Homework Assignment 4 Due: 3/6/13

1. (22.1) (10 pts) A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an engine lathe. Cutting speed = 2.30 m/s, feed = 0.32 mm/rev, and depth of cut = 1.80 mm. Determine (a) cutting time, and (b) metal removal rate.

Solution: 66 rev/s fr = Nf = 6.366(.3) = 1.17 mm/s Tm = L/fr = 700/1.17 = 598 s = 9.96 min Alternative calculation using Eq. (22.5), Tm = 200(700)/(2,300 x 0.32) = 597.6 sec = 9.96 min (b) RMR = vfd = (2.30 m/s)(103)(0.32 mm)(1.80 mm) = 1320 mm3/s

2. (22.6) (10 pts) A cylindrical work bar with 4.5 in diameter and 52 in length is chucked in an engine lathe and supported at the opposite end using a live center. A 46.0 in portion of the length is to be turned to a diameter of 4.25 in one pass at a speed of 450 ft/min. The metal removal rate should be 6.75 in3/min. Determine (a) the required depth of cut, (b) the required feed, and (c) the cutting time. Solution: (a) depth d = (4.50 - 4.25)/2 = 0.125 in (b) RMR = vfd; f = RMR/(12vd) = 6.75/(12 x 450 x 0.125) = 0.010 in f = 0.010 in/rev (c) N = v/D = 450 x 12/4.5 = 382 rev/min fr = 382(0.010) = 3.82 in/min Tm = 46/3.82 = 12.04 min
3. (22.7) (15 points) A 4.00-in-diameter workpiece that is 25 in long is to be turned down to a diameter of 3.50 in, using two passes on an engine lathe using a cutting speed = 300 ft/min, feed = 0.015 in/rev, and depth of cut = 0.125 in. The bar will be held in a chuck and supported on the opposite end in a live center. With this workholding setup, one end must be turned to diameter; then the bar must be reversed to turn the other end. Using an overhead crane available at the lathe, the time required to load and unload the bar is 5.0 minutes, and the time to reverse the bar is 3.0 minutes. For each turning cut an allowance must be added to the cut length for approach and overtravel. The total allowance (approach plus overtravel) = 0.50 in. Determine the total cycle time to complete this turning operation. Using 15 in at one end first, then reverse bar to do the remaining 10 in. Solution: First end: cut 15 in of 25 in length.

N = 300 x 12/4 = 286.4 rev/min, fr = 286.4(0.015) = 4.297 in/min Tm = (15 + 0.5)/4.297 = 3.61 min; this reduces diameter to 3.75 in N = 300 x 12/3.75 = 305.5 rev/min, fr = 305.5(0.015) = 4.583 in/min Tm = 15.5/4.583 = 3.38 min to reduce the diameter to 3.50 in Reverse bar, which takes 3.0 min and cut remaining 10 in of 25 in length. N = 300 x 12/4 = 286.4 rev/min, fr = 286.4(0.015) = 4.297 in/min Tm = (10 + 0.5)/4.297 = 2.44 min; this reduces diameter to 3.75 in N = 300 x 12/3.75 = 305.5 rev/min, fr = 305.5(0.015) = 4.583 in/min Tm = 10.5/4.583 = 2.29 min to reduce the diameter to 3.50 in Loading and unloading bar takes 5.0 min. Total cycle time = 5.0 + 3.61 + 3.38 + 3.0 + 2.44 + 2.29 = 19.72 min 4. (22.15) (10 points)A face milling operation is used to machine 6.0 mm from the top surface of a rectangular piece of aluminum 300 mm long by 125 mm wide in a single pass. The cutter follows a path that is centered over the workpiece. It has four teeth and is 150 mm in diameter. Cutting speed = 2.8 m/s, and chip load = 0.27 mm/tooth. Determine (a) the actual machining time to make the pass across the surface and (b) the maximum metal removal rate during cutting. Solution: (a) N = v/D = (2800 mm/s)/150 = 5.94 rev/s fr = Nntf = 5.94(4)(0.27) = 6.42 mm/s
A 0.5 D D 2 w2

= 0.5150

1502 1252

= 0.5(150 82.9) = 33.5 mm

Tm = (L + A)/fr = (300 + 33.5))/6.42 = 52 s = 0.87 min (b) RMR = wdfr = 125(6)(6.42) = 4813 mm3/s

5. (22.16) (10 pts) A slab milling operation is performed on the top surface of a steel rectangular workpiece 12.0 in long by 2.5 in wide. The helical milling cutter, which has a 3.0 in diameter and ten teeth, is set up to overhang the width of the part on both sides. Cutting speed is 125 ft/min, feed is 0.006 in/tooth, and depth of cut = 0.300 in. Determine (a) the actual machining time to make one pass across the surface and (b) the maximum metal removal rate during the cut. (c) If an additional approach distance of 0.5 in is provided at the beginning of the pass (before cutting begins), and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0.5 in, what is the duration of the feed motion. Solution: (a) N= v/D = 125(12)/3 = 159.15 rev/min fr = Nntf = 159.15(10)(0.006) = 9.55 in/min A = (d(D-d))0.5 = (0.30(3.0-0.30))0.5 = 0.90 in Tm = (L + A)/fr = (12.0 + 0.9)/9.55 = 1.35 min (b) RMR = wdfr = 2.5(0.30)(9.55) = 7.16 in3/min

(c) The cutter travels 0.5 in before making contact with the work. It moves 0.90 in before reaching full depth of cut. It then feeds the length of the work (12.0 in). The overtravel consists of the cutter radius (1.5 in) plus an additional 0.5 in. Thus, Tf = (0.5 + 0.9 + 12.0 + 1.5 + 0.5)/9.55 = 1.56 min
6. (22.17) (10 points) A face milling operation is performed on the top surface of a steel rectangular workpiece 12.0 in long by 2.5 in wide. The milling cutter follows a path that is centered over the workpiece. It has five teeth and a 3.0 in diameter. Cutting speed = 250 ft/min, feed = 0.006 in/tooth, and depth of cut = 0.150 in. Determine (a) the actual cutting time to make one pass across the surface and (b) the maximum metal removal rate during the cut. (c) If an additional approach distance of 0.5 in is provided at the beginning of the pass (before cutting begins), and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0.5 in, what is the duration of the feed motion. Solution: (a) N = v/D = 250(12)/3 = 318.3 rev/min fr = 318.3(5)(0.006) = 9.55 in/min
A 0.5 D D 2 w2

= 0.53

32 2.52 0.671 in

Tm = (12.0 + 0.671)/9.55 = 1.33 min (b) RMR = 2.5(0.150)(9.55) = 3.58 in3/min (c) The cutter travels 0.5 in before making contact with the work. It moves 1.50 in before its center is aligned with the starting edge of the 12.0 in workpiece. It then feeds the length of the work (12.0 in). The overtravel consists of the cutter radius (1.5 in) plus an additional 0.5 in. Thus, Tf = (0.5 + 1.5 + 12.0 + 1.5 + 0.5)/9.55 = 1.68 min

7. (23.3) (15 points) A series of turning tests were conducted using a cemented carbide tool, and flank wear data were collected. The feed was 0.010 in/rev and the depth was 0.125 in. At a speed of 350 ft/min, flank wear = 0.005 in at 1 min, 0.008 in at 5 min, 0.012 in at 11 min, 0.0.015 in at 15 min, 0.021 in at 20 min, and 0.040 in at 25 min. At a speed of 450 ft/min, flank wear = 0.007 in at 1 min, 0.017 in at 5 min, 0.027 in at 9 min, 0.033 in at 11 min, and 0.040 in at 13 min. The last value in each case is when final tool failure occurred. (a) On a single piece of linear graph paper, plot flank wear as a function of time. Using 0.020 in of flank wear as the criterion of tool failure, determine the tool lives for the two cutting speeds. (b) On a piece of natural log-log paper, plot your results determined in the previous part. From the plot, determine the values of n and C in the Taylor Tool Life Equation. (c) As a comparison, calculate the values of n and C in the Taylor equation solving simultaneous equations. Are the resulting n and C values the same? Solution: (a)

Flank Wear vs Time

0.035 0.030 0.025 0.020 0.015 0.010 0.005 0.000 0 5 10 15 Time (min)

Flank v = 350 ft/min Flank v = 450 ft/min

20

25

30

Using the graph, at 450 ft/min the tool last about 6.2 min; at 350 ft/min, it lasts 19.0 min. (b) The points are graphed in Excel and the line connecting the two points is extended to the axis.

Taylor Tool Life

Cutting Speed (ft/min)

100

10 1 10 Tool Life (min) 100

C is read from the Y-intercept and is approximately 680 ft/min. The slope, n, can be determined by taking the ln of the x and y coordinates of any 2 points and determining Y/X. It is positive because the Taylor tool life equation is derived assuming the slope is negative. Using the points (1,680) and (19,350) the slope is about 0.226.

(c) Depending on the values of tool life read from the flank wear graph, the values of n and C will vary. Two equations: (1) 350(19.0)n = C, and (2) 450(6.2)n = C (1) and (2) 350(19.0)n = 450(6.2)n ln 350 + n ln 19.0 = ln 450 + n ln 6.2 5.8579 + 2.9444 n = 6.1092 + 1.8245 n 1.1199 n = 0.2513 n = 0.224 (1) C = 350(19.0)0.224 = 677 (2) C = 450(6.2)0.224 = 677 C = 677

8. (23.5) (10 points) Tool life tests on a lathe have resulted in the following data: (1) at a cutting speed of 375 ft/min, the tool life was 5.5 min; (2) at a cutting speed of 275 ft/min, the tool life was 53 min. (a) Determine the parameters n and C in the Taylor tool life equation. (b) Based on the n and C values, what is the likely tool material used in this operation? (table 23.2) (c) Using your equation, compute the tool life that corresponds to a cutting speed of 300 ft/min. (d) Compute the cutting speed that corresponds to a tool life T = 10 min. Solution: (a) VTn = C; Two equations: (1) 375(5.5)n = C and (2) 275(53)n = C 375(5.5)n = 275(53)n 375/275 = (53/5.5)n 1.364 = (9.636)n ln 1.364 = n ln 9.636 0.3102 = 2.2655 n n = 0.137 C = 375(5.5)0.137 = 375(1.2629) C = 474 0.137 Check: C = 275(53) = 275(1.7221) = 474 (b) Comparing these values of n and C with those in Table 23.2, the likely tool material is high speed steel. (c) At v = 300 ft/min, T = (C/v)1/n = (474/300)1/0.137 = (1.579)7.305 = 28.1 min (d) For T = 10 min, v = C/Tn = 474/100.137 = 474/1.371 = 346 ft/min 9. (23.21) (10 points) The outside diameter of a cylinder made of a steel alloy is to be turned. The starting diameter is 300 mm and the length is 625 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 three of these parts. Solution: In this problem we want 3Tm = T, where Tm = machining time per piece and T = tool life. Both of these times must be expressed in terms of cutting speed. Tm = DL/fv and T = (C/v)1/n Tm = (300)(625)(10-6)/0.35(10-3)v = 1683/v = 1683 (v)-1 3Tm = 3(1683 (v)-1) = 5049(v)-1 T = (450/v)1/.24 = (450/v)4.1667 = 4504.1667(v)-4.1667 = 1135(108)(v)-4.1667 Setting 3Tm = T: 5049v-1 = 1135(108)(v)-4.1667 v3.1667 = 0.2248(108) v = {0.2248(108)}1/3.1667 = {0.2248(108)}0.3158 = 209.747 m/min Check: 3Tm = 5049 (209.747)-1 = 24.07 min T = (450/209.747)1/.24 = (450/209.747)4.1667 = 24.06 min (close enough)