ME 531 MACHINING MECHANICS AND

ANALYSIS

CHAPTER 6
ECONOMICS OF METAL
CUTTING OPERATIONS
Economics of Machining
• Production cost and production rate are vitally
important for a manufacturer.
• Increasing production rate means producing more from
the available resources.
• Decreasing production cost means less expenditure for
the same volume of production.
• If the conditions are so selected to maximize the
production rate and minimize the production cost,
his/her profit can be maximized.
• It is however not possible to find a common set of
manufacturing conditions to satisfy this.

2
Economics of Machining
• A common practice is to treat each case separately and
find the corresponding conditions, then to make a
compromise in between.
• Production of a component involves several machining
operations using a variety of machine tools.
• Only one operation to be performed on one machine will
be considered and the conditions leading to min.
production cost and max. production rate (min. prod.
time) will be evaluated.

3
Assumptions
• One operation-one machine, hence manual times
between operations and transportations between
machines are ignored.
• Components are ready at the side of the machine
before operation and to be stacked at the side of the
machine after operation.
• Appropriate tool and cutting fluid have already been
chosen.
• Depth of cut has been selected at maximum value
(limited by the total stock to be removed, chatter
vibrations, cutting force, etc.)

4
Optimization Criteria
• Unit production time: average time taken to produce one
component.
• Unit production cost: total average cost of producing one
component:
▫ As cutting speed and feed rate are increased, both criterias
tend to decrease due to an increase in metal removal rate.
▫ At the same time, they may tend to increase due to
increased frequency of tool changes (increasing tool wear
rate).
▫ Optimum conditions do exist where the measure of the
selected criterion is minimum.
• Profit rate: it is very difficult to attribute revenue to
individual operations and profit rate cannot be expressed as
an explicit function of cutting conditions.
5
Choice of Cutting Conditions
• Effects of depth of cut, feed rate and cutting speed on metal
removal rate are the same.
• Cutting speed has the highest adverse effect on tool life
amongst the cutting conditions.
• Common practice is to select depth of cut at its maximum
value, then choose feed rate as high as possible considering
the limitations such as the available feeds on the machine,
surface finish requirement, force level which the cutting
edge can withstand, etc.
• Cutting speed will be selected as the one to optimize the
selected criterion.

6
 Process parameters optimization: Speed
Model objective:
Given optimum feed, what is the optimum cutting speed

➔ provided upper limits, but not optimum

Need a relation between tool life and cutting speed (other parameters being constant)

Taylor’s model (empirically based): V tn = constant

Process parameters optimization: Speed
One batch of large number, Nb, of identical parts
Replace tool by a new one whenever it is worn

Total non-productive time = Nbtl

tl = time to (load the stock + position the tool + unload the part)
Nb be the total number of parts in the batch.
Total machining time = Nbtm
tm = time to machine the part
Total tool change time = Nttct
tct = time to replace the worn tool with a new one
Nt = total number of tools used to machine the entire batch.
Cost of each tool = Ct
Cost per unit time for machine and operator = M

Nt Nt
Average cost per item: C pr = Mtl + Mtm + M tct + Ct
Nb Nb
Process parameters optimization: Speed
Nt Nt
Average cost per item: C pr = Mtl + Mtm + M tct + Ct
Nb Nb

Nonproductive cost, constant for

the particular operation
Machining Cost
tl = time to (load the stock + position the
tool + unload the part) Let: total length of the tool path = L
M=Cost per unit time for machine and
operator L
tm =
V
L
M = MLV −1
V
Process parameters optimization: Speed
Nt Nt
Average cost per item: C pr = Mtl + Mtm + M tct + Ct
Nb Nb
Nb =Batch (Number) of components

tc = time to replace the worn tool with a new one

Nt = total number tools used to machine the entire batch
Ct =Cost of each tool

Tool Costs

t = tool life ➔
Nt = (Nb tm)/t
➔Nt / Nb = tm / t

Taylor’s model Vtn = C’ ➔ t = C’ 1/n / V1/n = C/V1/n

Process parameters optimization: Speed
N N
Average cost per item: C pr = Mtl + Mtm + M t tct + t Ct
Nb Nb

Taylor’s model
Vtn = C’
t = C’ 1/n / V1/n
= C/V1/n
n Values:
0.125 – HSS
0.25-0.3- Carbides
0.5-0.7 - Ceramics
Process parameters optimization: Speed
Nt Nt
Average cost per item: C pr = Mtl + Mtm + M tct + Ct
Nb Nb
Nb =Batch (Number) of components

tc = time to replace the worn tool with a new one

tm = time to machine the part
Nt = total number tools used to machine the entire batch
Ct =Cost of each tool
Tool Costs

t = tool life ➔ Nt = (Nb tm)/t ➔ Nt / Nb = tm / t

Taylor’s model Vtn = C’ ➔ t = C’ 1/n / V1/n = C/V1/n

L Nt tm L V 1/ n L V (1−n ) / n
tm = = = =
V Nb t V C C
Process parameters optimization: Speed

Nt Nt
Average cost per item: C pr = Mtl + Mtm + M tct + Ct
Nb Nb

L
M = MLV −1
V
Nt L V (1−n ) / n
=
Nb C

L
C pr −1
= Mtl + MLV + ( M tct + Ct ) V (1− n ) / n
C
Process parameters optimization: Speed

L
C pr = Mtl + MLV + ( M tct + Ct ) V (1− n ) / n
−1

C
Optimum speed (to minimize costs)

dC pr −2 L (1 − n) (1− 2 n ) / n
= 0 = − MLV + ( M tct + Ct ) V
dV C n
n
t = C’ 1/n / V1/n = C/V1/n
 MC n 

V *=   Substituting C = C’ 1/n =Vr1/ntr
 ( M tct + Ct ) (1 − n) 

n
 Mtr n 
Vc = vr  
 ( M tct + Ct ) (1 − n) 
Optimum speed (to minimize costs)
 Process parameters optimization: Speed
L
C pr −1
= Mtl + MLV + ( M tct + Ct ) V (1− n ) / n
C  Mtr n 
n

Vc = vr  
 ( M tct + Ct ) (1 − n) 
 Process parameters optimization: Speed
Optimum cutting speed giving maximum production rate (or minimum
production time)
Nt Nt
C pr = Mtl + Mtm + M tct + Ct
Nb Nb
Nt
Average time to produce part: t pr = tl + t m + tct
Nb
load/unload time
tool change time
machining time
Nt
t pr = tl + t m + tct
Nb Substitute, differentiate, solve for V*

L Nt L V (1−n ) / n
tm = =
V Nb C
 Process parameters optimization: Speed
Average time to produce part:
Nt
t pr = tl + t m + tct
Nb
L
tm = K
V tm =
V
where
v is the cutting speed,
K is a constant for the particular operation.

In cylindrical turning, for example, the value of K will be given by dwlw/f where lw is
the length to be turned, dw is the diameter of the workpiece, and f is the feed.

In general, K can be regarded as the distance moved by the tool corner relative to the
workpiece during the machining operation.
 Process parameters optimization: Speed
Optimum cutting speed giving maximum production rate (or minimum
production time)
L
Nt tm = Nt L V (1−n ) / n
=
t pr = tl + t m + tct V
Nb C
Nb t = C’ 1/n / V1/n = C/V 1/n

dt pr Substituting C = C’ 1/n =Vr1/ntr

Differentiating =0
dV

n
 tr n 
V p = vr  
 tct (1 − n) 
 Process parameters optimization: Speed

n
Optimum cutting speed for  Mtr n 
minimum cost Vc = vr  
 ( M tct + Ct ) (1 − n) 

n
Optimum cutting speed for  tr n 
maximum production rate V p = vr  
(or minimum production
time)
 tct (1 − n) 
Tool Life For Minimum Cost
Cutting speed for minimum cost

n
 Mtr n 
Vc = vr  

 ( M t ct + Ct ) (1 − n ) 

Substituting into Taylor's tool-life equation

Tool Life for minimum cost

1− n  Ct 
tc =  tct + 
n  M
20
Tool Life For Minimum Production Time
Cutting speed for minimum production time
n
 tr n 
V p = vr  
 tct (1 − n) 
Substituting into Taylor's tool-life equation
Tool Life for minimum production time

1− n 
tp =  tct
 n 
21
Tool Life For Minimum Cost and
Minimum Production Time
n Values:
Tool Life for minimum cost 0.125 – HSS
0.25-0.3- Carbides

1− n  Ct  0.5-0.7 - Ceramics

tc =  tct + 
n  M (1-n)/n Values:

7 HSS
Tool Life for minimum production time 3 Carbides
1 Ceramic

1− n 
tp =  tct
 n 
22
Tool Life and Cutting Speed For Minimum Cost
and Minimum Production Time
Tool Life and Cutting Speed for minimum cost

1− n  Ct   n 
n

tc =  tct +  Vc = vr 
Mtr

n  M  ( M tct + Ct ) (1 − n) 

Tool Life and Cutting Speed for minimum production time

1− n   tr n 
n
tp =  tct V p = vr  
 n 
 tct (1 − n) 
23
Estimation of Factors Needed to
Determine Optimum Conditions
The machine and operator costs, M, include the operator's rate of pay plus the
overhead associated with his or her employment and the depreciation rate of the
machine tool plus the overhead associated with its use.

 O0   Om 
M = W0 +   W0 + M t +  M t
where  100   100 
W0, is the operator's wage rate,
Mt is the depreciation rate of the machine tool,
O0 and Om being the percent overhead for the operator and machine, respectively.

Operator overhead (O0) can vary from 100 to 300% and includes the worker's benefits
provided by the company, the cost of providing the working facilities, and the cost of the
administrators necessary to employ the worker.

Machine overhead (Om) includes the cost of the power consumed by the machine, the
cost of servicing the machine, and possibly the cost of providing the location for the
machine. 24
Estimation of Factors Needed to
Determine Optimum Conditions

Machine depreciation rate Mt : O  O 

M = W0 +  0  W0 + M t +  m M t
 100   100 

𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒

𝑀𝑡 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑜𝑢𝑟𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟𝑥𝑎𝑚𝑜𝑟𝑡𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟𝑖𝑜𝑑

Amortization period: 2-10 years

25
 Estimation of Factors Needed to
Determine Optimum Conditions
1− n  Ct 
tc =  tct + 
Tool Cost for regrindable tools Ct : n  M
Tool Life for minimum cost
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑡𝑜𝑜𝑙
𝐶𝑡 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑖𝑛𝑔 +
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑠 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒

𝑇ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑠 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 𝑖𝑠 𝑎𝑝𝑝𝑟𝑜𝑥. 20.

In practice the actual number of regrinds might be less than ½ the
theoretical number.

Tool Cost for disposable-insert tools Ct :

𝐶𝑜𝑠𝑡 𝑜𝑓 𝑖𝑛𝑠𝑒𝑟𝑡
𝐶𝑡 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑖𝑛𝑔 +
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑝𝑒𝑟 𝑖𝑛𝑠𝑒𝑟𝑡
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑡𝑜𝑜𝑙 ℎ𝑜𝑙𝑑𝑒𝑟
+
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑙𝑖𝑓𝑒 𝑜𝑓 𝑡𝑜𝑜𝑙 ℎ𝑜𝑙𝑑𝑒𝑟
26
Estimation of Factors Needed to
Determine Optimum Conditions
1− n  Ct 
tc =  tct + 
Tool changing time tct: n  M
Tool Life for minimum cost

𝑇𝑖𝑚𝑒 𝑡𝑜 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛𝑠𝑒𝑟𝑡 𝑥

𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑝𝑒𝑟 𝑖𝑛𝑠𝑒𝑟𝑡 − 1 + 𝑡𝑖𝑚𝑒 𝑡𝑜 𝑟𝑒𝑝𝑙𝑎𝑐𝑒 𝑖𝑛𝑠𝑒𝑟𝑡
𝑡𝑐𝑡 =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑝𝑒𝑟 𝑖𝑛𝑠𝑒𝑟𝑡

27
Example
A large batch of steel shafts is to be rough-turned to a 76-mm diameter for 300 mm of
their length at a feed of 0.25 mm.

A brazed-type carbide tool is to be used, and the appropriate constants in Taylor's tool-
life equation for the conditions employed are as follows:
n = 0.25, and vr = 4.064 m/s when tr = 60 s (C = 800 ft/min).

The initial cost of the machine was $30,000 and is to be amortized over 5 years.

The operator's wage will be assumed to be $0.005/s ($18.00/h) and the operator and
machine overheads are 100%.

Tool-changing and resetting time on the machine is 300 s and the cost of regrinding the
tool is $6.00. The initial cost of a tool is $20.00, and, on the average, it can be reground
10 times.

Finally, the nonproductive time for each component is 120 s.

Find tc, vc, tp, vp, tm, Cpr, tpr,

28
Example

𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒

𝑀𝑡 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑜𝑢𝑟𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟𝑥𝑎𝑚𝑜𝑟𝑡𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟𝑖𝑜𝑑

O  O 
M = W0 +  0  W0 + M t +  m  M t
 100   100 

29
 Example

𝐶𝑜𝑠𝑡 𝑜𝑓 𝑡𝑜𝑜𝑙
𝐶𝑡 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑖𝑛𝑔 +
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑠 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒

𝑇𝑖𝑚𝑒 𝑡𝑜 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛𝑠𝑒𝑟𝑡 𝑥

𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑝𝑒𝑟 𝑖𝑛𝑠𝑒𝑟𝑡 − 1 + 𝑡𝑖𝑚𝑒 𝑡𝑜 𝑟𝑒𝑝𝑙𝑎𝑐𝑒 𝑖𝑛𝑠𝑒𝑟𝑡
𝑡𝑐𝑡 =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑢𝑠𝑒𝑑 𝑝𝑒𝑟 𝑖𝑛𝑠𝑒𝑟𝑡

30
Example

1− n  Ct 
tc =  ct
t + 
n  M

1− n 
tp =  tct
 n 

31
Example

K
tm =
V

Nt Nt
C pr = Mtl + Mtm + M tct + Ct
Nb Nb
32
Example

Nt
t pr = tl + t m + tct
Nb

The conditions for minimum production time can be obtained in a similar way. In
this case the machining time tm is found to be 139.1sec (2.32 min), the
corresponding production cost Cpr is $4.81, and the production time 305 s (5.08
min).

33
Machining at Maximum Efficiency
If in a machining operation the minimum cost condition is chosen, production time
will be greater than the minimum. Also, if the condition for minimum production
time is chosen, the cost of production will be higher than the minimum. To
compromise between these two conditions the maximum rate of profit may be
considered.

If S denotes the amount of money the machine shop receives for each component
machined, the profit per component is given by S – Cpr, and the rate of profit Pr is
given by

S − C pr
Pr =
t pr

34
Machining at Maximum Efficiency
Nt Nt
S − C pr C pr = Mtl + Mtm + M tct + Ct
Pr = Nb Nb
t pr
Nt
t pr = tl + t m + tct
Nb

−1 (1−n )
−1 −1
S − Mtl − MKv − Kv t ( Mtct + Ct )vn n

Pr = −1
r r
−1 (1−n )
n −1
tl + Kv + Kv t t vr r ct
n

Where Pr :rate of profit

If this eq. differentiated with respect to v, equated to zero, and combined with
Equation 6.3, the tool life tef for maximum efficiency (maximum rate of profit) is
obtained.
35
Machining at Maximum Efficiency
−1 (1−n )
−1 −1
S − Mtl − MKv − Kv t ( Mtct + Ct )v
n n
Pr
Pr = r r
−1 (1−n ) =0
tl + Kv −1 + Kv t t vn −1
r r ct
n
v
n
1− n  tl Ct  Ct K  tef 
tef =  tct + +  
n  S  nSvr  t r 
Unfortunately this equation can only be solved by numerical methods.

However, a simple method would be to assume a value of tnef equal to 6.5 Sn for
carbide tools or 2.5 Sn for high-speed steel tools and substitute this value in the right
side of the Eq. to obtain a new value of tef.

This iteration procedure can be continued and will rapidly converge to a sufficiently
close approximation.

Maximum efficiency is independent of the machine rate M.

36
 1− n  Ct 
tc =  tct + 
n  M
n
1− n  t l Ct  Ct K  tef 
tef =  ct
t + +  
n  S  nSvr  tr 

1− n 
tp =  tct
 n 

FIGURE 6.4 Effect of cutting

speed v and tool life t on rate
of profit Pr for a typical
turning operation, where
M = $0.00334/s, Ct = $2.60,
tct = 300 s, n = 0.25, tl = 60 s,
K = 328 m, tr = 1 s, and
vr = 12.2 m/s 37
Economics of Various Tool Materials and Tool
Designs
For an example, economic comparison of different tool materials, only
those conditions giving minimum cost will be employed.

Three comparisons are made in this section:

➢ A rough-turning operation using both a high-speed steel tool and a

brazed-carbide tool
➢ A finish-turning operation using both a brazed- and a disposable-
insert carbide tool and an aluminum oxide disposable-insert tool
➢ A milling operation and a shaping operation.

38
TABLE 6.1 Minimum Production Costs and Corresponding Production Times for a Rough-Turning Operation High-
Speed Steel and Brazed-Carbide Tools
Type of Tool
Production Costs and Times High-Speed Steel Brazed Carbide
Proportion of machining time when cutting edge is engaged, 1 1
Q
Machine and operator rate M, $/s 0.01 0.01
Cost of sharp tool Ct, $ 1.10 8.00
Tool changing time tct, s 240 240
Tool-life index n 0.125 0.25
Tool life for minimum cost, tc[(1/n) – 1] [tct + (Ct/M)], ks 2.45 3.12

Cutting speed for 1 min tool life vr, m/s 0.508 2.73
Cutting speed for minimum cost vc = vr (60/Qtc)n, m/s 0.32 1.02

Distance moved by cutting edge relative to workpiece K, m 200 200

Machining time tm = K/vc, s 626 197

Number of components produced per tool = tc/tm 4 16

Nonproductive time per component tl, s 300 300

Tool-changing time per component = (tm/tc) tct, s 61 15

Nonproductive cost per component Mtl, $ 3.000 3.000

Tool cost per component = (tm/tc) (Ct + Mtct), $ 0.894 0.656

Machining cost per component Mtm, $ 6.260 1.967

Total production time tpr, s 987 512
Total cost per component Cpr, $ 10.15 5.62 39
TABLE 6.2 Minimum Production Costs and Corresponding Production Times for a Finish-Turning Operation Using
Brazed-Carbide, Disposable-Carbide, and Disposable-Ceramic Tool
Type of Tool
Production Costs and Times Brazed Carbide Disposable Carbide Disposable Ceramic
Proportion of machining time when cutting edge 1 1 1
is engaged, Q
Machine and operator rate M, $/s 0.01 0.01 0.01
Cost of sharp tool Ct, $ 8.00 1.00 2.00
Tool changing time tct, s 240 60 60
Tool-life index n 0.25 0.25 0.50
Tool life for minimum cost, tc[(1/n) – 1] [tct + 3.120 0.480 0.260
(Ct/M)], ks
Cutting speed for 1 min tool life vr, m/s 6 6 50
Cutting speed for minimum costvc = vr (60/Qtc)n, 2.23 3.57 24.02
m/s
Distance moved by cutting edge relative to 1000 1000 1000
workpiece K, m
Machining time tm = K/vc, s 448 280 42
Number of components produced per tool = 7 2 6
tc/tm
Nonproductive time per component tl, s 240 240 240
Tool-changing time per component = (tm/tc)tct, s 34 35 10

Nonproductive cost per component Mtl, $ 2.40 2.40 2.40

Tool cost per component = (tm/tc) (Ct + Mtct), $ 1.492 0.934 0.416

Machining cost per component Mtm, $ 4.476 2.803 0.416

Total production time tpr, s 722 555 291
Total cost per component Cpr, $ 8.37 6.14 3.23 40
 TABLE 6.3 Minimum Production Costs and Corresponding Production Times for the Machining of a Flat Surface (150 mm
long and 80 mm wide) Using a Horizontal Milling Machine and a Shaper
Machining Operation
Production Costs and Times Milling Shaping
Proportion of machining time when cutting edge is 0.14 0.75
engaged, Q
Machine and operator rate M, $/s 0.012 0.008
Cost of sharp tool Ct, $ 40.00 2.00
Tool changing time tct, s 600 120
Tool-life index n 0.125 0.125
Tool life for minimum cost, tc[(1/n) – 1] [tct + (Ct/M)], ks 27.53 2.59

Cutting speed for 1 min tool life vr, m/s 1.0 1.0
Cutting speed for minimum cost vc = vr (60/Qtc)n, m/s 0.59 0.65

Machining time tm = K/vc, s 134.7 190.0

Number of components produced per tool = tc/tm 204 14

Nonproductive time per component tl, s 120 120

Tool-changing time per component = (tm/tc)tct, s 3 9

Nonproductive cost per component Mtl, $ 1.440 0.960

Tool cost per component = (tm/tc) (Ct + Mtct), $ 0.231 0.217

Machining cost per component Mtm, $ 1.616 1.520

Total production time tpr, s 257.6 318.8
Total cost per component Cpr, $ 3.29 2.70 41
PROBLEM
A cylindrical workpiece 125mm in diameter and 1m long is to be turned in
an engine lathe. Cutting conditions are: cutting speed = 2.5m/s, feed rate =
0.26mm/rev, and depth of cut = 2mm. A cemented carbide tool is used for the
operation with n = 0.23 and C = 400m/min. It takes one minute to index for a
new cutting edge whenever the tool gets worn-out. Loading and unloading
time/part is also one minute.

a) Determine the cutting time (Ans. 10 min).

b) Calculate the tool life to minimize the unit production time (Ans. 3.35
min).
c) Calculate the cutting speed to minimize the unit production time (Ans.
303 m/min).
d) Calculate the number of parts which can be machined with a sharp
cutting edge.
e) Calculate the unit production time.

42
EXAMPLE
For a single-shift working in a particular turning operation, the cost of the labor and
machine time in resetting a cutting edge is $0.50, the cost of each throwaway insert
having four cutting edges is $2.00, and the depreciation of the insert holder per insert
is $0.08.
The initial cost of the lathe was $30,000, which is amortized for 5 years. Machine
running costs including labor and overhead but neglecting depreciation are estimated
at $15.00/h.

If the Taylor tool-life index for the carbide inserts is 0.25, calculate,
for minimum-cost conditions, the tool life, in seconds (s), and cutting speed, in meters
per second (m/s), if the machine is to be used on a:

a.Single-shift, 40 hr/wk basis

b.Double-shift, 80 hr/wk basis

Assuming 50 working weeks per year, a cutting speed of 7.6 m/s, for 60 s tool life and
a nonproductive time for loading and unloading a component of 3 min.

43
 Nt Nt
C pr = Mtl + Mtm + M tct + Ct
EXAMPLE Nb Nb
n
Tool Cost for each cutting edge:  Mtr n 
Vc = vr  
0.5  ( M tct + Ct ) (1 − n) 
1− n  Ct 
tc =  tct + 
n  M

44
 Nt Nt
C pr = Mtl + Mtm + M tct + Ct
EXAMPLE Nb Nb
n
 Mtr n 
Vc = vr  
 ( M tct + Ct ) (1 − n) 
1− n  Ct 
tc =  tct + 
n  M

45
ME 531 MACHINING MECHANICS AND
ANALYSIS

CHAPTER 6
ECONOMICS OF METAL
CUTTING OPERATIONS