ME477 Fall 2004

Kwon 1
1
Economics and Product
Design Considerations
1. Machinability
2. Tolerance and Surface Finish
3. Selection of Cutting Conditions
4. Product Design Considerations
2
1. Machinability
Machinability A measure of the relative ease of a
machining operation usually on a work material and type
of machining operation, tooling, and cutting conditions.
Longer tool life means better machinability
Greater forces and power mean lower machinability
Better surface finish means better machinability
Easier chip disposal means better machinability
Higher MRR means better machinability
Mechanical properties and Machinability
High hardness of work materials means abrasive wear resistance
High strength of work materials means cutting forces, specific
energy, and cutting temperature increase
High ductility of work materials means tearing of metal as chip is
formed, causing chip disposal problems and poor surface finish
3
1.25 (Hard) Aluminum
2.00 (soft) Aluminum
0.2 220-280 Ti Alloys
0.40-0.70 60-230 Cast Iron
0.25-1.5 170-230 Alloy Steels
0.55 180-230 High Carbon Steels
0.65 140-210 Med. Carbon Steels
0.50 130-170 Low Carbon Steels
1.00 180-220 Base Steel: B1112
Machinability Rating Brinnell Hardness Work Materials
MR of base material =1.00 (100%)
MR of test material >1.00 (100%) means better machinability
4
Shape
Shape
Rotational parts turning and boring
Internal rotational features - drilling
Non-rotational parts milling
Dependency on the geometry of a tool
Generating Multi-axis milling machine
Forming form turning, drilling and broaching
Generating/Forming (threading)
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2. Tolerances & Surface Finish
Tolerances
Machining provides high accuracy relative to most other processes
Closer tolerances usually mean higher costs
Surface roughness in machining is determined by:
Work material factors
Geometric factors of the operation
Vibration and machine tool factors
Work Material Factors
Built-up edge effects
Damage to surface caused by chip
Tearing of surface for ductile materials
Cracks in surface for brittle materials
Friction between tool flank and new surface
6
Tolerance and Surface finish
Geometric factor
Types of Operations
Cutting tool geometry
Surface roughness,
where NR=nose radius
and because it depends
on work material and cutting speed
Other expressions of roughness
Nose Radius, Feed and End Cutting Edge Angle
NR
f
R
i
32
2
=
Cutting speed
R
a
t
i
o
,

r
a
i
Ductile metals
Cast iron
Machining alloys
i ai a
R r R =
1
1.2
1.8
Zero End Cutting Edge Angle
Small feed
Zero Nose Radius
ME477 Fall 2004
Kwon 2
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T
y
p
i
c
a
l

T
o
l
e
r
a
n
c
e
S
u
r
f
a
c
e

F
i
n
i
s
h
6.0m 0.5 Sawing
1.6m 0.075 Planing
1.6m 0.025 Slotting Shaping
0.05 End
0.025 Face
0.4m 0.025 Peripheral Milling
0.05 Broaching
0.075 D>25mm
0.05 12mm<D<25mm
0.4m 0.025 D<12mm Reaming
0.20 D>25mm
0.125 12mm<D<25mm
0.1 6mm<D<12mm
0.075 2.5mm<D<6mm
0.8m 0.05 D<2.5mm Drilling
0.075 D>50mm
0.05 25mm<D<50mm
0.8m 0.025 D<25mm Turning
Surface Finish
(Typical best)
Tolerance
(Typical)
Machining Operations
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Chatter (Vibration)
Vibration and Chatter
Related to machine tool, tooling, and setup:
Chatter (vibration) in machine tool or cutting tool
Deflections of fixtures
Backlash in feed mechanism
Without chatter, surface roughness is determined by
geometric and work material factors
How to avoid Chatter
Add stiffness and/or damping to setup
Operate at speeds that avoid natural frequency of
machine tool system
Reduce feeds and depths to reduce forces
Change cutter design to reduce forces
Use a cutting fluid
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3. Selection of Cutting Conditions
One of the tasks in process planning
For each operation, decisions on machine tool, cutting
tool(s), and cutting conditions based on workpart
machinability, part geometry, surface finish, and so forth
Cutting Tool Manufacturers Recommendation
Cutting conditions: speed, feed, depth of cut, and cutting
fluid
Depth of cut predetermined by workpiece geometry and
operation sequence.
In roughing, high depth to maximize material removal rate, but
limited by horsepower, machine tool and rigidity, and strength of
cutting tool.
In finishing, depth to achieve final part dimensions
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Selecting Feed and Speed
Feed: In general: feed first, speed second
Tooling Harder tool materials require lower feeds
Roughing or finishing - Roughing means high feeds, finishing
means low feeds
Constraints on feed in roughing: cutting forces, setup rigidity,
and sometimes horsepower
Surface finish requirements in finishing Select feed to produce
desired finish
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:
1. Maximum production rate
2. Minimum unit cost
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Maximum Production Rate
Maximizing production rate =minimizing cutting
time per unit
In turning, total production cycle time for one part
consists of:
Part handling time per part =T
h
Machining time per part = T
m
,
For a simple turning,
Tool change time per part =T
t
/n
p
,where n
p
=number
of pieces cut in one tool life where
and, from Taylors model, tool life is
( ) ) 1 /( 1
/ 1

= =
n
n
m
p
DLv
fC
T
T
n

vf
DL
T
m

=
n n
v C T
/ 1 / 1
=
12
Maximum Production Rate
Cutting speed
T
i
m
e

p
e
r

w
o
r
k
p
a
r
t
Total time per piece
Tool change time
Part Handling Time
Cutting time
( )
( )
t
n
t
c
n
n
t
h
p
t
m h c
T
n
T
T
n
C
v
dv
dT
fC
DLv T
fv
DL
T
n
T
T T T

= =
+ + =
+ + =

1
1
1
1
0
max
max
/ 1
1 / 1

The tool life:
v
max
ME477 Fall 2004
Kwon 3
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Example
Workpart: L=300mmand D=80mm.
Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min)
Machining condition: f=0.4mm/rev.
Operator and machine cost=$30/hr
Tooling cost/edge=$4
2min to load and unload and 3.5min to change tools
(a) Cutting speed for max. production rate
(b) Tool life in min. for max. production rate
(c) Cycle time and cost per unit of product for max. production rate
(a) C
o
=$30/hr=$.50/min
v
max
=75/[(1/.13-1)(3.5)]
.13
=49.8m/min
(b) T
max
=(75/49.8)
1/.13
=23.42min
(c) T
m
=DL/fv=(8)(300)/(.4x49.8x10
3
)=3.787min
n
p
=23.42/3.787~6pc/tool life
T
c
=T
h
+T
m
+T
t
/n
p
=2+3.787+3.5/6=6.37min/pc
C
c
=C
o
T
c
+Tool cost per edge/n
p
=0.5(6.37)+4/6=$3.85/pc
n
t
T
n
C
v

=
1
1
max
t
T
n
T

= 1
1
max
vf
DL
T
m

=
m
p
T
T
n =
p
t
m h c
n
T
T T T + + =
14
Minimum Cost Per Part
Cost of part handling
Cost of machine time
Cost of tool change
Tooling cost
g g
g
t
t
e
t
t
C T
n
P
C
n
P
C
+ =
=
h o
T C
m o
T C
p t o
n T C
p t
n C
( )
n
n
t t o
o
h o
p
t
p
t o
m o h o c
fC
DLv C T C
fv
DL C
T C
n
C
n
T C
T C T C C
1
1
1

+
+ + =
+ + + =

= =
o
t t o
n
t t o
o c
C
C T C
n
T
C T C
C
n
n
C v
dv
dC
1
1
1
0
min
min
inserts disposable for
inserts e regrindabl for
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Example
Workpart: L=300mmand D=80mm.
Taylors Eq. for a HSS tool: n=0.13 and C=75(m/min)
Machining condition: f=0.4mm/rev.
Operator and machine cost=$30/hr
Tooling cost/edge=$4
2min to load and unload and 3.5min to change tools
(a) Cutting speed for min. cost
(b) Tool life in min. for min. cost
(c) Cycle time and cost per unit of product for min. cost
(a) C
o
=$30/hr=$.50/min
v
min
=75/[0.5(1/.13-1)(0.5x3.5+4)]
.13
=42.6m/min
(b) T
min
=(75/42.6)
1/.13
=76.96min
(c) T
m
=DL/fv=(8)(300)/(.4x42.6x10
3
)=4.42min
n
p
=76.96/4.42~17pc/tool life
T
c
=T
h
+T
m
+T
t
/n
p
=2+4.42+3.5/17=6.63min/pc
C
c
=0.5(6.63)+4/17=$3.55/pc

=
o
t t o
n
t t o
o
C
C T C
n
T
C T C
C
n
n
C v
1
1
1
min
min
16
Comments
As C and n increase in Taylors equation,
optimum cutting speed should be reduced
Cemented carbides & ceramic tools at higher speeds.
v
max
is always greater than v
min
.
Reason: C
t
/n
p
term in unit cost equation pushes
optimum speed to left in the plot of C
c
vs. v.
Cutting speed should be reduced as tool change
time T
t
and/or tooling cost C
t
increase,
Tools should not be changed too often if either tool
cost or tool change time is high.
An advantage of disposable inserts over regrindable
tools due to the lower tool change time.
17
Product Design Guidelines I
Design parts to minimize machining
by using net shape (precision casting, closed die forging, or
plastic molding) or near net shape processes (impression die
forging)
Essential Reasons for machining
Close tolerances
Good surface finish
Flexibility
Special features such as threads, precision holes, cylindrical
sections with high degree of roundness
Specify Tolerances to satisfy functional requirements
and process capabilities (unnecessary cost from additional
processing, fixturing, inspection, sortation, rework, and scrap)
Specify surface finish to meet functional and/or
aesthetic requirements (add processing cost by requiring
additional operations such as grinding or lapping)
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Product Design Guidelines II
Avoid features such as sharp corners, edges, and points
They are difficult to machine
Sharp cutting tools tend to break and create burrs
Machined parts from standard stock sizes
Machining with standard cutting tools
Avoid special form tools
Minimize the number of individual cutting tools used
Select materials with good machinability
Materials with low machinabilitytake longer and cost more.
Minimize the number of setups