\
|
=
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Economics of machining
The number of pieces per tool grind is
Therefore from the above equations:
To find the optimum cutting speed and optimum tool life for minimum
cost:
m
p
T
T
N =
( ) 1
1
1
=
n
n
p
LDV
fC
N
t
0 =
c
c
V
C
p
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Economics of machining
Solving the above equation we get
( ) | || | { }
( ) | |
m m
c g g g m m c
n
c g g g m m c
n
m m
B L
D B L T B L T
n
T
D B L T B L T
n
B L C
V
+
+ + + +
=
+ + + +
+
=
) ( ) (
1
1
is T life, tool optimum the and
) ( ) ( 1
1
) (
speed cutting optimum The
0
o
0
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Economics of machining
To find out the optimum tool life and optimum cutting speed for
maximum production:
Which gives
0 =
c
c
V
T
p
( ) | | { }
( ) | |
c
n
c
T
n
T
T
n
C
V
1
1
is T life, tool optimum the and
1
1
speed cutting optimum The
0
o
0
=
=
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Machinability is used to refer to the ease with which a given work
material can be machined under a given set of cutting conditions. It is
of considerable economic importance for the production engineer to
know in advance the machinability of a work material so that its
processing can be efficiently planned. The machinability of a material
is usually defined in terms of four factors:
Surface finish and integrity of the machined part,
Tool life obtained,
Force and power requirement, and
Chip control.
Because of complex nature of cutting operation, it is difficult to establish
relationships that quantitatively define the machinability of a material.
In manufacturing plants, tool life and surface finish are generally
considered to be the most important factors in machinability.
Although not used much any more, approximate, machinability ratings
are used to get an idea about the machinability of any material.
Thus machinability is not a basic standard but is related.
Machinability of metals
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Specific cutting speed is defined as the cutting speed corresponding
to the predetermined tool life.
Machinability ratings can be very easily understood with the help of a
example.
For example if the tool life during a turning operation under standard
condition (of feed, depth of cut, tool material and tool geometry) is
found to be 60min at a cutting speed of 100 m/min, the specific
cutting speed for 60 min tool life, V
60
= 100 m/min.
Further if V
t
60
is the specific cutting speed for 60 min tool life for a
test material and V
s
60
is the corresponding specific speed for a
standard material,
then the machinability ratings MR of the test material is given by
% 100
V
V
M
s
60
t
60
R
=
SAE 1212 is taken as standard material for testing machinability.
Machinability Ratings
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Cutting fluids, sometimes referred to as lubricants or coolants are liquids and
gases applied to the tool and work piece to assist the cutting operation.
Functions of cutting fluids:
To cool the tool.
To cool the work piece.
To lubricate and reduce friction
To improve surface finish.
To protect the finished surface from corrosion.
To wash the chips away from the tool.
Properties of cutting fluids:
High heat absorption capability.
Good lubricating quality.
High flash point so as to eliminate the hazard of fire.
Stability so as not to get oxidized in presence of air.
Neutral so as not to react chemically.
Odourless so as not to produce bad smell even when heated.
Harmless to the skin of the operators.
Non corrosive to the work or the machine.
Transparency so that the cutting action of tool may be observed by the operators.
Low viscosity to permit free flow of the liquid.
Low priced to minimize production cost.
Cutting fluids
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Water: Water provided good cooling effect but is not a good lubricant. Water
is hardly used as cutting fluid because of its corrosiveness.
Soluble oil or water miscible cutting fluids: These are also called water
based cutting fluids. These comprises of mineral oil or fat mixtures and
emulsifiers added to water. The emulsifier breaks the oil into minute
particles and disperses them throughout water. These cutting fluids have
excellent lubricating properties. It has milky appearance.
Straight cutting oils: These oils have good lubricating but poor heat
absorption properties and therefore are suitable only for low cutting
speed.
These are of three types:
Mineral oil: Kerosene, low viscosity petroleum fraction.
Fatty oil: Lard oil
Combination of mineral and fatty oil
Oils with adhesives: The benefits of mineral oils can be improved with the
help of adhesives, which are generally compounds of sulphur or chlorine.
Addition of sulphur or chlorine compounds reduces chances of chip
welding on the tool rake face. Besides these there are other adhesives
which are also added to improve corrosion protection, prevent any organic
growth.
Types of cutting fluid
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
References
1. Kalpakjian, Schmid, Manufacturing Processes for Engineering Materials, 4th
edition,, Prentice Hall 2003
2. DeGarmo, E. P., J. T. Black, and R. A. Kohser, Materials and processes in
Manufacturing, PHI.
3. P.N. Rao, Manufacturing Technology Metal Cutting and Machine Tools, TMH.
4. George Schneider,Jr. CMfgE, Cutting Tool Applications
5. Amstead, B. H., P. F. Ostwald, and M. L. Begeman, Manufacturing Processes,
8th ed., Wiley, New York, 1988.
6. Amitabha Battacharya , Metal Cutting Theory and Practice
7. Shaw, M. C., Metal Cutting Principles, Oxford University Press, Oxford, 1984.
8. Schey, J. A., Introduction to Manufacturing Processes, McGraw-Hill, New York,
1977.
9. Lindberg, R. A., Processes and Materials of Manufacture,
10. William J Patton, Machine tool Operations, Reston publishing company
11. O W Boston, Metal Processing, 2nd edition 1951, John Wiley and Sons
12. B.S.Raghuwanshi, A course in Workshop Technology-Dhanpat Rai & Sons.
13. Hajra Choudhury, Elements of Workshop TechnologyVol.-II, Media Promoters
and Publishers.
14. O P Khanna, Production Technology-(Vol. II)
15. HMT, Production Technology, HMT