Assignment 1 - Manufacturing and Nano-Technology(MEC4104F)

Joshua Hobson(HBSJOS001) 13th March 2013

Question 1
High speed maching allows users to achieve greater accuracy and surface nishes while reducing maching time and componet cycle times. Thus manufacturing productivity will be greatly increased. Typically a machine is said to be capable of high speed maching if the average spindle speed is greater than 25 000 rpm. This high spindle speed allows for much higher feed rates, than those typically used in convetional machining. Although the depth of cut is smaller than conventional machining, increased feed rates still mean that overall maching time is reduced. The chips formed during the high speed maching process are extremely small and also absorb the bulk of the heat generated during the machining process. The small chip size means that vibrations are reduced. The coupling of lower maching temperatures and reduced vibrations result in better machining quality. This means that fewer parts are rejected, allowing for higher productivity. The cutting force from high speed maching is very low. This means that very little time is spent fully constraining and clamping the workpiece so that it doesnt move during machining. This saves valuable time and increases the manufacturing productivity. Of particular importance is the surface nished produced by high speed machining. Usually a component which has undergone conventional maching will require polishing and other process so that the desired surface nish is achieved. This costs vaulable time and means that the cycle time for each component is increased. High speed maching produces a surface nish which is very high, meaning that very little or no polishing is required after machining. This again reduces component cycle time. The type of lubricant used in high speed maching may also, for certain materials, mean that components dont have to go through an extra degreasing step after machining. This will also aid in reducing component cycle time. In summary high speed maching has many advantages which will decrease component cycle time, which will intern increase manufacturing productivity.

Question 2
The time taken to complete two dierent machining operations will be calculated, namely that of a convetional machining operation and that of a high speed machining operation. The conventional machining operation will be calculated rst. It comprises of milling a graphite tool which will be used to spark erode the hardened steel die. Concentional machining

Figure 1: Path taken by cutting head, to machine one layer of material

P ath taken to machine one layer = 40 + 6 + 40 + ... = 360 mm Since the depth of cut is 1 mm there will be 20 layers that will be machined. T otal distance machined = 20 360 = 7200 mm 7200 1000 = 7.2 min 7 : 12 min

(1) (2)

(3) (4)

T hus time taken =

(5) (6)

Spark erosion process takes place. T ime = 20 103 1 = 20000 s 5 : 34 hrs (7) (8)

Adding 10 min for a polishing process the total process time will be: T otal time = 5 : 34 + 10 + 7 : 12 = 5 : 51 : 12 hrs 2 (9) (10)

High speed machining This process consists of directly machining the hardened die using an end-mill and nally applying a polishing process. The path followed for machining can be seen in gure 2.

Figure 2: Path taken for high speed machining

The time taken for maching side A,B,C and D was calculated as follows. A = 100 + 2 + 100 + 2 + 100 + ... = 814 mm B = C = 80 + 2 + 80 + 2 + 80 + 2 + ... = 654 mm D = 60 + 2 60 + 2 + 60 + 2 + 60 + ... = 494 mm (11) (12) (13) (14) (15) (16) (17) (18)

The 10 mm rounds are then machined. Figure 3 shows that the rounds will only require one pass to machine as the value for x is less than the diameter of the cutting tool.

Figure 3: Path taken for high speed machining

machining distance = r 13 = 2 = 20.42 mm Thus the total maching distance for one layer is:

(19) (20) (21)

T otal distance per layer = 814 + 2 654 + 494 + 4 20.42 + 40 4 = 2857.68 mm

(22) (23)

Since the depth of cut is 0.5 mm, it will require 40 layers to reach the required depth of 20mm

T otal machining distance = 40 2857.68 = 114 307.2 mm Assumimg that the spindle speed is 40 000 rpm. The feed rate will be F eed rate = 40 103 0.01 mm = 4 000 min

(24) (25)

(26) (27)

Thus the total machining time can be calculated as follows 114307.2 4 103 = 28 : 35min

T ime =

(28) (29) (30) (31) (32) (33)

Adding 3 : 20 min f or polishing T ime = 31 : 55 min

Thus it can be seen that the high speed machining process is by much faster than the concevtional machining method.

Question 3
Minimum power required to conduct a turning operation is shown below. pw = ks f dl = 1.4 1000 0.3 = 15.75 kw 450 5 1 60 (34) (35) (36)

Question 4
The gure below displays the cutting time versus ank wear for varies cutting speeds.

Figure 4: Flank wear versus

Using the graph in gure 4, the cutting time for a ank wear of 0.381 mm was determined for all four cutting speeds. The table below shows the values. Table 1: Cutting time for a ank wear of 0.381 mm Cutting speed (m/min) 121.92 182.88 243.84 304.8 Cutting time (min) 55.40 13.15 4.50 1.74

The taylor life equation is given by V T n = C . Using a log(V) versus log(T) graph the values for n and C in the taylor life equation can be found by plotting the values from table 1. Figure 5 shows the graph used to determine the n and C values.

Figure 5: Log(V) versus log(T) From the graph n = 3.75 and C = 3.84 109 Thus the tool life for a cutting speed of m 91.44 is 107.84min min

Question 5
Cubic Boron Nitride(CBN) is better suited for machining steels. Both diamond and CBN consist of inter-penetrating face centered cubic lattices. Diamond is composed of only carbon atoms. Diamond is not the most stable form of carbon at standard conditions. This is exacerbated at high temperatures. When diamond is used to machine steels, the diamond surface is smoothly worn by a mechanism which appears to transform diamond to a graphite form. This graphitisation begins at just over 7300 C when machining steels. This temperature is easily reached during normal machining operations. Thus CBN is the best choice as it will be stable and undergo no phase change at those temperatures.

Question 6
It is critically important that a coating on a too and the substrate have the same coecient of thermal expansion. A mismatch between the two can be detrimental to the adhesion qnd quality of the coating, as well as resulting in high thermal stress at the interface. Spalling may also result due to the mismatch. All these factors contribute to decrese the life of the cutting tool dramatically.