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Machining Economics
Machining Economics
Machining Economics
1
Cost Components of Production
• handling cost/piece
Economics of Machining
• tooling cost/piece
• tool setting and changing cost/piece
• machining cost/piece
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Economics of Machining
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4
Min Cp
Vopt
Minimum cost
R
Cost of Production
V
3
2 4–31–Cost
––Cost
Cost
RCost
– of tool
ofof
ofmachining
Total changing
handling
tooling
Cost
Time Components of Production
• machining time/piece
Economics of Machining
• handling time/piece
• tool setting and changing time/piece
4
Economics of Machining
2
Min Tp
3
R
Minimum time
Vopt
Rate of Production
Maximum
production
1
V
5
Time
changing
21–3–Non-productive
–Tool
RMachining
– Total time
timetime
Economics of Machining
Minimum
Economics of Machining
cost
Production rate
Cost per piece
Maximum
Hi-E production
range
Vcp Vtp
V
6
Cost of Production
machining cost/piece
Economics of Machining
+ handling cost/piece
7
Cost of Production
machining cost/piece =
Economics of Machining
8
Cost of Production
tool setting cost/piece =
Economics of Machining
9
Cost of Production
tooling cost/piece =
Economics of Machining
10
Cost of Production
handling cost/piece =
Economics of Machining
Constant
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Cost of Production
Therefore, overall machining cost or production cost per
piece ,
Cp = Cm*tm + Cm*ts*(tm/T) + Ce*(tm/T) + Cm*th
Economics of Machining
……(1)
where,
Cm = Machining cost per unit time
tm = Machining time
ts = Tool setting time
T = Tool life
Ce = Tool cost per edge
th = Tool handling time
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Cost of Production
Since,
Machining time (tm) = ( π*d*l/ 1000*f*v)
Economics of Machining
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Rate of Production
machining time/piece
Time of Prodn. (Rp) + tool setting time/piece
+ handling time/piece
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Economics of Machining Rate of Production
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Economics of Machining Rate of Production
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Economics of Machining Rate of Production
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Economics of Machining Rate of Production
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b) Tool costs:
brazed tools – initial cost = Rs.80/-; grinding
time – 5 min/edge; tool changing time = 2
min; 9 grinds/tool before salvage.
Throw-away inserts: cost – Rs.300; tool
change time = 1.5 min; cutting edges = 8
i. Plot the cost/piece as a function of cutting speed
and hence find the cutting speed for minimum
cost for each case.
ii. Compute and compare the tool life for minimum
cost/piece for maximum production rate both for
brazed and inserted type cutting tools.
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Cost of Production
Extended Taylor’s tool life equation:
Economics of Machining
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Cost of Production
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Economics of Machining Rate of Production
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Economics of Machining Rate of Production
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Economics of Machining Rate of Production
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Exercise Problems
Pb.: A large batch of steel shafts are to be rough turned to 76 mm
diameter for 300 mm length at a feed of 0.25 mm/rev. A solid
HSS type tool is to be used and appropriate constant in Taylor’s
tool life equation for the conditions employed are as follows: n =
Economics of Machining
37
Exercise Problems
Pb.: A 200 mm long and 300 mm diameter bar is
turned on a lathe with feed = 0.25 mm/rev.
The operating cost is 5 paise/min while the
Economics of Machining
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Exercise Problems
A tool used in a turning operation is of the brazed
carbide tip type. Its cost is Rs. 450/- and on the average,
it can be reground 10 times. The cost of regrinding is
Economics of Machining
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Exercise Problems
Pb.: Illustrate in a sketch graph the economic factors
involved in metal cutting and show that cutting
Economics of Machining
Contd….
47