Sheet 3

Tool life and tool wear

1- Take n=0.15 and 0.3 for H.S.S and centered carbide tooling
respectively. Find the change in the tool life when increasing speed V to
twice initial value.

2- A tool life cutting test has the following results:

Cutting speed, m/min 110 120 130 140

Tool life, min. 24 9.5 5.5 2.5

Use these values to obtain the constant of the tool life equation.

3- Under certain machining conditions the tool life equation is VT 0.2=7.56

(Velocity in m/sec). The time taken to change the tool is 7 min, Shaw that
operating at a constant speed of 100 m/min gives higher output than
operating at 133 m/min or 67 m/min. Other cutting conditions remain
constant.

4- A cutting tool working on mild steel gives an average life of 3 hrs

between regrinding. When operating at a cutting speed of 40 m/min. At
what cutting speed would it have to work, if it had to least throughout a
complete shift of 8 hrs (Assume the value of n = 0.15).

5- in turning of a steel rod by cutting tool, the tool life decreases from 80
min to 20 min. Due to increase in cutting velocity, vc from 60 m/min to
120 m/min., then at what cutting velocity the life of that tool will be 40
min?

6- Given the following data for certain cutting conditions:

Cutting speed for 32 min. Tool life (V32) = 100 m/min, cutting speed for
8 min. Tool life (V8) = 132 m/min.
Time for changing the tool = 10 min
The cost of regrinding the tool = 11 L.E.
The initial cost of the tool = 200 L.E.
1
Number of possible regrinding for one tool = 20.
Cost of running the machine = 54 L.E/hr
Find out:
a- The cutting speed for 1 min tool life.
b- The optimum cutting speed for minimum cost.
c- The optimum cutting speed for maximum output.

7- A tool life cutting test has the following results:-

Cutting speed,
95 110 130 145 160
m/min
Tool life,
60 25 13 7 4.8
min

- Use this values to obtain the constants of the tool life equation.
Given the following data for the cutting conditions:-
- Time for changing the tool = 5 min.
- The cost of regrinding the tool = 10 L.E/regrinding.
- The initial cost of the tool = 120 L.E.
- Number of possible regrinds for one tool = 15.
- cost of running the machine = 48 L.E. /hr.

Find the optimum cutting velocity for minimum cost and that for maximum
production output.

"Taylors Tool Life Equation" ALL DEFINATION FOR SYMBOLES

 𝐶𝑜𝑡 = initial cost of the tool…..LE

𝑣𝑡 𝑛 =𝑐 vc = cutting speed for minimum cost….m/sec
𝑣𝑡⬚ vp = cutting speed for maximum output….m/sec
𝑣𝑎𝑣𝑔 =
𝑡⬚ +t𝑐 t 𝑐 = time for changing the tool … . 𝑆

M = cost of running the machine … … LE

𝑣𝑝 = optimum cutting speed for maximum output

𝑀 𝑛
𝑣𝑐 = 𝐶 ( 𝐶𝑔 = cost of regrinding the tool … . LE
1−𝑛
(𝑀𝑡𝑐 + 𝑐𝑡
𝑛 𝑅𝑔 = number of possible regrinding for one tool

𝑐 ⬚
𝑣𝑝 = "Cost of Each grinding Tool (Ct)" ………. LE/regrind
1−𝑛 𝑛
( ∗ 𝑡𝑐
𝑛 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑜𝑜𝑙
c𝑡 = 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑔𝑟𝑖𝑛𝑑𝑖𝑛𝑔 +
𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑔𝑟𝑖𝑛𝑑𝑠 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒
2
𝐶𝑜𝑡
c𝑡 = 𝐶𝑔 + 𝑅𝑔
 Equations data sheet final
Tool geometry:
(
tan( = sin( tan( − cos( tan( , ( = (

tan( = sin( tan( + cos( tan( , = cot + tan

( − )
For orthogonal cutting operation
t ( (
= tan( =t , r = =
( (

Ernst and Merchant: = − Oxley: = − . ( −

Lee and Shaffer: = −( − Merchant Shear strength: = −

Velocities relations:

= =
cos( cos( − sin(
Forces relations:
= sin( + cos( , = cos( − sin(
= cos( − sin( , = sin( + cos(
= tan( − , = R cos ( + − , = R cos
( −

F= . . + . .( , N= . .(

Tool life relations:

= , = , = (
+t ( +

= , c = +
( ∗