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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)π/(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/πD = 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.

5 in. (c) If an additional approach distance of 0.9) = 33. Solution: (a) N= v/πD = 125(12)/3 = 159.0 in diameter and ten teeth.5 in is provided at the beginning of the pass (before cutting begins).5 rev/min.29 min to reduce the diameter to 3.5(150 – 82.0 + 0.0 in long by 2. what is the duration of the feed motion.5 D  D 2  w2   = 0. this reduces diameter to 3. fr = 305.27 mm/tooth. (22.30))0.5 = (0.015) = 4.5 in wide.94(4)(0.N = 300 x 12/4 = 286.583 = 2.16 in3/min .4 rev/min.55) = 7. Determine (a) the actual machining time to make one pass across the surface and (b) the maximum metal removal rate during the cut.5(0. Cutting speed = 2.38 min to reduce the diameter to 3. The helical milling cutter. is set up to overhang the width of the part on both sides. this reduces diameter to 3. The cutter follows a path that is centered over the workpiece.006 in/tooth. and chip load = 0.29 = 19.27) = 6.30(3.297 in/min Tm = (15 + 0. It has four teeth and is 150 mm in diameter. N = 300 x 12/4 = 286.75 = 305.75 = 305.0-0.38 + 3.55 = 1.75 in N = 300 x 12/3.50 in Reverse bar.75 in N = 300 x 12/3.15) (10 points)A face milling operation is used to machine 6.5(0.4 rev/min.015) = 4.5))/6.42) = 4813 mm3/s 5. Cutting speed is 125 ft/min.5 rev/min.006) = 9. fr = 286.61 min.4(0.015) = 4.5/4.0 + 3.0 + 2.0 mm from the top surface of a rectangular piece of aluminum 300 mm long by 125 mm wide in a single pass. Determine (a) the actual machining time to make the pass across the surface and (b) the maximum metal removal rate during cutting.583 in/min Tm = 15. which has a 3.30)(9.44 + 2.42 mm/s A  0.42 = 52 s = 0.4(0.44 min.94 rev/s fr = Nntf = 5.297 = 2.5/4. fr = 286.0 min and cut remaining 10 in of 25 in length.5(0.8 m/s.300 in. and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0. Solution: (a) N = v/πD = (2800 mm/s)/150 = 5.583 = 3.87 min (b) RMR = wdfr = 125(6)(6.50 in Loading and unloading bar takes 5.5150  1502  1252  = 0. Total cycle time = 5.5)/4. (22.55 in/min A = (d(D-d))0.297 = 3.61 + 3.15(10)(0.015) = 4.90 in Tm = (L + A)/fr = (12.583 in/min Tm = 10. fr = 305.9)/9.15 rev/min fr = Nntf = 159.5 mm Tm = (L + A)/fr = (300 + 33.297 in/min Tm = (10 + 0. and depth of cut = 0.5)/4.16) (10 pts) A slab milling operation is performed on the top surface of a steel rectangular workpiece 12.72 min 4. feed is 0.35 min (b) RMR = wdfr = 2. which takes 3.5 = 0.0 min.

Solution: (a) N = v/πD = 250(12)/3 = 318.68 min 7.671 in  Tm = (12.3 rev/min fr = 318. Tf = (0.150 in. The overtravel consists of the cutter radius (1.0 in workpiece. (c) As a comparison.5 in. 0.55 = 1.5 in is provided at the beginning of the pass (before cutting begins).5 in before making contact with the work.5 in) plus an additional 0.17) (10 points) A face milling operation is performed on the top surface of a steel rectangular workpiece 12. determine the tool lives for the two cutting speeds.150)(9.52  0.017 in at 5 min. what is the duration of the feed motion. The milling cutter follows a path that is centered over the workpiece. The feed was 0. It moves 0.020 in of flank wear as the criterion of tool failure. flank wear = 0. The last value in each case is when final tool failure occurred.012 in at 11 min.5 in before making contact with the work.9 + 12. (a) On a single piece of linear graph paper.(c) The cutter travels 0.5 + 0. 0. It has five teeth and a 3.006 in/tooth.3) (15 points) A series of turning tests were conducted using a cemented carbide tool. The overtravel consists of the cutter radius (1.010 in/rev and the depth was 0.0.53  32  2.5 in.5 D  D 2  w2   = 0. plot flank wear as a function of time. Determine (a) the actual cutting time to make one pass across the surface and (b) the maximum metal removal rate during the cut.90 in before reaching full depth of cut. and 0. 0. At a speed of 450 ft/min.5 in wide. plot your results determined in the previous part.55 = 1.0 in). flank wear = 0. (c) If an additional approach distance of 0.5 + 1.006) = 9.5 + 0.5 + 12.005 in at 1 min.5 in) plus an additional 0. feed = 0. and depth of cut = 0. It then feeds the length of the work (12.50 in before its center is aligned with the starting edge of the 12.0 + 1.3(5)(0. Tf = (0.040 in at 25 min. Thus. Thus. 0.125 in.040 in at 13 min.015 in at 15 min. and 0.5 in.58 in3/min (c) The cutter travels 0.33 min (b) RMR = 2.007 in at 1 min.56 min 6. Are the resulting n and C values the same? Solution: (a) .0 + 0.033 in at 11 min. From the plot. determine the values of n and C in the Taylor Tool Life Equation.671)/9.5 + 0.0 in long by 2.027 in at 9 min. (b) On a piece of natural log-log paper. It moves 1. (22.55) = 3. and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0. (23. It then feeds the length of the work (12. calculate the values of n and C in the Taylor equation solving simultaneous equations.5(0.0 + 1.008 in at 5 min. 0. 0.5)/9. At a speed of 350 ft/min. Using 0.021 in at 20 min. and flank wear data were collected. 0.0 in diameter. Cutting speed = 250 ft/min.55 in/min A  0.0 in).55 = 1.5)/9.

The slope.350) the slope is about 0.040 Flank Wear (in) 0. at 450 ft/min the tool last about 6.2 min.0 min. it lasts 19.Flank Wear vs Time 0.020 0. It is positive because the Taylor tool life equation is derived assuming the slope is negative.226. Taylor Tool Life 1000 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. (b) The points are graphed in Excel and the line connecting the two points is extended to the axis.680) and (19.025 0.035 0.010 0. n.015 0. at 350 ft/min. Using the points (1.045 0.005 0. . can be determined by taking the ln of the x and y coordinates of any 2 points and determining ΔY/ΔX.030 0.000 0 5 10 15 Time (min) Flank v = 350 ft/min Flank v = 450 ft/min 20 25 30 Using the graph.

v = C/Tn = 474/100.5 mm. T = (C/v)1/n = (474/300)1/0. The starting diameter is 300 mm and the length is 625 mm.24 and C = 450.2) (c) Using your equation. (d) Compute the cutting speed that corresponds to a tool life T = 10 min.0)n = C.1092 + 1.2)0.1667 = 0.747)-1 = 24. the tool life was 5.224 (1) C = 350(19.137 = 375(1.2629) C = 474 0. and (2) 450(6.0 = ln 450 + n ln 6. the tool life was 53 min.2 5.2655 n n = 0. Both of these times must be expressed in terms of cutting speed.24 = (450/v)4.1 min (d) For T = 10 min. where Tm = machining time per piece and T = tool life.2513 n = 0. the values of n and C will vary.224 = 677 C = 677 8.1667(v)-4.06 min (close enough) .2248(108)}1/3.224 = 677 (2) C = 450(6. (c) At v = 300 ft/min. Compute the cutting speed that will allow the tool life to be just equal to the cutting time for three of these parts.24 = (450/209. compute the tool life that corresponds to a cutting speed of 300 ft/min. The feed is 0.636 0.5 min.636)n ln 1. (2) at a cutting speed of 275 ft/min.21) (10 points) The outside diameter of a cylinder made of a steel alloy is to be turned. Units for the Taylor equation are min for tool life and m/min for cutting speed.0)0.2248(108)}0.579)7. (23.1667 = 1135(108)(v)-4.2)n = C (1) and (2) 350(19.5)n 1.364 = n ln 9. (a) Determine the parameters n and C in the Taylor tool life equation.2)n ln 350 + n ln 19.137 Check: C = 275(53) = 275(1.7221) = 474 (b) Comparing these values of n and C with those in Table 23. Solution: In this problem we want 3Tm = T.2.0)n = 450(6.137 = 474/1. Two equations: (1) 375(5.1667 Setting 3Tm = T: 5049v-1 = 1135(108)(v)-4.747)4.1667 v3.9444 n = 6.35 mm/rev and the depth of cut is 2.3102 = 2.1667 = {0. (23.1667 = 4504.1667 = 24.8245 n 1. (b) Based on the n and C values.5)0. the likely tool material is high speed steel.305 = 28. Tm = DL/fv and T = (C/v)1/n Tm = (300)(625)(10-6)/0.(c) Depending on the values of tool life read from the flank wear graph.3158 = 209. The cut will be made with a cemented carbide cutting tool whose Taylor tool life parameters are: n = 0.07 min T = (450/209.35(10-3)v = 1683/v = 1683 (v)-1 3Tm = 3(1683 (v)-1) = 5049(v)-1 T = (450/v)1/. Solution: (a) VTn = C.371 = 346 ft/min 9.5)n = 275(53)n 375/275 = (53/5.747 m/min Check: 3Tm = 5049 (209. Two equations: (1) 350(19. what is the likely tool material used in this operation? (table 23.1199 n = 0.364 = (9.2248(108) v = {0.5) (10 points) Tool life tests on a lathe have resulted in the following data: (1) at a cutting speed of 375 ft/min.137 C = 375(5.747)1/.8579 + 2.137 = (1.5)n = C and (2) 275(53)n = C 375(5.