MANUFACTURING

PROCESS
CALCULATION SLIDE

Cutting Conditions in Turning

Rotational speed in turning

v Where, N = rotational speed (rev/min)/(rpm)

v = cutting speed (m/min)
N
D = original diameter of the part (m)
Do
o

2007 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern

 Depth of cut
d Do Df / 2

Where, Df = final diameter (mm)

Do = original diameter (mm)
d = depth of cut (mm)

Feed rate
fr Nf
Where, f

2007 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern

= feed rate (mm/min)

f = feed (mm/rev)

 Machining time

T L/ f

Where,
Tm = machining
time (min)
m
r
L = length of the cylindrical

workpart (mm)

Volumetric rate of material

removal

RMR vfd

Where,
RMR = material removal rate (mm3/min)
f = feed (mm)
v = cutting speed (m/min)
d = depth of cut (mm)
2007 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern

TURNING 1
A single point cutting tool having a rake angle of 12 degree was
preferred to machine a shaft having diameter of 50 mm into
final diameter of 47 mm with feed of the cut was 1.5 mm. The
work piece was rotating at 500 m/s. The machining produced
continuous chips having thickness of 1.8 mm. The forces were
measured by dynamometer. The cutting/horizontal force was
450 N and the trust/vertical force was 325 N.
Calculate the following:
(a)
Chip thickness ratio,
(b)
The shear angle,
(c)Resultant force,
(d)
Coefficient of friction,
(e)
Material removal rate, RMR
(f) Cutting power for the operation?

SOLUTION :

In a turning operation on aluminum, spindle speed is set to

provide a cutting speed of 2.0 m/s. The feed and depth of
cut are 0.25 mm and 2.4 mm respectively. The tool rake
angle is 8. After the cut, the deformed chip thickness is
measured to be 0.45 mm. Given specific energy for this
operation is 0.7 N-m/mm3 with correction factor of 1.05.
Determine:

shear plane angle,

friction angle,
cutting power for the turning operation, and
power to drive the lathe motor if mechanical efficiency is 90%.

Cutting Conditions in
Drilling

Rotational speed in drilling

v Where, N = spindle speed (rev/min)/(rpm)

v = cutting speed (mm/min)
N
D = the drill diameter (mm)
D
2007 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern

 Volumetric rate of material removal

RMR (D / 4) fr
2

Where,
RMR = material removal rate
(mm3/min)

2007 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern

In a drilling operation of medium carbon steel

workpiece, a 15.0 mm diameter twist drill is being
used to drill a through hole at a depth 30 mm and
the point angle is 118. The cutting speed is set
to 30 m/min and the feed is at 0.3mm/rev.
Determine the time required to completely
solution
produce the hole.
(a) N = v/D = 30(103) / (15.0) = 636.62 rev/min
fr = Nf = 636.62(0.30) = 191 mm/min
A = 0.5D tan (90 /2) = 0.5 x 15.0 tan (90-118/2) =
4.506 mm
Tm = t+A/fr = (30 + 4.506)/191 = 0.18 min

Cutting Conditions in Milling

Rotational speed in milling

vWhere, N = spindle speed (rev/min)/(rpm)

v = cutting speed (mm/min)
N
D = the diameter of milling cutter (mm)
D
2007 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern

 Feed rate

rate (mm/min)
fr n Nf Where, ff == feed
chip load (mm/tooth)
r

nt = number of teeth on the cutter

Material removal rate

RMR wdfr
Where,
RMR = material removal rate (mm 3/min)
fr = feed rate (mm/min)
w = width of workpiece (mm)
d = depth of cut (mm)

2007 John Wiley &

Sons, Inc. M P Groover,
Fundamentals of
Modern

A slab milling operation is performed to finish the top surface

of a steel rectangular workpiece 10.0 in long by 3.0 in wide.
The helical milling cutter, which has a 2.5 in diameter and
eight teeth, is set up to overhang the width of the part on
both sides. Cutting conditions are: v = 100 ft/min, f = 0.009
in/tooth, and d = 0.250 in. Determine:
a) the time to make one pass across the surface.
b) the metal removal rate during the cut.
Solution :

N = 100 x 12/2.5 =
152.8 rev/min.
fr = 152.8(8)(0.009) = 11.0 in/min
A = (d(D-d)).5 = (.25(2.5-.25)).5 = 0.75 in

(a) Tm = (10.0 + 0.75)/11 = 0.98 min.

(b) MRR = 3.0(.25)(11.0) = 8.25 in3/min.

A face milling operation is performed to finish the top surface

of a steel rectangular workpiece a long 800 mm wide. The
helical milling cutter, which has a 150 mm diameter and
ten teeth, is set up to overhang the width of the part from
side to another side. The cutting speed is 6000 mm/min,
the chip load is 0.8 mm/tooth, and the depth of cut is 3
mm. Determine:
(i) The feed rate of the operation,
(ii)The metal removal rate during the cut, and
(iii)
The machining time if 0.003 m3 volume of metal need to
remove.
(a) N = v/ D = 6000/ x 150 = 12.372 rpm
fr = ntNf = (10)(12.372)(0.8) = 85.856 mm/min
(b) RMR= wdfr = (800)(3)(85.856) = 206,054.4 mm3/min
(c) Tc = Volume/ RMR = 3 x 106/ 206,054.4 = 14.559 min

Tool Life Criteria in

Production
Two tests were conducted to determine the relationship
between cutting speed and tool life. In the first test, a cutting
speed of 300 m/min results a tool life of 25 minutes. In the
second test, a cutting speed, a cutting speed of 200 m/min
which results a tool life 65 minutes. Using Taylors equation,
determine
Solution : the constant.
VTn=C
equation for tool life

300 x 25 n = 200 x 65n

300 /200 = (65/25 ) n

1.5 = 2.6 n
log 1.5 = n ;log 2.6
0.176 = n x 0.414
n = 0.425
C = 300 X 25 0.425
C = 1175.

Sand Casting Operation

A sand core has a volume = 1875 cm3 and is located inside a sand
mold cavity. Determine the buoyancy force tending to lift the core
during pouring of molten lead into the mold. (The density of the
core = 1.6 g/cm3)

Solution:
Weight of the core = 1875(1.6) = 3000 g = 3 kg
The density of lead = 11.3 g/cm3 (based on table 11.1)
The weight of lead displaced by the core is 1875 (11.3) = 21,188 g
= 21.19 kg.
The difference = 21.19-3.0 = 18.19 kg. Given that 1 kg = 9.81 N,
The buoyancy force is therefore Fb = 9.81(18.19) = 178.4 N

A cylindrical riser must be designed for a sand-casting mold.

The casting itself is a steel rectangular plate with
dimensions as shown in the figure 1. Previous observation
have indicated that the total solidification time (TTS) for this
casting = 2.0 min. The cylinder for the riser will have a
diameter-to-height ratio = 1.0. Determine:
a)
b)

The dimensions of the riser so that its total solidification time

is 25% longer then casting.
Why the riser need to be designed so that it becomes the
last part to solidify? Explain your answer.
7.5 cm
riser
casting

15 cm

Molten steel flow

2.0 cm

Solution
Casting volume V = LWt = 7.5(15)(2.0) = 225 cm3
Casting area A = 2(7.5 x 15 + 7.5 x 2.0 + 15 x 2.0)

= 2(112.5 + 15+ 30)

= 315 cm2
V/A = 225/315 = 0.714
Casting TTS = Cm(0.714)2 = 2.0 min
Cm = 2.0/(0.714)2 = 3.923 min/cm2

Cylindrical casting with D = L

Volume V = D2L/4 (1)
Substitute the expression for L in the equation 1:
Volume V = D3/4

Area A = 2D2/4 + DL (2)

Substitute the expression for L in the equation 2
Area A = D2/2 + D2

= (D2 + 2D2) / 2
So, V/A =D/6
TTS = 3.923 (D/6)2 = 1.25 x 2

=3.923 (D/6)2 = 2.5

D2 = 22.94
D = 4.79 cm
D = L = 4.79 cm

(b) Riser need to be designed so its will be the last part to solidify due to the following
reasons:

To make sure that the molten metal is continually available from risers to prevent shrinkage