Professional Documents
Culture Documents
L4.2-Process Parameters and Machining Time
L4.2-Process Parameters and Machining Time
Prepared by Gebre F.
August 2022
Process Parameters
8/22/2022 2
Learning objectives
Students are able to know
22/08/2022 3
Introduction
❖There are only three parameters that can influence the
success of the machining.
➢ Cutting speed- the relative surface speed between the tool
and the job.
➢ Feed- is the distance the tool travels into the job in one
revolution of the work or the distance the table holding the
work travels per one stroke of the tool.
8/22/2022 4
Factors affecting Feed, Speed and Depth of cut
8/22/2022 5
1. Surface cutting speed
8/22/2022 6
Surface cutting speed Contd.
❖Cutting Speeds for Turning, Boring, Milling and Drilling
➢The maximum cutting speed “V” can be calculated by
using the maximum rotational speed “N” of the
workpiece/tool and the Workpiece/tool diameter “D” in
the following equation:
Where
✓ Vc is the surface cutting speed (m/min)
✓ D the diameter of the cutter(mm) and
✓ N the revolutions of the spindle
8/22/2022 7
Surface cutting speed Contd.
➢In turning and boring where a taper is being machined,
that is, the diameter is varying across the cutting
operation, the average diameter should be used.
Where,
✓D is the average diameter of the workpiece
✓d1 the diameter of the workpiece at the start
✓d2 the diameter of the workpiece at the end
8/22/2022 8
Surface cutting speed Contd.
Example 1- For the part shown in Figure 1, calculate the
maximum surface speeds for
Facing
Turning all surfaces and
Parting off
✓The maximum spindle speed of the lathe being used is
600rpm.
8/22/2022 9
Figure 1- Example part
8/22/2022 10
Cutting Speeds for Shaping and Planning
➢Cutting speed for shaping and planning is defined as the
average speed of the tool during the cutting stroke and
depends on the number of strokes per minute, N and length
of the stroke L.
➢The cutting speed can be determined as follows:
Where:
✓ V is the surface cutting speed (m/min),
✓ L- the length of stroke (mm),
✓ N- the number of strokes per minute and
✓ m-is the inverse of the cutting to return ratio.
8/22/2022 11
Cutting Speeds for Shaping and Planning Contd.
8/22/2022 12
Cutting Speeds for Grinding
➢Grinding machines operate over a range of speeds
depending on the type of machine being used.
Where
✓Vc is the surface cutting wheel speed (m/min)
✓D the diameter of the cutter (mm) and
✓N the revolutions of the cutting wheel (rpm)
➢In addition to the speed of the cutting wheel, the
workpiece also moves across the grinding wheel or vice
versa.
➢Typical workpiece speeds range from 10 to 60m/min
8/22/2022 14
Spindle Speeds and Number of Strokes
➢The cutting speed is used to calculate the time taken for
each operation and the total machining time.
8/22/2022 15
Spindle Speeds for Turning, Boring, Milling & Drilling
8/22/2022 16
Spindle Speeds for Turning, Boring, Milling & Drilling contd.
Where;
✓NR is the revolutions of the cutter or the workpiece
✓Vc is the surface cutting speed (m/min) and
✓D is the diameter of the cutter or the workpiece in (mm).
8/22/2022 17
Table 1- Surface cutting speeds in meters per minute
8/22/2022 18
Spindle Speeds for Turning, Boring, Milling & Drilling contd.
Example 3
Calculate the spindle speed required to turn a 75mm
diameter shoulder on a low-carbon steel component using a
high-speed steel tool.
8/22/2022 19
Spindle Speeds for Turning, Boring, Milling & Drilling Contd.
Solution
From table 1
From table 1
8/22/2022 20
Stroke Speeds for Shaping and Planning
8/22/2022 21
Stroke Speeds for Shaping and Planning Contd.
➢The equation presented to calculate the cutting speeds can
be used to calculate the number of strokes, N by simple
transposition as follows:
Where;
✓ N is the number of strokes per minute
✓ V is the surface cutting speed (m/min)
✓ m is inverse of return – to – cutting ratio and
✓ L is the length of stroke (mm).
8/22/2022 22
Stroke Speeds for Shaping and Planning Contd.
Example 4
➢The planer in Example 2 has been refurbished and
upgraded and it is now claimed that speeds of up to
80m/min are possible with a cutting-to-return ratio of 3:2.
8/22/2022 23
2. Feed Rates
8/22/2022 24
Feed Rates contd.
❖Feed Rates for Turning and Boring
❖The two most common tool materials used for turning
are;
➢ high-speed steels (HSS) and
➢ carbides
❖It is common practice for manufacturers to recommend
feed rates in millimeters per spindle revolution fr
(mm/rev).
❖Typical feed rates fr are given for both materials in
Table 2 , compiled from various sources.
8/22/2022 25
Table 2- Typical feed rates for turning/boring in mm/rev
8/22/2022 26
Feed Rates Contd.
➢The feeds fr in mm/rev can be converted to mm/min (fm) by
using the equation:
fm = fr N
Where;
✓fm the feed rate in mm/min,
✓fr the feed rate in mm/rev and
✓N the spindle speed (rpm)
8/22/2022 27
Feed Rates Contd.
❖Feed Rates for Milling
➢ The manufacturers of milling cutters state recommended
feed rates in :
➢ mm/rev ( fr)
➢ mm/min ( fm) or mm/tooth ( ft )
➢ When feeds are expressed in mm/rev or mm/min, they
usually refer to specific cutters in the manufacturers range
and cannot be generally applied.
➢Therefore, for general use feed rates expressed in
mm/tooth are more suitable.
8/22/2022 28
Feed Rates Contd.
➢This can be used to determine the feed rate in mm/rev as
follows:
fr = ft n
Where;
✓ fr is the feed rate in mm /rev,
✓ ft the feed rate in mm/tooth and
✓ n the number of teeth on the cutter
➢From this, the feed fm in mm/min can be found from the
equation
fm = fr N
8/22/2022 29
Table 3- Typical feed rates for milling in millimeters per tooth
8/22/2022 30
Feed Rates Contd.
Example 5
➢ An inserted tooth face milling cutter has 8 teeth.
✓ It is to be used to mill a surface using a spindle speed of
1250 rpm and a feed rate of 0.3 mm/tooth.
8/22/2022 31
Feed Rates Contd.
Solution
8/22/2022 32
Feed Rates contd.
❖Feed Rates for Drilling
➢ HSS drills are used extensively for producing smaller
holes.
8/22/2022 33
Feed Rates Contd.
Table 4- Typical feed rates for HSS and carbide drills
8/22/2022 34
Feed Rates Contd.
➢ The feed rates for drills are similar to those for carbide
end mill cutters (see Table 3).
➢ However, it should be noted that as the depth of the hole
being drilled increases, the speeds and feeds should be
reduced.
➢ Finally, the feed used will also depend on the surface
finish required.
➢ The feed rate fm (in mm/min) for drilling tools can be
determined, using the feed fr in mm/rev, from the feed
rate for turning:
fm = fr N
8/22/2022 35
Feed Rates Contd.
❖Feed Rates for Shaping and Planning
➢ The feed rates for both shaping and planning depend on
the machine power, length of the stroke, depth of cut, the
workpiece material and the surface finish required.
➢ The feed rates fS are generally expressed in millimeters
per stroke and are sometimes referred to as the cross-
feed, that is, it is the distance moved across the
workpiece.
➢ Typically feeds for shapers are in the range of 0.05–
0.75mm/stroke
➢ and for planers in the range of 0.5–3.0mm/stroke
8/22/2022 36
Feed Rates Contd.
➢ These can be converted to mm/min by using the following
equation:
fm = fS NS
Where;
8/22/2022 37
Feed Rates Contd.
Example 6
For the planer in Example 4, the feed per stroke fS is quoted
as 2mm/stroke.
Solution
✓ fm = ? fm = fSNS
✓ fS = 2mm/stroke fm = 2 x 24
✓ NS = 24strokes/min fm = 48mm/min
8/22/2022 38
Feed Rates Contd.
❖Feed Rates for Grinding
➢ This is the feed rate at which the grinding wheel
traverses across the workpiece while the table provides
the pass or stroke motion.
8/22/2022 39
Feed Rates Contd.
➢ The feed rate for cylindrical grinding is referred to as the
in-feed and is actually the depth of cut.
8/22/2022 40
3. Depth of Cut
➢ There are various factors, to be considered, that can
affect the depth of cut:
➢ the tool material
➢ the workpiece material and
➢ the tool geometry
8/22/2022 41
Depth of Cut Contd.
❖ Depth of Cut for Turning and Boring
➢ The depth of cut is the radial feeding of the tool into the
workpiece.
8/22/2022 42
Table 5- Typical depths of cut for turning/boring with carbide tooling
8/22/2022 43
Depth of Cut Contd.
8/22/2022 44
Depth of Cut Contd.
1. Slab milling
2. Face milling
3. Slot milling and
4. End milling
8/22/2022 45
Depth of Cut Contd.
❖ General guidelines
➢ for both face and slot milling, a recommended depth
of cut is 1–4mm.
8/22/2022 46
Depth of Cut Contd.
8/22/2022 47
Depth of Cut Contd.
Example 7
A series of holes have to be drilled for a component.
What should the depth of cut be if a 12mm HSS drill is
used?
8/22/2022 48
Depth of Cut Contd.
Table 4
3.5
Table 4
3.5
8/22/2022 49
Depth of Cut Contd.
❖ Depth of Cut for Grinding
➢ For surface grinding the depth of cut is the in-feed
distance the grinding wheel projects into the surface of
the workpiece.
➢ The data for speed, feed and depth of cut for the
processes will be used to calculate machining times.
8/22/2022 51
Machining Times contd.
❖ Machining Times for Turning and Boring
➢ For the calculation of machining times for turning and
boring, two basic feed motions must be considered.
8/22/2022 52
Machining Times contd.
➢ These can be used to determine the machining time as
follows:
where
✓ T is the machining time (min)
✓ L the length of the workpiece (mm)
✓ A an allowance for tool approach & exit (2-5mm)
✓ fr the feed rate (mm/rev) and
✓ N the revolutions of the cutter or the workpiece in (rev/min)
8/22/2022 53
Machining Times Contd.
➢ When Feeding into the workpieces, the cutting tool travels
across the diameter D of the workpiece a distance of
D/2 at a feed rate fr while the workpiece rotates at N in
rev/min.
➢ These can be used to determine the machining time as
follows: ✓ T the machining time (min)
✓ D the diameter of the workpiece (mm)
✓ A an allowance for tool approach and
exit (mm)
✓ fr the feed rate (mm/rev) and
✓ N the revolutions of the cutter or the
workpiece in (rev/min)
8/22/2022 54
Machining Times Contd.
Example 8
The component in (Figure 1) is to be made from mild steel
with carbide tooling at a constant surface speed of
100m/min on a lathe with a maximum spindle speed of
1500 rev/min.
The machining allowance is 2mm.
Determine:
(i) If the lathe is capable of turning the component at the
required surface speed;
(ii) the total machining time for the component.
8/22/2022 55
Machining Times Contd.
❖ Machining Times for Milling and Drilling
➢ In milling, two broad categories of operations can be
identified.
➢Peripheral milling- the surface is parallel to the axis of
cutter rotation and only the teeth on the periphery of the
tool perform the cutting.
where
✓ T is the machining time (min)
✓ L the length of cut (mm)
✓ A an allowance for tool
approach and exit (mm)
✓ fr the feed rate (mm/rev) and
✓ N the spindle speed (rpm)
8/22/2022 57
Machining Times Contd.
Where
✓ A an allowance for tool approach and exit (mm)
✓ D the cutter diameter (mm) and
✓ d the depth of cut (mm)
8/22/2022 58
Machining Times Contd.
Example 9
o The top surface of the aluminium alloy component shown
in Figure 2 is to be milled by slab milling.
8/22/2022 59
Machining Times Contd.
Determine:
(i) if the mill is capable of machining the component at
the required surface speed;
8/22/2022 60
8/22/2022 Figure 2- Aluminum alloy component 61
Machining Times Contd.
➢ Face milling operations include:
➢ Face milling
➢ End milling and
➢ Slotting
➢ In face milling the allowance A for both tool approach
and exit is half the cutting tool diameter D.
➢ Therefore, the total allowance A is equal to the half
diameter D of the cutter, that is,
A = D/2
8/22/2022 62
Machining Times Contd.
❖ Example 10
Consider Example 9 to be done on vertical milling machine
with a ø25mm carbide face milling cutter with 10 teeth.
Assume the machine is capable of spindle speeds
4000rpm & a speed of 80m/min.
Determine:
(i) if the milling machine is capable of machining the
component at the required surface speed;
(ii) the total machining time for the component
8/22/2022 63
Machining Times Contd.
❖ Machining time for drilling
➢ The above equation can also be used to calculate the
machining time for drilling operations.
8/22/2022 64
Machining Times Contd.
Example 11
8/22/2022 65
Machining Times Contd.
❖ Machining Times for Shaping and Planing
➢ The cutting tool passes over the workpiece NS strokes per
minute and also moves across the width w of the
workpiece at a feed fS.
➢ To determine the machining time:
Where
➢ T is the machining time (min)
➢ W the width of the part (mm)
➢ NS the number of strokes per minute and
➢ fS the feed (mm/stroke)
8/22/2022 66
Machining Times Contd.
Example12
✓A component of width 950mm and length 1400mm is to
be machined on the planning machine with a cutting speed
of 80m/min. How long will it take to machine the
component surface? Take cutting to return ratio of 3:2, and
use the data from example 6 for Ns and fs.
8/22/2022 67
Thank You!!!
8/22/2022 68