PART B: TECHNOLOGY DESIGN PROBLEM

I.) Consider the following component to be machined in a slab milling machine. The
machining has to be done only on the three surfaces marked. Other surfaces are left as cast.
Assume that an allowance of Imm on the machined surfaces to be removed in single pass
on each side. The slab milling cutter of 70mm diameter and 160mm long with 8 teeth is
used. The maximum allowed cutting speed is 20m/min. The maximum feed per tooth is
O.lmm. The specific power, mechanical efficiency and correction factor can be assumed as
1.3 Ws/mm" 75 % and 1.15. Neglect the cutting allowance. You can neglect the
machining stock for calculation. (20 Marks)
Find out the following:
a) The maximum rpm ofthe cutter
b) The maximum possible width ofthe cut at any time, in mm
c) The maximum feed per minute in mmlmin
d) The total cutting time to machine the three faces in min
e) The maximum possible MRR in mm
3
/min
t) The actual MRR with no allowance in mm
3
/min
g) The maximum motor power required in Watts
h) The total machining cost( Assume $2751hr) in $
P
specijicpower * MRR * CF
ower =
77

2 marks
2 marks
2 marks
3 marks
3 marks
3 marks
3 marks
2 marks
100mm
L-__________ -' --]5 150mm
I. 200mm I
7
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fM ::t2.1''3
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:::::: c::l-[ + i2oo 'SOJX1 + 200./00-1
= dl. [ + 5;oooJ + 2ooCC'
:=. ";fo 000 '(Y\ IV\ S
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div,'o\e 60
= 2'1- X g'2S- :::: 6p<t? jt
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