Assumed values for cutting parameters

Nose radius =NR=0.4mm

Feed=f=0.65mm

Rai=2.4

Cutting speed=Cs=v=27m/min

Original dia=Do=50mm

Final dia = Df=46mm

Cutting force =1349N

Calculation of surface roughness

2
f
Ri=
32 NR

( 0.65 )2
=
(32)(0.4)
Ri=0.0333 μm

Surface roughness =Ra= (Rai)(Ri)

= (2.4)(0.0333)

Ra=0.08 μm

Calculation of rotational speed feed rate depth of cut RMR

power
v 27000
Rotational speed N= = =171.8rev/min
π D o ( π )(50)
Feed rate fr=(N)(f)=(171.8)(0.65)=111.7

D f −D o 50−46
Depth of cut =d= = =2
2 2
Material removal rate =RMR=vfd=(27000)(0.65)(2)=35100mm 3/min

27
Power =pc=Fcv=(1349)( =0.81H.p
(60)(746)

Assumptions for minimum cost and maximum production rate

Tylor tool life constant =n =0.08

Cutting speed =C = 27m/min

Length of work piece =150mm

Original dia=Do=50mm

Part handling time = Th =2.5 min

Tool change time = Tt =1.5 min

Tool cost Ct =4$/cutting edge

Cost of machining and operator =0.2$/min

Calcuations for minimum cost and maximum production rate

Vmax
C 27

(( ) ) (( ) )
n 0.08
Vmax= 1 = 1 =21.49m/min
−1 ( Tt ) −1 ( 1.5 )
n 0.08

vmin

(( )( )) (( )( ))
n 0.08
n Co 0.08 0.2
vmin = C = 27 =17.37m/min
1−n CoTt +Ct 1−0.08 (0.2)(1.5)+ 4

tool life for Vmax

( ) ( )
1 1
c n 27 0.08
Tmax= = =17.34 min/cutting edge
Vmax 21.49

tool life for Vmin

( )
1
27 0.08
Tmin= ¿ ¿ = =248min/cutting edge
17.37

Machiening time for vmax

πDoL π (50)(150)
Tm = = = 1.6min
f Vmax (0.65)(21.49∗103)

Machiening time for vmin

 πDoL π (50)(150)
Tm = = = 2min
fVm∈¿ ¿ (0.65)(17.37∗103 )

Number of pieces for vmax

Tmax 17.34
Np = = =10.8 pieces
Tm 1.6

Number of pieces for vmin

¿ ¿ 248
Np=Tm∈
Tm = 2 =142 pieces

For Vmax production cycle time and cost

Tt
Tc=Th+Tm+
np
1.5
=2.5+1.6+ = 4.23 min/pc
10.8
(Co)(Tt ) Ct (0.2)(1.5) 4
Cc=CoTh+CoTm+ + = (0.2)(2.5)+(0.2)(1.6)+ + = 1.25$/pc
np np 10.8 10.8

For Vmin production cycle time and cost

Tt
Tc=Th+Tm+
np
1.5
=2.5+2+ = 4.23 min/pc
142
(Co)(Tt ) Ct (0.2)(1.5) 4
Cc=CoTh+CoTm+ + = (0.2)(2.5)+(0.2)(2)+ + = 0.93$/pc
np np 142 142