Introduction

“The method of determination of optimum

cutting conditions for given economic condition”

•Minimum cost criteria

•Maximum production rate criteria

•Maximum profit criteria

 Introduction
Machine and Labor

Fix Tool Fix w/p Machining Tool grinding Machining Unload w/p

Speed Speed
Feed Feed
Depth Depth

Fixed Control Fixed Control Fixed

Speed, Feed, Depth Machining Cost

Tool wear Tool changing Machining Cost

• Optimum speed which balances these opposing factors

Taylor’s Tool Life Equation
VTn=C

V=cutting velocity(m/min)

T=tool life(min/number of pieces/vol. of MR)

n=Taylor’s exponent

C=Taylor’s constant
Minimum Cost Criteria
 Machining Cost(Cm)
Cm = Tm × Lm

Tm = machining time / piece(min.,)

Lm = labour rate for machining(Rs./min.)

Tm =L/(f×N)=(Π×D×L)/(1000×f×V)

f=feed rate(mm/rev)

D=diameter of work piece (mm)

L=axial length of work piece machined (mm)

 Idle cost (Ci)
Ci = Ti × Lm

Ti = idle time/piece

Loading, unloading, adjusting speeds, feeds, personal

breaks, etc.
 Set-up cost (Cs)
Cs = Ts × Ls / Ns

Ts = set-up time (min.)

Ls= set-up labour rate

Ns = number of pieces made per set up

 Tool changing cost (Cc)
Cc = Tc × Lm × (Tm / T)
Number of Tools used

Tc = tool changing time (min.)

Tm= machining time per piece(min.)

T = tool life (min.)

 Tool and regrinding costs(Cg)
Cg = [(Tg × Lg)+ Dg] × (Tm/T)

Tg = tool regrind time(min.)

Lg = labour rate (Rs./min.)

Dg = cost per tool edge

– regrind = tool cost ÷ permissible regrinds

– insert = tool cost ÷ edges

 Total cost per piece (Cp)
Cp = Tm × Lm

+ Ti × Lm

+ Ts × (Ls/Ns)
Tm =(ΠDL)/(1000fV)
+ Tc × Lm × (Tm/T) T=(C/V)1/n

+ [(Tg × Rg)+ Dg] × (Tm/T)

+ Cr
Total cost per piece (Cp)

(1)
Cutting speed Vs. Cost
Minimum cost cutting velocity (Vcm)
Minimum cost tool life (Tcm)
Max. Production rate Criteria
Cutting speed Vs. Total time
For maximum production rate
 Example

For the following cut, determine the velocity for the

minimum cost (Vcm) and for the maximum production
rate (Vtm) per piece using a HSS tool
LASER BEAM MACHINING

P S Suvin
 DEFINITION
• Laser beam machining is an unconventional
machining process in which a beam of highly
coherent light called a laser is directed towards the
work piece for machining

• It can be used to perform precision machining on all

microelectronic substrates such as ceramic, silicon,
diamond, and graphite
 PROCESS DESCRIPTION
• Process in which a laser
beam is focused for
melting and vaporizing
the unwanted materials
from parent workpiece.
• Elements :
• Lasing medium or Laser
material
• Energy source or flash
lamp system
• Optical feedback system
• Work table setup
 OPERATING PRINCIPLE
• Melting and vaporization

• The emitted beam is focused by the lens system

and the focused beam strikes the workpiece
• Removes a small fraction of metal by vaporization
• Metal vaporized so quickly that a high mechanical
impulse is generated throwing out a large portion of
liquid metal
 MECHANICS OF LBM
• Machining of laser beam
achieved through the
following phases
1. Interaction of laser beam
with work material
2. Heat conduction and
temperature rise
3. Melting , vaporization and
ablation
CRItICAL pRoCESS pARAMEtERS
• Beam power intensity
• Beam diameter
• Melting temperature
 Process parameters Effect
• Wavelength , Focal length of • Feature size, ablation rate
lens
• Beam shape • Feature shape, uniformity of
micromachining
• Beam energy, Pulse width • Size of HAZ
• Pulse repetition range • Depth of material removal
• Depth of focus • Aspect ratio
 ADVANTAGES
1. No physical contact between work-tool pair, no
possibility of breakage or wear of tool
2. Precision location is ensured by focusing of the
beam
3. Large aspect ratio can be achieved
4. Very small holes can be drilled in very hard
materials like diamond in seconds
 DISADVANTAGES

• Very large power consumption

• Cannot cut materials with high heat conductivity and

high reflectivity

• Proper cooling is needed

 APPLICATIONS
• Manufacturing of MEMS devices

• Optical switches

• Drug delivery systems

• Engraving purposes
tHANk you
PLASMA ARC MACHINING

P S Suvin
 Plasma Arc Cutting
 PAC is a thermal material
removal process that is
primarily used for cutting
thick sections of electrically
conductive materials.

 Plasma can be defined as a

“superheated, electrically
ionized gas.”
 PLASMA ARC MACHINING
(PAM)
• Process used to cut steel and
other metals using a plasma gas
through plasma torch.
• Plasma : Mixture of neutral
atoms, free electrons and
positively charged ions.
• Plasma behaves like a high
temperature gas but it conducts
electricity.
• Due to high temperature of
plasma, workpiece material
melts and vaporizes and is
finally cut into pieces.
 ELEMENTS OF PLASMA ARC
MACHINING :
1. Power supply system
2. Gas supply system
3. Cooling water system
4. Plasma torch
 MECHANISM OF METAL
REMOVAL:
• Hot tungsten rod – negative polarity – cathode
• Nozzle/Work – positive polarity – anode
• Gas is introduced around cathode and flows to anode
• Strong arc is established, and there is a collision
between molecules of gas and electrons in the arc.
• The molecules are ionised and develop heat.
• High temperature (20000 to 50000 ºF) plasma arc
impinges on workpiece, melting and vaporising it.
• High velocity gas blows off the molten metal away.
 System Components
 Torch
 Power Supply
 Arc Starting Circuit
 System Components
A. The Torch:
 The torch is the holder of
the consumable electrode
and nozzle.

 Responsible for forming

the arc and maintain it in a
vortex.
A. The Torch:

Types of Torches:
 Air Plasma Torch
 Oxygen-Injected Torch
Air Plasma type
 Water Injected Torch
 Dual Gas Torch

Water Injected type

B. Power Supply:

 Constant DC current
source.

 Speed and cut

thickness are
determined by the
amount of output
current.
C. Arc Starting Circuit:

 High frequency generator

circuit that produces a high
AC Current.

 To start the arc, the AC

current ionizes the cutting
gas, which makes it
conductive to allow the DC
current to flow through it.
 Types of Arcs
1. Transferred Arc:
The generated arc is between
the electrode and the work-
piece.
 Types of Arcs
2. Non-Transferred Arc:
The generated arc is between the
electrode and the nozzle and
heat is carried to the work-piece
by the plasma gas.
Only used for electrically non
conductive materials
 Gases Used
 Primary Gases:
Gases that are used to create the plasma arc.
Examples are nitrogen, argon/hydrogen, or mixture of
them

 Secondary Gases or Water:

Surrounds the electric arc to aid in confining it and
removing the molten material.
 PROCESS PARAMETERS:
1. Cutting speed
2. Cutting current
3. Cutting height/Stand off distance
4. Gas pressure and Gas flow rate
 PRoCeSS CAPAbILIty
• Thickness upto 150 mm easily machinable
• Tolerance in the range of 0.3 – 0.8 mm
achievable
• 5 – 7.5 µm surface finish
 PRoS ANd CoNS
Advantages
• No complicated
maintenance
• Minimum energy to operate
• Much more economical than
oxy fuel cutting
Disadvantages
• For non-conducting
materials MRR very low
• Tolerance is poor and
directly depends on
thickness of material
 Applications
• Pipe industry – preparing pipe
edges for welding.

• Plasma Arc Welding (PAW)-

plasma arc is produced and
aimed at the weld area to weld.

• Used for butt and lap joints

because of higher energy
concentrations and better arc
stability.
tHANk you