Machine Time Calculation

Turning process
The machining time in the lathe work can be calculated for a particular operation if the speed
of the job, feed and length of the job is known.
If “f” is the feed of the job per revolution expressed in mm per revolution
“L” the length of the job in mm,
In one revolution or rotation material equal to feed is removed from the work
Number of revolutions of the job required for a complete cut will be:
L/f.
1
The time required for one rotation =
N
The time is taken for a complete cut or to make L/f rotation.
L
machining time=
fN
RPM of the work is N
Drilling process
Cutting speed
πDN
cutting speed V = m/sec
1000∗60
Where D is in mm, N is in rev/min.
Feed
The feed in a drilling machine refers to the distance moved by the drill in one revolution
expressed as mm/rev.
Depth of cut
The depth of cut in drilling refers to the radius of the drill being used expressed in mm.
D
depth of cut= mm
2
D=dia of drill
Machining time in drilling is given by
Lc
machining time=
fN
where L=length of hole
f =feed∈mm/rev
N=rpm
also we have V =πDN ( relation between lenear velocity∧rpm )
πD Lc
∴ drilling time= min
1000 V c f
Material removal rate
2 3
πD mm
1

MRR= fN
4 min
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f =feed∈mm per revolution

 D=dia of drill
For drilling a through hole
LC = Lh + A + O + C
A, O = approach and over run
D
C= cotρ
2
D = diameter of the hole, i.e., drill
ρ = half of the drill point angle.
N =rpm
f = feed in mm/rev
πD Lc
∴ drilling time=
1000 V c f

Reciprocating machines (shaper, planer & slotter)

Cutting speed
It is defined as the average linear speed of the tool during the cutting stroke in m/min. This is
expressed in meter per minute. It depends on the length of stroke and number of stroke per
minute. Cutting stroke means one forward stroke and return stroke.

Length of cutting stroke

cutting speed =
Time takenby the cutting stroke
Length of cutting stroke ( L ) ∈meters
time takenby cutting stroke=
cutting speed ( V ) meter /min ⁡

time for cutting stroke=time of cutting +time for return stroke

L mL
Time for one cutting∧return stroke= +
V V
L
ie= ( 1+m )
V
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If the rpm of bull gear is N, then N number of strokes takes place per minute. So the time taken for
one stroke and cutting speed can be expressed as below
1 L
ie = ( 1+m ) ie cutting speed(V )=NL(1+m)
N V
L=length of cutting stroke
L=Lw+ A +O
Lw=length of job
A=approch length
O=over run length
m=ratio between return time to cutting time (2: 3)
time of return stroke
m=
time of cutting stroke
N=rpm of bull gear
V =cutting speed(m /min ute)
w=width of work
f =feed
Total machining time for entire machining
w
Number of such stroke required for full machining=
f
L ( 1+m )∗w
Total time for complete machining= (min)
V f

Milling process
Machining time for milling
The time required to mill a surface for any operations can be calculated from the formula
L
T=
f∗Z∗N
where ,
T =time for machining in min ute
Z=number of teeth
f =table feed per tooth in mm
3

N=rpm
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TURNING PROCESS
PROBLEM 1
A cylindrical stainless steel rod with length L=150 mm, diameter D 0 = 12 mm is being reduced in
diameter to Df =11 mm by turning on a lathe. The spindle rotates at N = 400 rpm, and the tool is
travelling at an axial speed of U=200 mm/min

Calculate:
a. Cutting speed V (maximum and minimum)
b. The material removal rate MRR
c. The cutting time t
d. The power required if the unit power is estimated to 4 W.s/mm3

SOLUTION: 4
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PROBLEM 2
The part shown below will be turned in two machining steps. In the first step a length of (50 + 50) =
100 mm will be reduced from Ø100 mm to Ø80 mm and in the second step a length of 50 mm will be
reduced from Ø80 mm to Ø60 mm. Calculate the required total machining time T with the following
cutting conditions:
Cutting speed V=80 m/min,
Feed is f=0.8 mm/rev,
Depth of cut = 3 mm per pass.

SOLUTION:
V=80 m/min
f=0.8 mm/rev
The turning will be done in 2 steps. In first step a length of (50 + 50) = 100 mm will be reduced from
Ø100 mm to Ø80 mm and in second step a length of 50 mm will be reduced from Ø80 mm to Ø60
mm.
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PROBLEM 3
How much machining time will be required to reduce the diameter of a cast iron rod from 120 mm
to 116 mm over a length of 100 mm by turning using a carbide insert? Reasonably select values of V C
and feed.

DRILLING PROCESS
PROBLEM 4
Determine the time that will be required to drill a blind hole of diameter 25 mm and depth 40 mm in
a mild steel solid block by a HSS drill of 1180 cone angle. Assume suitable values of VC and so.
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PROBLEM 5
Find the time required to drill 4 holes in a cast iron flange each of 2 cm depth, if the hole diameter is
2 cm. Assume cutting speed as 21.9 m/min. and feed as 0.02 cm/rev. (8 marks) (AU N/D

SHAPING PROCESS
PROBLEM 6
In a mild steel block, a flat surface of length 100 mm and width 60 mm has to be finished in a
shaping machine in a single pass. How much machining time will be required if Ns = 80, so = 0.2
mm/stroke, A = O = 5 mm, QRR = 0.5.
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PROBLEM 7
Find the machining time required for machining the surface 600 × 800 mm, on a shaping machine.
Assume, cutting speed as 8 m/min. The return to cutting time ratio is 1:4, and the feed is 2
mm/double stroke. The clearance at each end is 70 mm.
Lj = 600 mm,
w = 800 mm,
v = 8 m/min, m = ¼,
f = 2 mm/stroke,
c = 70 mm
Given clearance at each end: c=75 mm • length of stroke: L = 600 + 2×70 = 740 mm

Assume 8.65 strokes/min available • Machining time for 800 mm width

PROBLEM 8
Find the time required on a shaper to machine a plate 600 mm × 1,200 mm, if the cutting speed is 15
meters/min. The ratio of return stroke time to cutting time is 2 : 3. The clearance at each end is 25
mm along the length and 15 mm on width. Two cuts are required, one roughing cut with cross feed
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of 2 mm per stroke and one finishing cut with feed of 1 mm per stroke.
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Problem 9

Milling operation
Problem 10
Determine TC for plain milling a rectangular surface of length 100 mm and width 50 mm by a helical
fluted plain HSS milling cutter of diameter 60 mm, length 75 mm and 6 teeth. Assume A = O = 5 mm,
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VC = 40 m/min and so = 0.1 mm/tooth

Problem 11
Estimate the machining time that will be required to finish a vertical flat surface of length 100 mm
and depth 20 mm by an 8 teeth HSS end mill cutter of 32 mm diameter and 60 mm length in a
milling machine. Assume, VC = 30 m/min, so = 0.12 mm/tooth.

Problem 12
A keyway has to be cut in spindle whose dimensions are 40 cm long 4 cm diameter with a 1 cm
width. The cutter diameter is 10 cm. If the cutter is revolving at 120 rpm, what time will be required
to cut one cm deep keyway at a feed of 0.05 cm/rev of cutter? (8 marks)

Problem 13
A 20 × 5 cm CI surface is to be faced on a milling m/c with a cutter having a diameter of 10 cm and
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having 16 tooth for the cutting speed and feed are 50 m/min and 5 cm/min respectively, determine
the milling time, rpm, and feed/tooth.
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Problem14
A T-slot is to be cut in a C.I. slab as shown in Fig. Estimate the machining time. Take cutting speed 25
m/min, feed is 0.25 mm/rev. Dia of cutter for channel milling is 80 mm.

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