Chapter -3 Optimization of Machining Parameters in Shaping Operations

CHAPTER 3

OPTIMIZATION OF MACHINING
PARAMETERS IN SHAPING OPERATIONS

3.1. INTRODUCTION

The optimization of shaping process is treated in a similar way as

the turning process. The impact force, generated on the cutting tool,
at the beginning of cutting stroke, is considered in the constrained
imposed on the cutting process. The optimization is performed
under some practical constraints such as: maximum allowable
cutting force and cutting temperature, required surface finish and
the available power, feed and number of strokes per minutes on the
shaping machine.

3.2. ECONOMY OF SHAPING PROCESS

The main difference between the economy calculations of turning

and shaping operations is the machining time (Tm) and cutting
speed (n) as shown in Equations 3.1 and 3.3 respectively. This
because the main motion in shaping process is reciprocating, while
in turning the main motion is rotary, Fig.3.1.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

Vr
n, V
Fc Vc
ΔL1

Ls Lw

f t
ΔL2
f
Ww

Fig.3.1. The cutting process in shaping.

Ww .Ls .i
Tm = (3.1)
f .Vc .C r

Where
Ww : Width of workpiece.
Ls: Stroke length = workpiece length + tool approach (ΔL1) and
overtravel (ΔL2) the workpiece.
i : Number of cuts in depth
Cr: Cutting ratio = Cutting time/total time
f : Feed per stroke.
Vc : Cutting speed ;
The cutting speed was calculated from the Extended Tayler’s
equation as;

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

CV
V= (3.2)
T . f p .t q
L
m

Where TL is the tool life (Equation 2.15), f is the feed per stroke, t is
the depth of cut, m, p, q and Cv are exponents and constants, which
depend on work piece and tool materials. The number of strokes
per minute (n) is calculated from the following equation:

1000Vc
n= (3.3)
2 LS

3.3. CUTTING VARIABLES AND CONSTRAINTS

The cutting variables to be optimized for shaping operations are

cutting speed (Vc), that is related to the number of strokes/min (n),
depth of cut (t), and the feed per stroke (f). Optimization of these
variables is performed under some practical constraints that are:
a) The depth of cut ≤ 5 mm. If depth of cut larger than 5 mm the
shaping process must be achieved through multi passes with
equal values of depth of cut with the condition t < 5 mm.

hwi − hwf
t= (3.4)
i

Where hwi and hwf are the initial and final workpiece hight, and i
is the number of passes.
b) The estimated optimum cutting speed should be related to one
of the available number of strokes per minute on the shaping
machine used in the process.

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Chapter -3 Optimization of Machining Parameters in Shaping Operations

c) The estimated optimum feed rate should be one of the available

feed per stroke on the machine.

d) The calculated generated cutting temperature (Q) should less

than the red hardness temperature of the cutting tool. (600 °C)
for High Speed Steel tool and (1200°C) for Carbide tool. The
generated cutting temperature can be estimated from the
relation;

C q K S .Vcx f y t z
Q= (3.5)
Ctxx C pyy

Where
x, y, z, xx, yy are exponents depend on the tool and workpiece
materials, and the cutting conditions.
KS: Specific cutting resistance (Kg/mm2).
Ct: Thermal conductivity of workpiece material
(Cal/cm.sec.°C)
CP: Specific heat of workpiece material (Cal/Kg.°C)

e) The main cutting force (Fc) is calculated as;

Fc = Ks . t . f (3.6)
f) The cutting power (Pc) should be less than the available power
of the shaper used. The cutting power is given by:

Fc .Vc
Pc = ≤ η.Pe kW (3.7)
60 *1000

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Chapter -3 Optimization of Machining Parameters in Shaping Operations

g) The impact force (FI) between tool and workpiece was found to
be depending on both cutting speed (V) and feed rate (f). The
relation between the main cutting force (Fc) and the impact
force can be simply written, for the most severe cutting
condition, as;

FI = 1.5 Fc (3.8)

h) The maximum allowable bending stress on tool edge is

calculated as;

6.FI .t
σ b −edge = (3.9)
B.H 2

Where
σb-edge : Bending stress on tool edge
FI : Impact force
B: Tool mean width (mm)
t : Depth of cut (mm)
H : Tool mean thickness (mm)
i) The roughness of the machined surface should not exceed the
required surface finish. The surface roughness (Ra) is
calculated using the center line average relation;

f
Ra = (3.10)
31.18 * r

Where r is the tool nose radius.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

3.4. THE OPTIMIZATION PROCEDURE

Optimization of cutting variables in shaping is performed for each

cutting operation separately, in order to achieve minimum
production cost for each operation, and hence, for all cutting
operations to be performed on a certain workpiece. The procedure
is described by the flow chart of Fig.3.2, where step by step search
algorithm is adopted for the optimization. The procedure can be
explained as the following.

a- The optimum tool life is first calculated from Eq.(2.15)

b- Let the maximum allowable depth of cut to be 5 mm. If the

depth of cut exceeds than 5 mm the shaping process must be
achieved through multi passes.

c- The maximum feed per stroke on the machine is then taken as

initial value for feed rate (f).

d- Using these values for feed (f), depth of cut (t) and optimum
tool life (TL) the cutting speed (V) is calculated from Eq.3.2 at
specific values of exponents and constant that depend on the
tool and workpiece materials.

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Chapter -3 Optimization of Machining Parameters in Shaping Operations

e- The cutting speed (V) is, then, converted to number of strokes

per minute (n) using Eq.3.3. If, the calculated number of
strokes is not found on used shaping machine, the next smaller
value on the machine is selected. Using this value of (n) a new
cutting speed (V) is calculated using Eq.3.3 once more.

f- The initial values for cutting variables, depth of cut (t), feed (f)
and cutting speed (V) are used to calculate cutting temperature
(Q) using Eq.3.5, cutting force (Fc) and cutting power (Pc) from
Eqs.3.6, 3.7, also impact force (FI) and bending stress (σb-edge)
from Eqs.3.8, 3.9. The surface roughness is, also, calculated
using Eq.3.10.

g- These estimated values are then compared with the stored

values of cutting constraints, which are maximum allowable
cutting temperature (Qmax), maximum available power (Pc-max),
maximum allowable bending stresses (σb-max) and the required
surface finish (Ra-max). If any of these limits is exceeded the
feed rate (f) is reduced to the next lower value on the used
machine. Anew cutting speed (V) is then calculated and all the
cutting constraints are checked again.

h- If the minimum feed rate on the shaping machine is reduced

without satisfying all the cutting constraints the depth of cut (t)
is reduced by increasing number of passes (i) by one. The
maximum feed rate is taken this time and a new cutting speed is

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Chapter -3 Optimization of Machining Parameters in Shaping Operations

calculated. The previous steps are repeated until all the cutting
constraints are satisfied.

i- If the minimum depth of cut (0.5 mm) is reached without

satisfying all the constraints the tool material is changed to a
harder material and the previous calculations are repeated once
more.

j- The optimization procedure is continued until all the cutting

constraints are fulfilled. The optimum values for the three
cutting variables can, then, be used to calculate the operation
time (To) and operation cost (Co) using Equations 2.1, 2.12.

k- The previous steps are repeated for each cutting operation, to

be performed on the given workpiece, in order to fined the
optimum values for the cutting variables in each operation.
Using the optimum values for cutting variables the operation
time and operation cost are calculated and, then, summed for all
operations to get the total production time and production cost
for the given workpiece.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

START

Input lathe M/C specifactions, W.P. and tool details,

standard times and coasts, and the recommended
exponents for the cutting process

Calculate the optimum tool life TL

Calculate the height of metal to be removed

Maximum depth of cut

Maximum feed per stroke

Calculate the cutting speed and

change it to No. of strokes/min.

CUTTING CONSTRAINTS
1- Cutting temperature Next
2- Motor power operation
3- Tool deflection
4- Impact force
5- Tool bending stress
6- Surface roughness Reduce
D.O.C.
Are
yes
all the constraints
satisfied? Reduce
Print operation dimensions, feed
optimum cutting variables, no
constraints values no
Min. Feed rate?
Calculate machining time,
yes
operation time and coast
no
Min D.O.C?
Print operation
time and coast yes
no
All operations?

yes
Calculate and print total production time and coast

END

Fig.3.2. Flow chart of the optimization procedure for cutting conditions.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

3.5. SOLVED EXAMPLS

Example 1.
It is required to reduce the thickness of a plain steel workpiece from
hwi = 48 mm to hwf = 45 mm using a mechanical shaping machine.
If the main cutting force (Fc) acting on the tool edge is given by:

Fc = 15.5 t.f kN

Where t = depth of cut and f = feed per stroke.

Determine the optimum feed (mm/stroke) and speed (No. of strokes
per min.) given that:
- The workpiece length = 40 mm; tool approach and overtravel the
workpiece by 1mm
- The width and thickness of tool shank = 10 and 14 mm
respectively
- The tool cost: machining cost rates C2/C1=16.
- Max. impact force which the feed drive can withstand = 50 kN.
- The permissible shear stress on the tool shank = 145 MPa
- Max. permissible bending stress of the tool edge = 210 MPa.
- Cutting time/total = 0.75

If the maximum deflection of the tool point is limited to 0.02 mm,

find the over hung tool length. Calculate the maximum bending
stress on the tool shank (E=2.1x105 MPa). Select the suitable
cutting tool material based on the generated cutting temperature (Q)
that calculated from the following equation.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

160
V = m / min .
T L
0.22
. f 0.4 .t 0.21

Q = 110.Vc0.33 . f 0.15 .t 0.35 o

C

Solution
Fc = 15.5 t. f = 15.5 *3 *f = 46.5 f

a) FI = 1.5 Fc = 46.5 f * 1.5 = 69.75 f ≤ 50 ∴ f = 0.72 mm/stroke

6 FI .t 6 * 69.75 f * 3
b) σ b − edge = 2
= = 641 f ≤ 210 ∴ f = 0.33 mm / stroke
B.H 10 * (14) 2

c) τ = FI/A = 69.75*103 f/(10*14)=498 f ≤145 ∴ f = 0.29 mm/stroke

Take f = 0.29 that satisfy the cutting constraints.

C 2 ⎡1 − m ⎤ ⎡1 − 0.22 ⎤
d ) TL = ⎢ ⎥ = 16 ⎢ = 56.7 min .
C1 ⎣ m ⎦ ⎣ 0.22 ⎥⎦

160
V= 0.22
= 85.7 m / min
56.7 * 0.29 0.4 * 30.21

1000 * V 1000 * 85.7

∴n = = = 1020 stroke / min .
2 LS 2 * 42

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

∴The optimum cutting conditions are:

f = 0.29 mm/stroke
n = 1020 stroke/min.

∴FI = 69.75*0.29 = 20.23 kN

FI .L3t 20.23 *1000 L3t

e) y = = = 1.4 *10 − 5 L3 ≤ 0.02
3EI 1
3 * 2.1 *10 5 * (10)(14) 3
12
∴ Lt = 11.25mm

M .Y FI .Lt .Y 20.23 * 10 3 * 11.25 * 14 / 2

f ) σ b − shank = = = = 698 MPa
I I 1
(10)(14) 3
12

Q = 110(85.7)0.33 (0.29)0.15 (3)0.35 = 583 °C

The HSS cutting tool can be used, where its red hardness
temperature equal 600oC.

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 Chapter -3 Optimization of Machining Parameters in Shaping Operations

3.6. PROBLEMS
It is required to reduce the thickness of a plain steel workpiece from
hwi = 55 mm to hwf = 51 mm using a mechanical shaping machine.
If the main cutting force (Fc) acting on the tool edge is given by:

Fc = 20 f.t(1-m) kN

Where t = depth of cut and f = feed per stroke.

Determine the optimum feed (mm/stroke) and crank speed (R.P.M)
given that:
- The workpiece length = 80 mm; tool approach and overtravel
the workpiece by 5mm
- The width and thickness of tool shank=14 and 28 mm
respectively. The overhang tool length=20 mm.
- C2/C1 = 16
- Max. impact force which the feed drive can withstand = 40 kN.
- Max. permissible bending stress of the tool edge = 200 MPa.
- Max. normal stress on the tool shank =250 MPa, E=2.1x105
MPa
- Max. shear stress on the tool shank = 150 MPa
- Max. deflection of the tool point is limited to 0.02 mm

If the cutting speed was calculated from the following equation;

160
V = 0 . 22
m/min
T L
. f 0 . 4 .t 0 . 21

Calculate the cutting power.

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