Exercise Problems

Pb.: A large batch of steel shafts are to be rough turned to 76

mm diameter for 300 mm length at a feed of 0.25 mm/rev.
A solid HSS type tool is to be used and appropriate
Economics of Machining

constant in Taylor’s tool life equation for the conditions

employed are as follows: n = 0.25; measured tool life at
the cutting speed of 245 m/min is 60 sec. The initial cost
of the machine was Rs. 1,50,000/- and is to be amortized
in 5 years. The operator’s wages are Rs. 20/hour and the
operator and machine overheads are 100%. Tool changing
and resetting time on the machine is 300 sec and the cost
of regrinding the tool is Rs.10/-. The initial cost of the tool
is Rs.50/- and it can be ground 10 times. Non productive
time for each component is 120 sec. Obtain optimum
speed for minimum cost of production and hence obtain
the tool life; rate of production and the cost of producing
the component. 1
 Exercise Problems
Pb.: A 200 mm long and 300 mm diameter bar is
turned on a lathe with feed = 0.25 mm/rev.
Economics of Machining

The operating cost is 5 paise/min while the

tool cost is Rs. 1/edge. Tool changing time is
1 min. The requirements are such that either
of the two tool materials X or Y can be used.
Compare the machining cost per component
whilst operating under most economical
conditions for the two materials.
Material ‘X’  VT0.1 = 67
Material ‘Y’  VT0.1 = 90
2
 Exercise Problems
Pb.: A 100 mm long 35 mm diameter bar is to be
turned at a feed of 0.26 mm/rev. The
Economics of Machining

operating cost is Rs. 10/min. and the tool

cost is Rs. 75/edge. The tool changing time
is 4 min. A carbide tool is used with two
cutting fluids for which the tool life
equations are given below:
Cutting fluid ‘X’  VT0.22 = 67
Cutting fluid ‘Y’  VT0.32 = 67

3
 Exercise Problems
A tool used in a turning operation is of the brazed
carbide tip type. Its cost is Rs. 450/- and on the average,
it can be reground 10 times. The cost of regrinding is
Economics of Machining

Rs. 45/-. The lathe cost is Rs.2 lakhs, used 8 hrs/day, 5

days/week and 50 weeks/year. Its cost is to be amortized
over 10 years. The machine overheads are 100%. The
operator’s wages are Rs. 20/hr. and the operator’s
overheads are 100%. Tool life equation is VT0.25 = 7,
where V is in m/sec and T is the tool life in sec. the tool
changing time is 4 min, and the handling time per
component is 5 min. The workpiece with 50 mm
diameter and 400 mm length is machined at the rate of
0.25 mm/rev. Calculate minimum production cost and
hence obtain minimum production time.
4
 Exercise Problems
Pb.: A 200 mm long and 65 mm diameter bar is to be
turned at a feed of 0.15 mm/rev. The operating
cost is Rs. 0.50/min. and the tool cost is Rs.
Economics of Machining

10/edge. The tool changing time is 2 min. Assume

weight of workpiece as 0.14 kg. The following two
workpiece materials have been used.:
Material ‘X’ (cost Rs.100/kg)  VT0.10 = 67
Material ‘Y’ (cost Rs.120/kg)  VT0.16 = 90
Calculate tool life and optimum cutting velocities
for min. cost with no consideration for material
cost; and maximum production rate criteria for
both the w/p materials. State which material
should be chosen for total minimum cost.
5
 Exercise Problems
Pb.: A tool used in a turning operation is of brazed
type. Cost of the tool is Rs. 100 and on average, it
Economics of Machining

can be reground 10 times. The cost of each

regrinding is Rs.5/-. The lathe cost is to be
amortized over 10 years and the machine
overheads are 100%. The lathe cost is Rs.2,00,000
and is used 8 hrs/day, 5 days/week and 50
weeks/yr. The tool life relationship is VT0.25 = 400.
Tool changing time is 4 min, handling time per
component is 5 min, cutting distance per
component is 200 m. Calculate minimum
production cost and time.

6
 Exercise Problems
Pb.: Illustrate in a sketch graph the economic factors
involved in metal cutting and show that cutting
Economics of Machining

speed has an optimum value.

When finish turning a 50 mm diameter, 130 mm
long bore in a high-tensile steel at a feed of 0.13
mm/rev. The tool life equation was VT0.12 = 146.
The cost of regrinding the tool was Rs. 8 and the
tool changing time was 10 min. If the inclusive
cost of operating the machine is Rs. 13.5/hr,
determine (a) the economic machining time per
component, (b) the number of components to be
produced between tool changes.
7
 Exercise Problems
Pb.:An automatic lathe is to be used to machine brass
components 75 mm long X 50 mm diameter using a
Economics of Machining

depth of cut 1.25 mm. Select the speed that

minimizes the machining cost and calculate the
corresponding tool life. Also estimate the cutting
speed for minimum tool life of production. Assume:
Labor + overhead rate Cm = Rs. 5/hr.
Reconditioning cost of the tool edge = Rs 0.25/edge
Loading and unloading time of the work = 15 Sec.
Tool change time = 5 min.
Tool life relationship: VT0.25 = 300
8
 Exercise Problems
Pb.: A 1.0 m long cut is to be given on a 100 mm
diameter steel bars on an engine lathe. The depth of
Economics of Machining

cut is 6 mm and the feed rate is 0.5 mm/rev. the

following cost data are available for this operation:
machine labor: Rs.20/hr; machine burden rate:
400% of labor; tool cost: Rs. 180; tool changing
time: 2 min.; regrinds available: 5/tool; grinding
time: 6 min/edge; tool grinding labor: Rs.30/hr;
tool grinding burden: 500% of labor; loading time:
5 min/component; Tool life equation: VT0.25 = 200.
Obtain optimum speed for minimum cost of
production and hence obtain the tool life, rate of
production and the cost producing a component.
9
 Exercise Problems
Pb.: A 200mm long and 30 mm diameter bar is to
be turned on a lathe with a feed rate of 0.25
Economics of Machining

mm/rev. The rpm is 200. The operating cost is

5 paise/min while the tool cost is Rs. 1/edge.
The design provisions indicate that either of
the following two materials may be used.
State which material should be chosen for
minimum cost.
Material cost/kg tool life eqn.
X Rs. 2.00 VT0.10 = 67
Y Rs. 3.00 VT0.16 = 90
10
 Exercise Problems
Pb.: A 600 mm long cut is to be made on a 150 mm dia
bar on a lathe with a depth of cut of 1.5 mm and
feed of 0.25 mm/rev. The tool life equation is VT0.25
Economics of Machining

= 475. For the above operation, two types of tools

may be used: (i) brazed tool and (ii) throw away
carbide inserts. The following cost data have been
collected:
(a) Machine costs: machining cost = Rs 1/hr;
machine overhead = 100%; grinding cost =
Rs.1.5/hr; grinding machine overhead = 200%;
idle time = 5 min.

Contd….
11