TM20 - Economic and Product Design Considerations in Machining PDF

ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING
1. Machinability
2. Tolerances and Surface Finish
3. Selection of Cutting Conditions
4. Product Design Considerations in Machining
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability
 Capability of a material to be easily machined using

appropriate tooling and cutting conditions
 Depends on
 work material
 type of machining operation,
 tooling
 cutting conditions
Machinability Criteria in
Production
Quantification by means of:

 Tool life – longer tool life for the given work material
means better machinability
 Forces and power – lower forces and power mean
better machinability
 Surface finish – better finish means better
machinability
 Ease of chip disposal – easier chip disposal means
better machinability
Machinability Rating
Machinability is expressed as a machinability rating

(MR):
 MR of base material (AISI 1112) = 1.00 (100%)

 MR of test material > 1.00 (100%) means better
machinability
Machinability Rating
AISI 1112 1.00

Medium Carbon steel 0.65
Stainless steel 0.35
Inconel 0.30
Aluminum alloy 2.00
MACHINING
1. Machinability
Tolerances and Surface Finish
 Tolerances
 Machining can provide high accuracy, but
 Closer tolerances usually mean higher costs
 Surface roughness
 Machining can provide surface finish, but
 Low roughness usually mean higher costs
Surface Finish
 Surface roughness in machining is determined by:
1. Geometric factors of the operation
2. Work material factors
3. Vibration and machine tool factors
Geometric Factors
 Machining parameters that determine surface

geometry:
 Nose radius (NR)
 Feed f
 End cutting edge angle
Geometric Factors Affecting
Surface Finish
 Effect of (a) nose radius, (b) feed, and (c) ECEA
Ideal Surface Roughness
Ri = f2
32NR
where Ri = theoretical
arithmetic average
surface roughness; f =
feed; and NR = nose
radius
Ideal Surface Roughness
Work Material Factors
Other factors increasing surface roughness:

 Built-up edge effects
 Damage to surface caused by chip
 Tearing of surface when machining ductile materials
 Cracks in surface when machining brittle materials
 Friction between tool flank and new work surface
They mainly depend on cutting speed
Actual Surface Roughness
Ra = rai x Ri
Evaluation of the ratio of

actual to theoretical
roughness according to:
 Workpiece material
 Cutting speed
Vibration and Machine Tool
Factors
 Chatter (vibration) in machine tool or cutting tool
 Deflections of fixtures
 Backlash in feed mechanism (old machine tools)
These factors can be reduced, then surface roughness

is determined by geometric and work material factors
MACHINING
1. Machinability
Selection of Cutting Conditions
In the following order:
1. Depth of cut
2. Feed
3. Cutting speed
Selecting Depth of Cut
 Depth of cut is often predetermined by workpiece

geometry and operation sequence
 In roughing, depth is made as large as possible
to maximize material removal rate, subject to
limitations of horsepower, machine tool and setup
rigidity, and strength of cutting tool
 In finishing, depth is set to achieve final part
dimensions and surface finish
Determining Feed
Determining feed rate depends on:
 Tooling – harder tool materials require lower

feeds
 Roughing / finishing
 In roughing, 0.5 – 1.25 mm/rev
 In finishing, 0.125 – 0.4 mm/rev
Determining Feed
Determining feed rate depends on:
 Constraints in roughing: limits on feed are

imposed by forces, setup rigidity and horsepower
 Surface roughness in finishing: select feed to

achieve desired finish
Optimizing Cutting Speed
 Select cutting speed to achieve a balance between

high metal removal rate and suitably long tool
life
 Mathematical formulas available to determine
optimal speed
 Two alternative objectives in these formulas:
 Maximum production rate
 Minimum unit cost
Maximum Production Rate
 Maximizing production rate is equivalent to

minimizing cutting time per unit
 In turning, total production cycle time for one part
consists of:
1. Part handling time per part = Th
2. Machining time per part = Tm
3. Tool change time per part = Tt / np, where np =
number of pieces cut in one tool life
Cycle Time vs. Cutting Speed
Minimizing Cost per Unit
 In turning, total production cycle cost for one part

consists of:
1. Cost of part handling time = CoTh , where Co =
cost rate for operator and machine
2. Cost of machining time = CoTm
3. Cost of tool change time = CoTt/np
4. Tooling cost = Ct/np , where Ct = cost per cutting
edge
Unit Cost vs. Cutting Speed
MACHINING
1. Machinability
Product Design
Design for Manufacturing (DFM)
Product Design Guidelines
 Select materials with good machinability

 parts made of materials with low machinability
take longer and cost more to produce
 Tolerances should be specified to satisfy functional

requirements, but process capabilities should also be
considered
 Very close tolerances add cost but may not add
value to part
 Costs generally increase due to additional
processing, fixturing, inspection, etc.
 Surface finish should be specified to meet functional

and/or aesthetic requirements
 However, better surface finish generally
increases processing cost by requiring additional
operations such as grinding or lapping
Design rule:
Machined features
such as sharp
corners, edges,
and points should
be avoided
Design rule:
Machined parts
should be
designed with
features that can
be achieved with
standard cutting
tools
Design rule:
 Design parts that need no machining
 Use net shape processes such as precision
casting, closed die forging, or plastic molding
Design rule:
 Avoid undercuts as
in (a)
 Additional setups,
operations, and
often special tooling
are required for
undercuts as in (b)
Design rule:
 Design parts with features that can be produced in a

minimum number of setups

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ECONOMIC AND PRODUCT

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

 Capability of a material to be easily machined using

Quantification by means of:

Machinability is expressed as a machinability rating

 MR of base material (AISI 1112) = 1.00 (100%)

AISI 1112 1.00

Aluminum alloy 2.00

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

 Surface roughness in machining is determined by:

1. Geometric factors of the operation

2. Work material factors

3. Vibration and machine tool factors

 Machining parameters that determine surface

Other factors increasing surface roughness:

They mainly depend on cutting speed

Evaluation of the ratio of

 Chatter (vibration) in machine tool or cutting tool

 Backlash in feed mechanism (old machine tools)

These factors can be reduced, then surface roughness

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

In the following order:

 Depth of cut is often predetermined by workpiece

Determining feed rate depends on:

 Tooling – harder tool materials require lower

Determining feed rate depends on:

 Constraints in roughing: limits on feed are

 Surface roughness in finishing: select feed to

 Select cutting speed to achieve a balance between

 Maximizing production rate is equivalent to

 In turning, total production cycle cost for one part

2. Tolerances and Surface Finish

3. Selection of Cutting Conditions

4. Product Design Considerations in Machining

Design for Manufacturing (DFM)

 Select materials with good machinability

 Tolerances should be specified to satisfy functional

 Surface finish should be specified to meet functional

 Design parts with features that can be produced in a

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