PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Operating Conditions
and Tool Life
Unit 30

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
 30-2

Objectives
• Describe the effect of cutting conditions on
cutting-tool life
• Explain the effect of cutting conditions on
metal-removal rates
• State the advantages of new cutting-tool
materials
• Calculate the economic performance and
cost analysis for a machining operation
 30-3

Operating Conditions
• Three operating variables influence metal-
removal rate and tool life
– Cutting speed
– Feed rate
– Depth of cut
 30-4

Depth of Cut, Feed Rate,

and Cutting Speed
• Metal-removal rate (MRR)
– Rate which metal removed from unfinished part
– Measured in cubic inches or cubic centimeters per
minute
– Change accordingly with each variable (cutting
speed, feed, and depth of cut)
• Difference can be proven by test piece on lathe
 30-5

Effects of Changing
Operating Conditions
• Minimum depth of lathe cut
– 10 times rate of feed
• After testing variable and effect on tool life
– Changes in depth of cut have least effect
– Changes in feed rate have greater effect than
depth-of-cut changes
– Changes in cutting speed of any material have
greater effect than either depth-of-cut or feed-
rate changes
 30-6

Reduction in Tool Life

Operating Conditions

CUTTING FEED DEPTH OF

SPEED + 50% RATE + 50% CUT + 50%

90% 60% 15%

 30-7

General Operating Condition Rules

• Proper cutting speed most critical factor to

consider establishing optimum conditions
– Too slow: Fewer parts produced, built-up edge
– Too fast: Tool breaks down quickly
• Optimum cutting speed should balance
metal-removal rate and cutting-tool life
• Choose heaviest depth of cut and feed rate
possible
 30-8

Factors Affecting Production Rate

• Inadequate horsepower
– Limits metal-removal rate
• Surface finish requirements
– May limit feed rate
• Machine rigidity
– May not be sufficient to withstand cutting
forces, feed rate and depth of cut
• Rigidity of part being machines
– May limit depth of cut
 30-9

Economic Performance
• Many factors considered for true cost
• Most important factor affecting metal-
removal rate is type of cutting tool used
• Two factors considered for total machining
cost equation
– Cost of using cutting tool
– Price of cutting tool
 30-10

Cost of Using the Tool

• Ability of cutting tool to remove stock determines
production rate and amount of labor to produce
part
• Tool's ability to remove stock governed by
number of times tool must be reconditioned or
replaced
• Rate cutting tool wears influences how often tool
removed and replaced
• Tool must be reconditioned and stored in
inventory affecting total machining cost