MANUFACTURING
MANUFACTURING
PROCESS
PROCESS
CALCULATION SLIDE
CALCULATION SLIDE
©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
C())in* Con+i)ion in T($nin*
Rotational speed in turning
Where, N = rotational speed (rev/min)/(rpm) v = cutting speed (m/min)
D
o = original diameter of the part (m)
o
D
v
N
π =©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
•
De,)h o- "()
»
Whe$e! Df . /nl +i1e)e$ 113 » Do . o$i*inl +i1e)e$ 113 » d . +e,)h o- "() 113•
Fee+ $)e
»
Whe$e! f r . -ee+ $)e 11'1in3» f . -ee+ 11'$e%3
2
/
f oD
D
d
=Nf
f
r =©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
•
M"hinin* )i1e
Whe$e! T m . 1"hinin* )i1e 1in3
L . len*)h o- )he "ylin+$i"l 4o$5,$) 113
•
6ol(1e)$i" $)e o- 1)e$il
$e1o%l
Whe$e!
RMR . 1)e$il $e1o%l $)e 11'1in3
f . -ee+ 113
v . "())in* ,ee+ 1'1in3 d . +e,)h o- "() 113 r m
L
f
T
=/
vfd
R
MR =A in*le ,oin) "())in* )ool h%in* $5e n*le o- 2 +e*$ee 4
,$e-e$$e+ )o 1"hine h-) h%in* +i1e)e$ o- 80 11 in)o
/nl +i1e)e$ o- 97 11 4i)h -ee+ o- )he "() 4 #8 11# The
4o$5 ,ie"e 4 $o))in* ) 800 1'# The 1"hinin* ,$o+("e+
"on)in(o( "hi, h%in* )hi"5ne o- #: 11# The -o$"e 4e$e
1e($e+ ;y +yn1o1e)e$# The "())in*'ho$i<on)l -o$"e 4
980 N n+ )he )$()'%e$)i"l -o$"e 4 28 N#
Cl"(l)e )he -ollo4in*=
3
Chi, )hi"5ne $)io!
;3
The he$ n*le!
"3Re(l)n) -o$"e!
+3
Coe>"ien) o- -$i")ion!
e3
M)e$il $e1o%l $)e! R
MR-3 C())in* ,o4e$ -o$ )he o,e$)ion?
In )($nin* o,e$)ion on l(1in(1! ,in+le ,ee+ i e) )o
,$o%i+e "())in* ,ee+ 2#0 1'# The -ee+ n+ +e,)h
o-"() $e 0#28 11 n+ 2#9 11 $e,e")i%ely# The )ool $5e
n*le i :@# A-)e$ )he "()! )he +e-o$1e+ "hi, )hi"5ne i
1e($e+ )o ;e 0#98 11# Gi%en ,e"i/" ene$*y -o$ )hi
o,e$)ion i 0#7 N1'11
4i)h "o$$e")ion -")o$ o- #08#
De)e$1ine=
he$ ,lne n*le! -$i")ion n*le!
"())in* ,o4e$ -o$ )he )($nin* o,e$)ion! n+
©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
C())in* Con+i)ion in
D$illin*
Rotational speed in drilling
Where, N = spindle speed (rev/min)/(rpm) v = cutting speed (mm/min)
D = the drill diameter (mm)
D
v
N
π
©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
•
6ol(1e)$i" $)e o- 1)e$il $e1o%l
Whe$e!
R
MR. 1)e$il $e1o%l $)e
11
'1in3
rf
D
R
MR(
/
4
)
2 π =In +$illin* o,e$)ion o- 1e+i(1 "$;on )eel
4o$5,ie"e! 8#0 11 +i1e)e$ )4i) +$ill i ;ein*
(e+ )o +$ill )h$o(*h hole ) +e,)h 0 11 n+
)he ,oin) n*le i :@# The "())in* ,ee+ i e)
)o 0 1'1in n+ )he -ee+ i ) 0#11'$e%#
De)e$1ine )he )i1e $e(i$e+ )o "o1,le)ely
,$o+("e )he hole#
3 N . v 'D . 003 ' 8#0π3 . #2 $e%'1in f r . Nf . #20#03 . B 11'1in A . 0#8D )n B0 θ'23 . 0#8 H 8#0 )n B0:'23 . 9#80 11 T m . t+A'f r . 0 9#803'B . 0.18 min ol()ion
©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
C())in* Con+i)ion in Millin*
Rotational speed in milling
Where, N = spindle speed (rev/min)/(rpm) v = cutting speed (mm/min)
D = the diameter of milling cutter (mm)
D
v
N
π
©2007 John Wiley & Son! In"# M P G$oo%e$! Fundamentals of
•
Fee+ $)e
»
» Whe$e! f r . -ee+ $)e 11'1in3
» f . "hi, lo+ 11')oo)h3
» nt . n(1;e$ o- )ee)h on )he "())e$
»
•
M)e$il $e1o%l $)e
Whe$e!
RMR . 1)e$il $e1o%l $)e 11'1in3
f r . -ee+ $)e 11'1in3
w . 4i+)h o- 4o$5,ie"e 113 d . +e,)h o- "() 113
Nf
n
f
r = t rwdf
R
MR =A l; 1illin* o,e$)ion i ,e$-o$1e+ )o /nih )he )o, ($-"e
o- )eel $e")n*(l$ 4o$5,ie"e 0#0 in lon* ;y #0 in 4i+e#
The heli"l 1illin* "())e$! 4hi"h h 2#8 in +i1e)e$ n+
ei*h) )ee)h! i e) (, )o o%e$hn* )he 4i+)h o- )he ,$) on
;o)h i+e# C())in* "on+i)ion $e=
v . 00 -)'1in! f . 0#00B
in')oo)h! n+
d . 0#280 in# De)e$1ine=
3 )he )i1e )o 15e one , "$o )he ($-"e#
;3 )he 1e)l $e1o%l $)e +($in* )he "()#
N . 00 H 2'2#8 . 82#: $e%'1in#
-$ . 82#::30#00B3 . #0 in'1in
A . +D+33#8 . #282#8#2833#8 . 0#78 in
3 T
1. 0#0 0#783' .
0.98 min.
;3 MRR . #0#283#03 .
8.25 in
3/min.
Sol()ion =A -"e 1illin* o,e$)ion i ,e$-o$1e+ )o /nih )he )o, ($-"e
o- )eel $e")n*(l$ 4o$5,ie"e lon* :00 11 4i+e# The
heli"l 1illin* "())e$! 4hi"h h 80 11 +i1e)e$ n+
)en )ee)h! i e) (, )o o%e$hn* )he 4i+)h o- )he ,$) -$o1
i+e )o no)he$ i+e# The "())in* ,ee+ i 000 11'1in!
)he "hi, lo+ i 0#: 11')oo)h! n+ )he +e,)h o- "() i
11# De)e$1ine=
i3 The -ee+ $)e o- )he o,e$)ion!
ii3The 1e)l $e1o%l $)e +($in* )he "()! n+
iii3
The 1"hinin* )i1e i- 0#00 1
%ol(1e o- 1e)l nee+ )o
$e1o%e#
3 N = v/ ΠD = 6000/ Π x 150 = 12.372 rmf r = nt Nf = !10"!12.372"!0.#" = 85.856 mm/min
;3 RMR= wdf r = !#00"!3"!#5.#56" = 206,054.4 mm3 /min
Tool Li-e C$i)e$i in
P$o+(")ion
T4o )e) 4e$e "on+(")e+ )o +e)e$1ine )he $el)ionhi,
;e)4een "())in* ,ee+ n+ )ool li-e# In )he /$) )e)! "())in* ,ee+ o- 00 1'1in $e(l) )ool li-e o- 28 1in()e# In )he e"on+ )e)! "())in* ,ee+! "())in* ,ee+ o- 200 1'1in 4hi"h $e(l) )ool li-e 8 1in()e# Uin* Tylo$K e()ion! +e)e$1ine )he "on)n)#
6Tn.C e()ion -o$ )ool li-e
00 H 28 n. 200 H 8n 00 '200 . 8'28 3 n #8 . 2# n lo* #8 . n lo* 2# 0#7 . n H 0#99 n = 0.425 C . 00 28 0#928 C = 1175. Sol()ion =
Sn+ C)in* O,e$)ion
• A n+ "o$e h %ol(1e . :78 "1 n+ i lo")e+ ini+e n+
1ol+ "%i)y# De)e$1ine )he ;(oyn"y -o$"e )en+in* )o li-) )he "o$e +($in* ,o($in* o- 1ol)en le+ in)o )he 1ol+# The +eni)y o- )he "o$e . # *'"13
• Sol()ion=
Wei*h) o- )he "o$e . :78#3 . 000 * . 5*
The +eni)y o- le+ . # *'"1;e+ on );le #3
The 4ei*h) o- le+ +i,l"e+ ;y )he "o$e i :78 #3 . 2!:: * . 2#B 5*#
The +ie$en"e . 2#B#0 . :#B 5*# Gi%en )h) 5* . B#: N! The ;(oyn"y -o$"e i )he$e-o$e , . B#::#B3 . 178.4 N
A "ylin+$i"l $ie$ 1() ;e +ei*ne+ -o$ n+")in* 1ol+#
The ")in* i)el- i )eel $e")n*(l$ ,l)e 4i)h
+i1enion ho4n in )he /*($e # P$e%io( o;e$%)ion
h%e in+i")e+ )h) )he )o)l oli+i/")ion )i1e T
TS3 -o$ )hi
")in* . 2#0 1in# The "ylin+e$ -o$ )he $ie$ 4ill h%e
+i1e)e$)ohei*h) $)io . #0# De)e$1ine=
3 The +i1enion o- )he $ie$ o )h) i) )o)l oli+i/")ion )i1e i 28 lon*e$ )hen ")in*#
;3 Why )he $ie$ nee+ )o ;e +ei*ne+ o )h) i) ;e"o1e )he l) ,$) )o oli+i-y? EH,lin yo($ n4e$#
")in*
$ie$
Mol)en )eel o4
1 cm !" cm
Sol()ion
C)in* %ol(1e % . L-t . 7#8832#03 . 228 "1 C)in* $e A . 27#8 H 8 7#8 H 2#0 8 H 2#03 • . 22#8 8 03 • . 8 "12 %/A . 228'8 . 0#79 C)in* T T . m0#7932 . 2#0 1in m . 2#0'0#7932 . #B2 1in'"12 •Cylindrical casting with D = 6ol(1e % . π D2L'9 3
S(;)i)()e )he eH,$eion -o$ L in )he e()ion = 6ol(1e % . π D'9
•
A$e A . 2π D2'9 π DL 23
S(;)i)()e )he eH,$eion -o$ L in )he e()ion 2 A$e A . π D2'2 π D2 • . π D2 2π D23 ' 2 o) %/A =D/6 T T . #B2 D'32 . #28 H 2 • =#B2 D'32 . 2#8 • D2. 22#B9 • D = *.7 $m • D ! ! 4."9 cm
;3 Rie$ nee+ )o ;e +ei*ne+ o i) 4ill ;e )he l) ,$) )o oli+i-y +(e )o )he -ollo4in* $eon=
