Manufacturing Processes (January 2022) Exercises [3 points]

P1 0 1 2 3 4 1 point

In an ISO standardized precision fit, the holes and shafts have a nominal diameter of 16 mm, are made of the same type of steel, and
should be assembled ensuring a minimum clearance of 30 m and a maximum clearance of 65 m. In order to prevent an excessive
manufacturing cost increase, the tolerance grades of both components should not be lower than IT4.

A shaft-basis fit system has been chosen to avoid machining of shafts, while the holes will be reamed to ensure the dimensional
tolerance of their diameter. The reamer that will be used, made of High Speed Steel (HSS) has been tested in previous experiments
carried out at a temperature of 20 °C, which yielded a final average diameter of 16,025 mm. In case this dimension were out of the
desired tolerance for the hole, the reamer will be heated or cooled to a proper temperature before use.

Supposing that the wear of the reamer is negligible, and that there is no temperature change during the machining of the holes,
determine the temperature at which the reamer should be heated or cooled just before use.

DATA: - Coefficients of Thermal Expansion:  9,9 10 °C -1

Solution: 𝑇 121 ℃ (being 16𝐸7/ℎ6 the standard fit)

Resolution

First, the span of the fit is calculated from the requirements:

𝑆𝑝𝑎𝑛 𝐽 −𝐽 65 − 30 35 m

The addition of the IT grades of both components should be lower than this value (35 m). For a nominal size of 16 mm, the IT grades
of higher quality (less costly) will be IT6 for the shaft and IT7 for the hole.
𝐼𝑇6: 𝑡 11 m
→ 𝑡 𝑇 29 m 35 m
𝐼𝑇7: 𝑇 18 m

Then, the known component is the shaft, 16h6, as a shaft-basis fit system is employed.

ℎ → 𝑒𝑠 0
16ℎ6 → → 16 ,
𝐼𝑇6 → 𝑡 11 m

Applying the requirements about the maximum and minimum clearance:

𝐽 ≤ 0,065 mm → 𝐸𝑆 − 𝑒𝑖 ≤ 0,065 mm → 𝐸𝑆 − −0,011 ≤ 0,065 mm → 𝐸𝑆 ≤ 0,054 mm

𝐽 ≥ 0,030 mm → 𝐸𝐼 − 𝑒𝑠 ≥ 0,030 mm → 𝐸𝐼 − 0 ≥ 0,030 mm → 𝐸𝐼 ≥ 0,030 mm

Now, the ISO standard designation is determined. In first place, the amplitude of the tolerance interval is found:

𝑇 𝐸𝑆 − 𝐸𝐼 ≤ 0,054 − 0,030 → 𝑇 ≤ 0,024 mm

For a nominal size of 16 mm, the standard tolerance grades that fulfill the previous condition range from IT01 (𝑇 0,5 m) to IT7
(𝑇 18 m). As mentioned above, IT7 will be selected to reduce manufacturing costs.

In second place, the position for the fundamental deviation is searched in the tables for holes (Tables 2 and 3), selecting that position
whose lower limit deviation (EI) is higher to +0,030 mm but closer to that value. The fundamental deviation is that deviation (ES or
EI) whose corresponding limit is closer to the reference line.
16
→ "𝐸" 𝐸𝐼 0,032 mm
𝐸𝐼 ≥ 0,030 mm
Thus, the ISO standard tolerance for the hole is:
,
16𝐸7 ≡ 16 ,

The maximum and minimum clearance of the standard fit (16𝐸7/ℎ6) are determined:

𝐽 = 𝐸𝑆 − 𝑒𝑖 = +0,050 − −0,011 = 0,061 mm ≤ 0,065 mm

𝐽 = 𝐸𝐼 − 𝑒𝑠 = +0,032 − 0 = 0,032 mm ≥ 0,030 mm

Therefore, the proposed fit fulfills the given requirements.

In order to manufacture the holes, a target diameter is established taken the mean value of the tolerance interval:
𝐷 +𝐷 16,050 + 16,032
𝐷 = = = 16,041 mm
2 2

As the reamer yields holes whose diameter (𝐷 ) is 16,025 mm at 20 °C, it is necessary to heat the tool until its diameter (𝐷 )
will be enlarged enough to produce holes with a diameter equal to 16,041 mm.

𝐷 =𝐷 · 1+ · 𝑇 −𝑇

16,041 mm = 16,025 mm · 1 + 9,9 · 10 ℃ · 𝑇 − 20 ℃

𝑇 = 121 ℃

If a tolerance grade IT 4 were selected for the shaft, that is, 16h4:

ℎ → 𝑒𝑠 = 0
16ℎ4 → → 16 ,
𝐼𝑇6 → 𝑡 = 5 m

Then the deviations for the hole would be:

𝐽 ≤ 0,065 mm → 𝐸𝑆 − 𝑒𝑖 ≤ 0,065 mm → 𝐸𝑆 − −0,005 ≤ 0,065 mm → 𝐸𝑆 ≤ +0,060 mm

𝐽 ≥ 0,030 mm → 𝐸𝐼 − 𝑒𝑠 ≥ 0,030 mm → 𝐸𝐼 − 0 ≥ 0,030 mm → 𝐸𝐼 ≥ +0,030 mm

And the ISO standard designation that best matches the previous interval is:
,
16𝐸8 ≡ 16 ,

that meets the requirements:

𝐽 = 𝐸𝑆 − 𝑒𝑖 = +0,059 − −0,005 = 0,064 mm ≤ 0,065 mm

𝐽 = 𝐸𝐼 − 𝑒𝑠 = +0,032 − 0 = 0,032 mm ≥ 0,030 mm

Therefore, the target diameter in the reaming operation would be:

𝐷 +𝐷 16,059 + 16,032
𝐷 = = = 16,0455 mm
2 2

Finally, the reamer should be heated to a temperature:

16,0455 mm = 16,025 mm · 1 + 9,9 · 10 ℃ · 𝑇 − 20 ℃

𝑇 = 150 ℃
P2 0 1 2 3 4 1 point

In a metallurgical company dedicated to sheet rolling it is necessary to replace the work roll of a four-high stand employed in the
processing of sheets made of three different materials:

Material ℎ [mm] ℎ [mm] 𝑆 𝜀 [daN/mm ]

A 2,1 2,0 15ε + 15
B 2,2 2,0 12ε + 12
C 4,0 2,0 3ε + 2

Each material is formed independently. All the sheets have a width of 200 mm. To replace the work rolls, a supplier provides the
following options:

Rolls R1 R2 R3 R4
𝐷 [mm] 100 150 200 250

Knowing that the maximum load supported by the system that regulates the vertical positioning of the rolls is 10 tons, please indicate
in a reasoned manner which rolls would allow for the rolling of all three material. Do NOT consider friction.

Solution: 𝑅1 𝐷 = 100 mm , 𝑅2 (𝐷 = 150 mm)

Resolution:

The constraint to consider when selecting the new rolls is the maximum load supported by vertical positioning system of the four-high
stand. Neglecting the influence of friction, the required load in a rolling process 𝑃 is calculated as:

𝑆 −𝜎 + 𝑆 −𝜎 𝑆 +𝑆
𝑃 =𝑞·𝐴 =𝑞·𝑤·𝐿 ≅𝑞·𝑤· 𝑅· ℎ −ℎ = ·𝑤· 𝑅· ℎ −ℎ = ·𝑤· 𝑅· ℎ −ℎ
2 2

In this case, the load for rolling each material should be lower to the maximum load supported by the stand positioning system:
𝑆 +𝑆
𝑃≅ ·𝑤· 𝑅· ℎ −ℎ ≤𝑃
2

From this inequation, the size of the rolls (through the radius or diameter) can be determined as:

𝑃 1 𝑃 1
𝑅≤ · ⇒ 𝐷 ≤2· ·
𝑆 +𝑆 ℎ −ℎ 𝑆 +𝑆 ℎ −ℎ
2 ·𝑤 2 ·𝑤

As the law of plastic behavior is a linear equation of the type:

𝑆 (𝜀) = 𝑎 · 𝜀 + 𝑏

being 𝐾 the material ((𝐾 = 𝐴, 𝐵 or 𝐶)), the constraint about the roll diameter can be rewritten in the form:

⎛ ⎞
𝑃 1
𝐷 ≤2·⎜
⎜
⎟ ·
⎟ ℎ
⎜ ℎ ℎ ⎟ −ℎ
𝑎 · Ln + 𝑏 + 𝑎 · Ln +𝑏
ℎ ℎ
⎝ · 𝑤⎠
2

Replacing the corresponding values for each sheet of each material, the following restrictions are obtained:

⎛ 10000 [daN] ⎞ 1
𝐷 ≤2·⎜ ⎟ · (2,1 − 2,0) [mm] ≅ 211,8 mm
2,1 2,1
15 · Ln + 15 + 15 · Ln + 15 daN
2,1 2,0
⎝ · 200 [mm]⎠
2 mm2

⎛ 10000 [daN] ⎞ 1
𝐷 ≤2·⎜ ⎟ · (2,2 − 2,0) [mm] ≅ 158,2 mm
2,2 2,2
12 · Ln + 12 + 12 · Ln + 12 daN
2,2 2,0
⎝ · 200 [mm]⎠
2 mm2
 ⎛ 10000 [daN] ⎞ 1
𝐷 ≤2·⎜ ⎟ · (4,0 − 2,0) [mm] ≅ 270,6 mm
4,0 4,0
3 · Ln + 2 + 3 · Ln + 2 daN
4,0 2,0
⎝ · 200 [mm]⎠
2 mm2

It can be appreciated that the material demanding a more restrictive range of diameter is the material B.

Considering all the three expressions, it can be concluded that the valid options for rolling the three materials are:

𝑅1 (𝐷 = 100 mm), 𝑅2 (𝐷 = 150 mm)

P3 0 1 2 3 4 1 point

A steel round (150 mm diameter and 400 mm long) is straight turned in a roughing operation whose target is a final diameter of
134 mm. To avoid problems derived from vibrations, the total height of the machined profile (Rt) in all of the passes should be
maintained under 15 µm.

The tool used for the operation consists of a rhombic insert with 80° between cutting edges, and with a nose radius (𝑟 ) of 1,2 mm,
mounted on a toolholder that defines a cutting edge angle of 75°.

To ensure the stability of the operations, the tangential component of the resultant force has been limited to a value of 2280 N. The
specific cutting for the workpiece material is estimated to be 1450 N/mm2.

The operation is carried out in a CNC lathe, with a continuous range of rotational speed. The nominal power is 15 kW with an
efficiency of 85%. The maximum speed of the headstock is 2000 rpm.

During the roughing cycle, the values for the cutting speed, feed, and depth-of-cut remain constant.

If the objective is to minimize the machining time, determine the cutting time in the machining of each workpiece.

DATA: - The total height of the roughing profile can be determined theoretically from the expression:

𝑓
𝑅𝑡 = with 𝑅𝑡 in mm, 𝑓 in mm/rev 𝑦 𝑟 in mm
8·𝑟

𝑡 = 2,70 min; 𝑣 = 347,58 m/min; 𝑓 = 0,38 mm/rev; 𝑎 = 4 mm (2 passes)

Solution:
or 𝑣 = 335,53 m/min; 𝑓 = 0,19 mm/rev; 𝑎 = 8 mm (1 pass)

Resolution:

To minimize the time required for machining, the maximum values for the cutting conditions (cutting speed, feed, and depth-of-cut)
should be selected. In the first alteranative, the maximum depth-of-cut will be established to reduce the number of passes. Supposing
that the size of the cutting insert would allow for removing the whole volume of material in a single pass, the depth-of-cut would be:
𝐷 −𝐷 150 − 134
𝑎 = = = 8 mm
2 2

In second place, the feed will be determined. On one hand, feed is constrained by the limit in the tangential component of the resultant
force, as this component, that constitutes the cutting force, is proportional to the area of the undeformed chip section, that is equal to
the product of the feed and the depth-of-cut:
2280 N
𝐹 ≤ 2280 N → 𝐾 · 𝐴 = 𝐾 · 𝑏 · ℎ = 𝐾 · 𝑓 · 𝑎 ≤ 2280 N → 𝑓≤
𝐾 ·𝑎

2280 N 2280 [N]

𝑓≤ = = 0,19 mm/rev
𝐾 ·𝑎 N
1450 2 · 8 [mm]
mm

On the other hand, feed affects the total height of the roughness profile 𝑅𝑡, so this parameter should be checked:

𝑓 0,19
𝑅𝑡 = = = 0,004 mm = 4 μm < 15 μm
8·𝑟 8 · 1,2

Now, the cutting speed (measured at the middle point of the active cutting edge) is determined from the power available:
𝑃𝑤𝑟 ·𝜂 15000 [W] · 0,85
𝑃𝑤𝑟 = 𝐹 · 𝑣 ≤ 𝑃𝑤𝑟 ·𝜂 → 𝑣 ≤ = = 5,59 m⁄s = 335,53 m/min
𝐹 2280 [𝑁]

The rotational speed to achieve that cutting speed should be checked to not exceed the capability of the headstock. Note that the
diameter to enter in the equation (𝐷 ) should correspond to the middle point of the active cutting edge.
1000 · 𝑣 1000 · 335,53 1000 · 335,53
𝑛= = = = 752 rpm < 2000 (𝑛 )
𝜋·𝐷 150 + 134 𝜋 · 142
𝜋· 2
Calculation of the cutting time

In a single workpiece, the time for cutting is:

𝑙 𝑙 𝑙 400 [mm] 400 [mm]
𝑡 = = = = = = 2,70 min
𝑣 𝑓 · 𝑛 𝑓 · 𝑛 0,19 [mm⁄rev] · 752 [rev⁄min] 147,83 [mm⁄min]
In a second alternative, feed is increased at cost of reducing the depth-of-cut, performing more passes.

In this case, the strategy for determining the cutting conditions involves performing the following steps:

1. The feed 𝑓 will be obtained from the constraint related with the roughness parameter 𝑅𝑡
2. The depth-of-cut 𝑎 will be calculated from the feed 𝑓 and the constraint related with the tangential force 𝐹
3. The cutting speed will be deterrmined from the feed 𝑓, the depth-of cut 𝑎 , and the constraint related with the power

Calculation of the feed f

𝑓
𝑅𝑡 = ≤ 0,015 mm → 𝑓≤ 0,015 · 8 · 𝑟 = 0,015 · 8 · 1,2 ≅ 0,38 mm/rev
8·𝑟

Calculation of the depth-of-cut 𝑎

2280 N
𝐹 ≤ 2280 N → 𝐾 · 𝐴 = 𝐾 · 𝑏 · ℎ = 𝐾 · 𝑓 · 𝑎 ≤ 2280 N → 𝑎 ≤
𝐾 ·𝑓

2280 N 2280 [N]

𝑎 ≤ = = 4,14 mm
𝐾 ·𝑓 N
1450 2 · 0,38 [mm]
mm

With this value, it is possible to determine the number of passes, and then to recalculate the depth-of-cut, as it should be equal
for all of the passes.
𝐷 −𝐷 150 − 134
2 2 8
𝑛 = = = = ⌈1,93⌉ = 2 𝑝𝑎𝑠𝑎𝑑𝑎𝑠
𝑎 4,14 4,14

Therefore, the depth-of-cut in each pass will be 4 mm.

Calculation of the cutting speed 𝑣

𝑃𝑤𝑟 ≤ 𝑃𝑤𝑟 ·𝜂 → 𝐹 ·𝑣 ≤ 𝑃𝑤𝑟 ·𝜂 → 𝐾 ·𝑓·𝑎 ·𝑣 ≤ 𝑃𝑤𝑟 ·𝜂

𝑃𝑤𝑟 ·𝜂 15000 [W] · 0,85

𝑣 ≤ = = 5,79 m⁄s = 347,58 m/min
𝐾 ·𝑓·𝑎 N
1450 · 0,38 [mm] · 4 [mm]
mm2

Before proceeding to calculate the cutting time, the rotational speed of the workpiece at each pass should be checked:
1000 · 𝑣 1000 · 347,58
𝑛 = = = 758 rpm < 2000 (𝑛 )
𝜋·𝐷 𝜋 · 146

1000 · 𝑣 1000 · 347,58

𝑛 = = = 802 rpm < 2000 (𝑛 )
𝜋·𝐷 𝜋 · 138

Calculation of the cutting time

In a single workpiece, the times for cutting each one of the two passes are:
𝑙 𝑙 400 [mm]
𝑡 = = = = 1,39 min
𝑣 𝑓·𝑛 0,38 [mm⁄rev] · 758 [rev⁄min]

𝑙 400 [mm]
𝑡 = == = 1,31 min
𝑣 0,38 [mm⁄rev] · 802 [rev⁄min]

Finally, the time for cutting in the machining of a single workpiece is:

𝑡 =𝑡 +𝑡 = 1,39 + 1,31 = 2,70 min

Why is the cutting time identical in both solutions?

The cause of the identical solution for the cutting time in both alternatives is that the product of the three cutting conditions is
constrained for the power available at the lathe.
𝑃𝑜𝑡 ·𝜂
𝑃𝑜𝑡 ≤ 𝑃𝑜𝑡 ·𝜂 → 𝐾 ·𝑓·𝑎 ·𝑣 ≤ 𝑃𝑜𝑡 ·𝜂 → 𝑓·𝑎 ·𝑣 ≤
𝐾

The mentioned product constitutes the parameter that indicates the Material Removal Rate (MRR):

𝑀𝑅𝑅 = 1000 · 𝑣 ·𝑓·𝑎

which can be also defined as the ratio between the volume of material removed and the time for cutting that volume:
𝑉𝑜𝑙
𝑀𝑅𝑅 =
𝑡

In case of removing the material in a single pass, the time for cutting will be:
𝜋 𝜋
𝑉𝑜𝑙 · 𝐷 −𝐷 ·𝑙 · (150 − 134 ) [mm ] · 400 [mm] 1427539,70 [mm ]
𝑡 = = 4 = 4 = = 2,70 min
𝑀𝑅𝑅 1000 · 𝑣 · 𝑓 · 𝑎 1000 [mm/m] · 335,53 [m/min] · 0,19 [mm] · 8 [mm] 527586,21 [mm /min]

On the other hand, if two passes are performed, the time for cutting is:

𝑉𝑜𝑙 𝑉𝑜𝑙
𝑡 =𝑡 +𝑡 = +
𝑀𝑅𝑅 𝑀𝑅𝑅

The MRR in each pass will be identical, as the cutting conditions are constant:

𝑀𝑅𝑅 = 𝑀𝑅𝑅 = 𝑀𝑅𝑅 = 1000 · 𝑣 · 𝑓 · 𝑎 = 1000 [mm/m] · 347,58 [m/min] · 0,38 [mm] · 4 [mm]

𝑀𝑅𝑅 = 527586,21 [mm /min]

Moreover, the value of the MRR is equal to the one in the case of a single pass, as it has been calculated from the same constraint
derived from the power available at the lathe.

Returning to the expression of the cutting time:

𝑉𝑜𝑙 𝑉𝑜𝑙 𝑉𝑜𝑙 + 𝑉𝑜𝑙 𝑉𝑜𝑙

𝑡 =𝑡 +𝑡 = + = =
𝑀𝑅𝑅 𝑀𝑅𝑅 𝑀𝑅𝑅 𝑀𝑅𝑅

that is the same expression than in the case of a single pass.

Therefore, it can be concluded that, independently of the number of passes, as long as the Material Removal Rate remains constant,
the cutting time will be equal for any of the solutions.