tool change time Tt and/or tooling cost Ct increase, cutting

speed should be reduced
 Tools should not be changed too often if either tool cost or
tool change time is high
 Disposable inserts have an advantage over regrindable
tools because tool change time is lower
 MACHINING COST ESTIMATION
•COST ESTIMATION consists in calculating the costs of the product or/and services that a company
offers.

•Most commonly used machining COST ESTIMATION methods are:

• PRIMA (PRocess Information Maps)
• Parametric calculation  an estimation of manufacturing cost
• Analytic calculation  a more precise cost calculation method
• WHY DO WE NEED TO DO A COST ESTIMATION METHOD?
• To identify if a new product is feasible or not, and to modify it in an early design stage.
• To define the product price.
• To verify offers obtained from different suppliers  subcontracting
• To identify the most economical process to manufacture the product.
• To identify expenses and help in their minimization.
• To take strategical decissions: eliminate a product, subcontracting, discounts,…
MACHINING COST ESTIMATION
 MACHINING COST ESTIMATION
ANALYTIC Cost Estimation
• As mentioned before, the price is defined by the market and not by our production/manufacuring cost.
• So we must always produce below the market price.

Direct cost + indirect cost + profit = product price ideal business

Direct cost + indirect cost = product price no profit Direct cost +

indirect cost < product price no business

• PROS:
• It offers a very accurate estimation.
• CONS:
• It is a time consuming cost estimation method.
• A lot of data is necessary to feed the method.
 MACHINING COST ESTIMATION
ANALYTIC Cost Estimation
• In the ANALYTIC cost estimation, the final cost of the product is calculated by considering the real
cost of all the steps/processes.
• Each step/ process adds a value to the final product but for doing so a cost is necessary.
• The main cost that are taken into consideration are as follows:

Material cost DIRECT COST (DC)

Tooling cost Machining time
Manufacturing cost calculus is required.
Any subcontracting cost + PRODUCT TOTAL PRICE
Commercial cost ( ~ %10 DC) INDIRECT
Indirect cost ( ~ %25 DC) COST (IC)
+
DESIRED
PROFIT ( ~
%15 (DC + IC))
COST ELEMETS
COST ELEMETS
COST ELEMETS
OVERALL COST
OVERALL COST
 SUMMARY
3 mins
•Machine parameters
•Machine controls

•Operational Cost:
•Machine time,
•Labour Cost, T
•ooling cost,
•Setup cost,
•Raw material cost
 SUMMARY
3 mins
Tooling/Fixtures
CNC programming
Programming software

•Efficient and can help increase

manufacturing
Thank You