5.1 operating conditions - turning, milling & drilling
DESCRIPTION
Operating Conditions - Turning, Milling & DrillingTRANSCRIPT
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Operating ConditionsTurning, Milling and Drilling
K. Govindarajan Product Management & Technical Services
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Operating Conditions
–Depth of Cut
– Feed Rate
–Cutting Speed
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Operating ConditionsCutting speed
Feed
doc(m/min)
(mm/rev)
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Definition Of Speed (Cutting Speed Vc)
In turning, the peripheral speed of the work; usually measured in meters/minute (m/min)
In Milling the peripheral speed of the Cutter; usually measured in meters/minute (m/min)
In Drilling the peripheral speed of the Drill; usually measured in meters/minute (m/min)
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Cutting Speed(Vc) vs. RPM
RPM - not dependant on diameter.Vc- dependant on diameter of work piece / Cutter / Drill
(305 mm)
(100 mm)
Vc(m/min)= 3.14 x Workpiece Dia x RPM1000
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6Effective Diameter
Cutting Speed (Vc) vs. RPM
Vc - dependant on diameter
Vc= 3.14 x Cutter Diameter x rpm1000
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Definition Of Feed mm/rev
TURNING: The relative amount of motion of the tool into the work for each spindle revolution. Usually measured in mm/revolution (mm/rev)
MILLING: The movement of the Cutter into the workpiece. Usually measured in millimeter per minute (mm/min)] [millimeter per Tooth (mm/tooth)]
DRILLING: The Axial motion of the tool into the work for each revolution, stroke, or unit of time. Usually measured in mm per revolution (mm/rev )
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Definition Of Depth of Cut (doc)For Turning The distance between the bottom of the cut and the uncut surface of the work, measured in a direction at right angles to the machined surface of the work.*
Depth of Cut = ½ the diameter of the drill
For Drilling
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Depth Of Cut - Milling
Radial DOC Axial DOC
In Milling Depth of Cut is normally associated with Axial Depth of Cut.
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TURNING CONDITIONS
Workpiece Material 4140 Alloy SteelHardness 250 HBContinuous CutStock Remaining For Finish Pass -0.5 mm / sideWorkpiece Diameter = 97 mmLength of Cut =216 mmFinish required = 1.2 Ra (µmm)Rigid Setup
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Determine Machine RPM:Cutting speed is defined as the distance in mtrsthat is travelled by a point on the work piece peripheryin one minute.
RPM = Vc
Pi x Diameter
Vc= RPM x Cutter CircumferenceVc = RPM x 3.14D
Circumference = Pi x Diameter, WherePi = 3.14.. RPM = Vc .
CircumferenceRPM = Vc
Cutter Circumference= Vc
3.14D
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Vc 3.14D
RPM=
Because we work in (mm) more than we do in (mtr),we need to convert the “(mtr)”in Vc to (mm).Since there are 1000mm in 1 mtr.
RPM = x (1000mm)(1 m)
Vc 3.14D
Hence,
RPM = 1000 Vc3.14 x D (mm)
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GIVEN: Workpiece Diameter = 97 mmCutting Speed (Vc) = 300 m/min
--------------------------------------------------------------------
RPM = Vc x 10003.14 x Dia(mm)
300 x 10003.142 x 97
Determine Machine RPM:
=984 RPM
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Determine Metal Removal Rate (MRR)TURNING (cm3/min)
GIVEN: Cutting Speed = 300 m/minDepth of Cut = 0.5mm or 0.05 cmFeed Rate = 0.4mm/rev
------------------------------------------------------------------------MRR = Vc X DOC X FEED RATE
= Vc m x DOC mm x fr mmmin rev
= 300 m x 0.05cm x 0.04cm x100cm =60cm3/minmin rev m
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GIVEN: Machine RPM = 984 RPMLength of Cut = 216 mmFeed Rate = 0.4 mm/ rev
------------------------------------------------------------------------Cut Time = Length Of Cut = 216 mm
Feed Rate x RPM 0.4 mm x 990 revrev min
= 216 min0.4 x 984
= 0.549 min= 32.94 seconds
Determine Cutting Time (min.):
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Lets say we made a mistake, our workpiece is 9.7mmnot 97mm, If the maximum RPM on our lathe is 5,000 RPM
We proved that RPM = Vc x 10003.14 x Dia
Vc = 3.14 x Dia x RPM1000
= 3.142 X 9.7 X 50001000
= 152m/min
Determine Machine Vc:
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Turning Formulas (metric)
To Find Formula
Vc 3.14 D N 1000
RPM Vc x 1000 3.14 D
f r (mm/rev) mm/minRPM
fmm/min mm/rev x RPM
Cut time Length of cutmm/rev x rpm
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Feed Rate- Milling
Feed rate in mm per minute (mm/min) is measured as the total advance of the cutter per minute.(w.r.t to table)Feed Rate (mm) per tooth (mm/tooth) is measured by the amount of metal cut by each tooth on each revolution of the cutter (fz).
F = fz x Z x RPM(mm/min)
fz = F (mm/min)(mm/tooth) Z x RPM
f = F . (mm/rev) RPM
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Workpiece Material Gray Cast Iron Class 20
Hardness 250 BHN
Radial Width of Cut = 100 mm
Axial Depth of Cut = 2.5 mm
Diameter of Cutter = 160 mm
Number of Inserts In Cutter = 10
0° Lead Angle Cutter
50HP Machine / Rigid Setup
MILLING CONDITIONS
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STARTING PARAMETERS
From Table
•Kyon 3500•Starting Cutting Speed 700 mtrs/min•Feed 0.15 mm/tooth•Dry
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GIVEN: Cutter Diameter = 160 mmCutting Speed = (700 mtrs/min)
Determine Machine RPM:
RPM = Cutting Speed x 1000 =Diameter x 3.14
700 x 1000 =1393 rev/min160 x 3.14
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GIVEN: Number of Inserts In Cutter = 10Machine RPM = 1393Chip Load = 0.15 mm/tooth
Determine Feed Rate (mm/min):Milling
F = fz x No. of Teeth x RPM
= 0.15 X 10 X 1393
= 2090 mm/min
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GIVEN: Axial Depth of Cut = 2.5 mmFeed Rate = 2090 mm/minRadial Width of Cut = 100 mm
MRR = RWOC x ADOC x Feed Rate
Determine Metal Removal Rate (cm3/min):
100 x 2.5 x 20901000
= 522.5 cm3/min
=
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To Find Given Formula
Vc D, rpm Vc = 3.14 x D x RPM1000
RPM D, Vc RPM = Vc x 1000
3.14 x D
f F f = F / RPM
F fz, Z, RPM F = fz x Z x RPM
fz F, Z, RPM fz = F .Z x RPM
fz Z, f Fz = F / Z
Formulas
LegendVc Cutting Speed
f Feed per revolution
F Feed per minute
fz Feed per tooth
Z No. of effective tooth or inserts in cutter
3.14 3.1416
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Workpiece Material 303 Austenitic Stainless SteelHardness 200 BHNDiameter of Drill = 32mmDepth of Hole = 76mmHorizontal ApplicationHigh Pressure Coolant AvailableHole Tolerance Required ±0.1
DRILLING CONDITIONS
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KSEM DRILLFrom Table
Starting Speed 70m/min
Feed 0.3mm/rev
STARTING PARAMETERS
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GIVEN: Diameter of Drill =32 mmCutting Speed = 70 M/Min.
------------------------------------------------------------RPM = (Cutting speed x 1000) / (3.1415 x Diameter (mm) )
RPM = ( 70 X 1000) / ( 3.1415 X 32) = 696
Determine Machine RPM:
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GIVEN: Feed Rate = 0.3mm / rev.Machine RPM = 696 RPM
---------------------------------------------------------Feed rate ( MM/Min) = RPM X Feed (mm/rev) Feed rate ( MM/Min.)= 696 x 0.3
RESULT: 209 mm / min.
Determine Feed Rate (mm / min.)
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GIVEN: Diameter 32mm (D )
Feed mm/min. = 209mm / min.
------------------------------------------------------------------------MRR = Pi (D²) x Feed mm/min.
4 1000
= (3.14) (32mm.)² x 209mm/min.4 1000= 168 cm³ / min.
Determine Metal Removal Rate(cm³ / min.):
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BASIC FORMULAS
To find Formula
Cutting Speed Vc
3.14 x d x rpm 1000 (m/min)
rpm 1000 x Vc3.14 x d
mm per rev mm per minrpm
mm per min mm per rev x rpm
Cut time Drill hole depth mm per min ( min)
MRR π d2
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