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Solving session 6

The document contains solutions to various machining problems from chapters 17 to 20, including calculations for lathe power requirements, cutting temperatures, machining times, and metal removal rates. It also addresses tool life in relation to cutting speeds and costs associated with machining operations. Each problem is solved step-by-step, providing equations and results for different machining scenarios.

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8 views

Solving session 6

The document contains solutions to various machining problems from chapters 17 to 20, including calculations for lathe power requirements, cutting temperatures, machining times, and metal removal rates. It also addresses tool life in relation to cutting speeds and costs associated with machining operations. Each problem is solved step-by-step, providing equations and results for different machining scenarios.

Uploaded by

nashimounir
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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Solving session 6

Chapters 17-18-19
Equations used in chapters 17 and 18
Equations used in chapters 17 and 18
Equations used in chapters 19 and 20
Equations used in chapters 19 and 20
Equations used in chapters 19 and 20
Problem 17.4
• In a turning operation on stainless steel, cutting speed = 150 m/min,
feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power
will the lathe draw in performing this operation if its mechanical
efficiency = 90%.
Problem 17.5
In Problem 17.10, compute the lathe power requirements if feed = 0.50
mm/rev.

Solution:
From Table 17.2, U = 2.8 J/mm3. With the correction factor, U =
2.8(0.87) = 2.44 J/mm3.
RMR = vfd = (150 m/min)(103 mm/m)(0.50 mm)(7.5 mm) = 562,500
mm3/min = 9,375 mm3/s
Pc = (9,375 mm3/s)(2.44 J/mm3) = 22,838 J/s = 22,838 W = 22.84 kW
Accounting for mechanical efficiency, Pg = 22.84/0.90 = 25.4 kW
Problem 17.6
• Orthogonal cutting is performed on a metal whose mass specific heat
= 1.0 J/g-C, density = 2.9 g/cm3, and thermal diffusivity = 0.8 cm2/s.
Cutting speed = 3.5 m/s, uncut chip thickness = 0.25 mm, and width
of cut = 2.2 mm. Cutting force = 950 N. Determine the cutting
temperature if the ambient temperature = 22C.
Problem 17.6 – Solution
C = (2.9 g/cm3)(1.0 J/g-C) = 2.90 J/cm3-C = (2.90x10-3) J/mm3-C
K = 0.8 cm2/s = 80 mm2/s
U = Fcv/RMR = 950 N x 3.5 m/s/(3500 mm/s x 0.25 mm x 2.2 mm) = 1.727 N-m/mm3

T = 0.4U/(ρC) x (vto/K)0.333
= 22 + (0.4 x 1.727 N-m/mm3/(2.9x10-3) J/mm3-C) [3500 mm/s x 0.25 mm/80 mm2/s]0.333
= 22 + (0.2382 x 103 C)(10.94).333 = 22 + 238.3(2.22) = 22 + 528 = 550C
Problem 18.1
• An engine lathe is used to turn a cylindrical work part 150 mm in
diameter by 500 mm long. Cutting speed = 2.50 m/s, feed = 0.30
mm/rev, and depth of cut = 3.0 mm. Determine (a) cutting time and
(b) metal removal rate
Problem 18.1 - Solution
(a) N = v/(πD) = (2.50 m/s)/0.150 = 5.305 rev/s
fr = Nf = 5.305(.30) = 1.59 mm/s
Tm = L/fr = 500/1.59 = 314 s = 5.24 min
Alternative calculation using Eq. (18.5), Tm = 150(500)π/(2,500 x 0.30) =
314 s = 5.24 min

(b) RMR = vfd = (2.50 m/s)(103)(0.30 mm)(3.00 mm) = 2250 mm3/s


Problem 18.4
• A drilling operation is performed on a steel part using a 12.7-mm-
diameter twist drill with point angle = 118. The hole is a blind hole
with a depth of 60 mm. Cutting speed = 15 m/min, and feed = 0.20
mm/rev. Determine (a) cutting time of the operation and (b) metal
removal rate after the drill bit reaches full diameter.
Problem 18.4 - Solution
(a) N = v/πD = 15(103)/(12.7) = 376 rev/min
fr = Nf = 376(0.20) = 75.2 mm/min
A = 0.5D tan (90 – θ/2) = 0.5(12.7)tan(90 – 118/2) = 3.82 mm
Tm = (d + A)/fr = (60 + 3.82)/75.2 = 0.845 min

(b) RMR = 0.25πD2fr = 0.25(12.7)2(75.2) = 9,526 mm3/min


Problem 18.5
• Peripheral milling is performed on the top surface of a rectangular
work part that is 400 mm long by 50 mm wide. The milling cutter is 70
mm in diameter and has five teeth. It overhangs the width of the part
on both sides. Cutting speed = 60 m/min, chip load = 0.25 mm/tooth,
and depth of cut = 6.5 mm. Determine (a) machining time of the
operation and (b) maximum material removal rate during the cut.
Problem 18.5 – Solution
(a) N = v/πD = 60(103) mm/70 = 273 rev/min
fr = Nntf = 273(5)(0.25) = 341 mm/min
A = (d(D-d))0.5 = (6.5(70-6.5))0.5 = 20.3 mm
Tm = (400 + 20.3)/341 = 1.23 min

(b) RMR = wdfr = 50(6.5)(341) = 110,825 mm3/min


Problem 19.1
• Turning tests using cemented carbide tooling resulted in a 1-min tool
life at a cutting speed = 4.8 m/s and a 22-min tool life at a speed = 2.0
m/s. (a) Find the n and C values in the Taylor Tool Life equation. (b)
Project how long the tool would last at a speed of 1.0 m/s.
Problem 19.1 – Solution
(a) For data (1) T = 1.0 min, then C = 4.8 m/s = 288 m/min
For data (2) v = 2 m/s = 120 m/min
120(22)n = 288
22n = 288/120 = 2.4
n ln 22 = ln 2.4
3.0910 n = 0.8755 n = 0.283
The tool life equation is vT0.283 = 288

(b) At v = 1.0 m/s = 60 m/min


60(T)0.283 = 288
(T)0.283 = 288/60 = 4.8
T = (4.8)1/0.283 = (4.8)3.531 = 254 min
Problem 19.3
• In a turning operation using high-speed steel tooling, cutting speed =
100 m/min. The Taylor tool life equation has parameters n = 0.125
and C = 120 (m/min) when the operation is performed dry. When a
coolant is used in the operation, the value of C is increased by 15%.
Determine the percent increase in tool life that results if the cutting
speed is maintained at 100 m/min.
Problem 19.3 – Solution
Dry: 100(T)0.125 = 120
T = (120/100)1/.125 = (1.2)8 = 4.3 min
With coolant: 100(T)0.125 = 120(1 + 15%) = 120(1.15) = 138
T = (138/100)1/.125 = (1.38)8 = 13.15 min
Increase = (13.15 – 4.3)/4.3 = 2.06 = 206%
Problem 20.2
• A part turned in an engine lathe must have a surface finish of 1.6 m.
The part is made of a free-machining aluminum. Cutting speed = 200
m/min, and depth of cut = 4.0 mm. The nose radius on the tool = 1.5
mm. Determine the feed that will achieve the specified surface finish.
Problem 20.2
Problem 20.2 – Solution
For free-machining aluminum at 100 m/min, the ratio rai = 1.1 in Figure
20.2 so Ra = Ri (1.1)

Ri = f2/32NR = 1.6/1.1 = 1.45 m

Rearranging, f2 = Ri(32NR) = 1.45(10-6)(32)(1.5)(10-3) = 69.8(10-9) =


6.98(10-8) m2

f = (6.98(10-8) m2)0.5 = 2.64(10-4) m = 0.264 mm (mm is interpreted


mm/rev)
Problem 20.9
A high-speed steel tool is used to turn a steel work part that is 350 mm
long and 75 mm in diameter. The parameters in the Taylor equation
are: n = 0.13 and C = 75 (m/min) for a feed of 0.4 mm/rev. The operator
and machine tool rate = $36.00/hr, and the tooling cost per cutting
edge = $4.25. It takes 3.0 min to load and unload the work part and 4.0
min to change tools. Determine (a) cutting speed for maximum
production rate, (b) tool life, and (c) cycle time and cost per unit of
product.
Problem 20.9 – Solution
(a) Co = $36/hr = $0.60/min
vmax = 75/[(1/0.13 - 1)(4.0)].13 = 75/[6.692 x 4.0].13 = 48.9 m/min

(b) Tmax = (75/48.9)1/.13 = (1.534)7.692 = 26.85 min

(c) Tm = DL/fv = (75)(350)/(.4 x 48.9 x 103) = 4.216 min


np = 26.85/4.216 = 6.37 pc/tool life Use np = 6 pc/tool life
Tc = Th + Tm + Tt/np = 3.0 + 4.216 + 4.0/6 = 7.88 min/pc
Cc = 0.60(7.88) + 4.25/6 = $5.44/pc
Problem 20.10
Solve Problem 20.9 except that in part (a), determine cutting speed for minimum
cost.
Solution:
(a) Co = $36/hr = $0.60/min
vmin = 75[0.60/((1/0.13 - 1)(.60 x 4 + 4.25))].13 = 75[.60/(6.692 x 6.65)].13 = 42.8
m/min

(b) Tmin = (75/42.8)1/.13 = (1.75)7.692 = 74.8 min


(c) Tm = DL/fv = (75)(350)/(.4 x 42.8 x 103) = 4.817 min/pc.
np = 74.8/4.817 = 15.5 pc/tool life Use np = 15 pc/tool life
Tc = Th + Tm + Tt/np = 3.0 + 4.817 + 4/15 = 8.08 min/pc.
Cc = 0.60(8.08) + 4.25/15 = $5.13/pc

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