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    Machining Time Calculations

    Uploaded by

    thirumalaikumaran
    The document provides calculations for determining machine speed, cutting time, and material removal rate for various machining operations including: 1) Turning, boring, facing, slot cutting, and cutoff where machine speed is calculated based on desired cutting speed and part diameter. Cutting time is based on length cut and feed rate. 2) Slab and face milling where machine speed is based on cutting speed and cutter diameter. Table feed rate is calculated from feed per tooth and number of teeth. Cutting time accounts for approach and overtravel lengths. 3) Drilling where machine speed is calculated similarly and cutting time includes allowance for initial entry into the workpiece.

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    Machining Time Calculations

    Uploaded by

    thirumalaikumaran
    295 views11 pages
    The document provides calculations for determining machine speed, cutting time, and material removal rate for various machining operations including: 1) Turning, boring, facing, slot cutting, and cutoff where machine speed is calculated based on desired cutting speed and part diameter. Cutting time is based on length cut and feed rate. 2) Slab and face milling where machine speed is based on cutting speed and cutter diameter. Table feed rate is calculated from feed per tooth and number of teeth. Cutting time accounts for approach and overtravel lengths. 3) Drilling where machine speed is calculated similarly and cutting time includes allowance for initial entry into the workpiece.

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    Machining time calculations

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    Machining time calculations

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    The document provides calculations for determining machine speed, cutting time, and material removal rate for various machining operations including: 1) Turning, boring, facing, slot cutting, and cutoff where machine speed is calculated based on desired cutting speed and part diameter. Cutting time is based on length cut and feed rate. 2) Slab and face milling where machine speed is based on cutting speed and cutter diameter. Table feed rate is calculated from feed per tooth and number of teeth. Cutting time accounts for approach and overtravel lengths. 3) Drilling where machine speed is calculated similarly and cutting time includes allowance for initial entry into the workpiece.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    295 views11 pages

    Machining Time Calculations

    Uploaded by

    thirumalaikumaran
    The document provides calculations for determining machine speed, cutting time, and material removal rate for various machining operations including: 1) Turning, boring, facing, slot cutting, and cutoff where machine speed is calculated based on desired cutting speed and part diameter. Cutting time is based on length cut and feed rate. 2) Slab and face milling where machine speed is based on cutting speed and cutter diameter. Table feed rate is calculated from feed per tooth and number of teeth. Cutting time accounts for approach and overtravel lengths. 3) Drilling where machine speed is calculated similarly and cutting time includes allowance for initial entry into the workpiece.

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    of 11

    MACHINE OPERATION CALCULATIONS

    I. Turning

    A. Machine Speed: To achieve a specific cutting speed:

    1000 * V
    N=
     * D1

    N = machine speed in revolutions/minute (RPM)


    k is a constant to “correct” speed (V) and part diameter (Di ) units
    V is desired cutting speed, a Handbook Value
    D1 is largest part diameter (initial size)

    V given in meters per minute (MPM), D1 in mm: k = 1000

    If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/1000

    B. Cutting Time: minutes per operation


    CT is cutting time per “pass”
    L is length cut
    A is “allowance” or starting offset
    fr is machine feed rate units/revolution, a Handbook Value
    C. Material Removal
    (L + A) Rate (MRR or Q):
    CT = Volume Removed
    fr * N

    cutting time

     * L (D12 - D22 )
    MRR = 4L
    fr N

    D2 is Finished Diameter

    D1 - D2 D1 + D2
    MRR = k f r V [ ] * [ ]
    2 2 D1
    - D1
    D2
    [ ]  t
    2
    D1 + D2
    [ ]  1
    2 D1

    Substituting for N from above:

    and:

    t is Depth of cut (inch or mm)

    Therefore:
    MRR  k V f r t

    II. Boring

    A. Machine Speed: as above except D1 is the finished (larger) diameter

    B. Cutting Time: same as above

    C: Material Removal Rate: as above except D1 is finished diameter while D2 is Initial (smaller)
    diameter.

    III. Facing, Slot Cutting or Cut Off

    In facing, slot (plunge) cutting and cut off, the cutting speed for a given RPM decreases
    as the tool progresses toward the center of the piece being cut. This follows since most (manual)
    lathes cannot increase spindle speed (N) during cutting operations. Thus, the required N is
    calculated as above using the outside (largest) diameter of the part for a given V.
    A. Machine Speed

    k* V
    N =
     * D1

    If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k

    B. Cutting Time

    (L + A)
    CT =
    fr * N

    C. Material Removal Rate (here D1 is Outside Diameter)

    Vol.Removed  D12 f r tN
    MRR = =
    CT 4*L

    D1 D1 - D i
    where: L is 2 for solids; 2 for tubes

    Di is inside diameter

    t is width of cut (tool)

    Substituting for N and L:

    MRR  k
    2 f r tV

    IV. Slab (Horizontal) Milling (be careful with units!!)


    Terms Used:
    N: RPM of Cutter
    n: Number of Teeth on Cutter
    W: Width of cut (may be full cutter or partial cutter)
    t: depth of cut
    V: cutting speed -- a Handbook value
    L: Length of pass or cut
    fm: Table (machine) Feed
    ft: feed/tooth of cutter -- a Handbook value
    D: Cutter Diameter

    A. Cutting Speed:

    kV
    N =
    D

    If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k

    B. Table Feed Rate:

    f m = f t * N* n

    C. Cutting Time:
    L + LA
    CT =
    fm

    LA is Length of Approach of Tool to Work

    LA = t(D - t)

    D. Material Removal Rate:

    Vol. Removed L* W* t
    MRR = = = W* t* f m
    CT CT

    Remember that the length of approach calculated here puts the cutter against the work at the
    start, we will add a small additional air gap to spin the tool to speed and allow the table to
    achieve target feed rate before chip making begins. When determining cutting time and MRR,
    care must be exercised. Ask yourself if total cutting time or time to make one pass across the
    part is being requested, ie. is a single or multiple pass operation to be studied. Also, note that in
    the MRR equation the “cutting time” term does not include the time of partial engagement (L A).
    Again, if a multi-pass operation is being employed, the appropriate width term should be used in
    the MRR equation.
    V. Face (Vertical) Milling

    Terms Used:
    N: RPM of Cutter
    n: Number of Teeth on Cutter
    W: Width of cut (may be full cutter or partial cutter)
    t: depth of cutter engagement
    V: cutting speed -- a Handbook value
    L: Length of pass or cut
    fm: Table (machine) Feed
    ft: feed/tooth of cutter -- a Handbook value
    D: Cutter Diameter
    LA: Approach Length
    LO: Length of “OverTravel”

    A. Cutting Speed:
    kV
    N =
    D

    If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k

    B. Table Feed:

    f m = f t * N* n
    C. Cutting Time. Here several situation must be considered, these include:
    1. Tool Not Fully Engaged with W<D/2
    2. Tool not Fully Engaged but W> D/2
    3. Tool Fully Engaged, Roughing Pass -- Doesn’t require “Full Wipe”
    4. Tool Fully Engaged, Finishing Pass -- requires “Full Wiping Action”

    (L+ L A + L O )
    CT =
    fm

    1. L A = L O = W (D - W )

    D
    2. L A = L O = 2

    D
    3. L A = 2 L O = - 0.5 * D 2 - W 2

    D
    4. L A = L O = 2

    D: Metal Removal Rate:


    Vol. Removed L* W* t
    MRR = = = W* t* f m
    CT CT

    Again, the cautions on single vs. multiple pass CT and MRR apply as with Slab Milling.
    Remember too, that the length of approach here puts the cutter against the work at the start, we
    will add a small additional air gap to spin the tool to speed and allow the table to achieve target
    feed rate before chip making begins. Also, care should be exercised with regards to units.
    VI. Drilling

    kV
    N =
    D

    A. Drill Speed, RPM

    k is a “Units Constant”
    D is Drill Diameter
    V is cutting speed, a Handbook Value, if Cutting Speed for a given RPM rate is desired,
    solve above equation for V: V = ND/k

    B. Cutting Time (min)


    (L + A)
    CT =
    fr*N

    D
    A is allowance; usually 2

    f r is drill feedrate

    L is length of Hole

    C. M
    RR
    Vol.Removed  D2 Lf r N  D2 f r N is
    MRR = = =
    CT 4L 4

    (again) Material Removal Rate

    And note, no material is removed while the Drill travels through the “Allowance Zone”

    Use caution with units!!

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