Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
22 CUTTING TOOL TECHNOLOGY Review Questions 22.1 22.1
Wht Wht re re the the t!o t!o prin prin"ip "ipl l spe spe"ts "ts of "utt "uttin# in#$to $tool ol te"h te"hnol nolo#y o#y%% Answer. &he t!o prin"ipl spe"ts of "uttin# tool te"hnolo#y re (1) tool 'teril nd (2) tool #eo'etry.
22.2 22.2
'e 'e the the thr three ee 'od 'odes es of of tool tool fi filu lure re in in '"h '"hin inin in#. #. Answer. &he three tool filure 'odes re (1) fr"ture filure, (2) te'perture filure, nd () #rdul !er.
22. 22.
Wht Wht re the the t!o t!o prin"i prin"ipl pl lo"t lo"tion ionss on "utt "uttin# in# tool tool !here !here tool tool !er !er o""urs% o""urs% Answer. Wer o""urs on the top f"e of the "uttin# tool s "rter !er nd on the side or fln* of the tool, "lled fln* !er. Portions of fln* !er re often identified seprtely s not"h !er, "orrespondin# to the surf"e of the !or*+ nd nose rdius !er, "orrespondin# to the tool point.
22. 22.
-dentify -dentify the 'e"hnis 'e"hnis's 's by by !hi"h !hi"h "utt "uttin# in# tools tools !er !er duri durin# n# '"h '"hini inin#. n#. Answer. &he i'portnt tool !er 'e"hnis's re (1) brsion, (2) dhesion, () diffusion, nd () plsti" plsti" defor'tion defor'tion of the "uttin# "uttin# ed#e.
22.5 22.5
Wht Wht is the the phy physi si" "ll inte interp rpret rett tio ion n of the the pr pr'et 'eter er C in in the &ylor tool life eution% is the "uttin# speed "orrespondin# to one$'inute tool life. C is is the Answer. &he pr'eter C is speed$is inter"ept on the lo#$lo# plot of the tool life dt.
22.
-n ddition ddition to "uttin# "uttin# speed, !ht other "uttin# "uttin# vribles vribles re in"luded in"luded in the the epnded epnded version version of the &ylor tool life eution% Answer. &he epnded version of the &ylor eution "n in"lude ny of the follo!in# feed, depth of "ut, nd/or !or* 'teril hrdness.
22. 22.
Wht Wht re so'e so'e of of the tool tool life life "rit "riteri eri used used in produ produ"tio "tion n '"hin '"hinin# in# oper operti tions ons%% Answer. 3s identified in the tet, tool life "riteri used in produ"tion in"lude (1) "o'plete filure of the tool, (2) visul observtion of fln* or "rter !er, () fin#ernil test to feel fln* !er, () sound of the tool, (5) "hip disposl proble's, () de#rdtion of finish, () po!er in"rese, (4) !or*pie"e "ount, nd () len#th of "uttin# ti'e for the tool.
22.4 22.4
-dentify -dentify three three desi desirb rble le prop propert erties ies of "uttin "uttin#$t #$tool ool 'teri 'teril. l. Answer. &hree desirble properties re (1) tou#hness to resist fr"ture filure, (2) hot hrdness to resist te'perture filure, nd () !er resistn"e to prolon# the life of the tool durin# #rdul !er.
22. 22.
Wht Wht re re the the prin" prin"ipl ipl lloyi lloyin# n# in#r in#redi edient entss in hi#h$s hi#h$spee peed d steel% steel% Answer. Prin"ipl lloyin# in#redients in 6SS re (1) either tun#sten or "o'bintion of tun#sten nd 'olybdenu', (2) "hro'iu', () vndiu', nd () "rbon. So'e #rdes of 6SS lso "ontin "oblt.
22.10
Wht is the the differen"e differen"e in in#redien in#redients ts bet!een bet!een steel "uttin# "uttin# #rdes #rdes nd nonsteel nonsteel$"utti $"uttin# n# #rdes of of "e'ented "rbides% Answer. -n #enerl, non$steel "uttin# #rdes "ontin only W7 nd 7o. Steel "uttin# #rdes "ontin &i7 nd/or &7 in ddition to W7$7o.
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
22.11 22.11
-dentify -dentify so'e of of the "o''on "o''on "o'pounds "o'pounds tht tht for' for' the thin thin "otin#s "otin#s on the the surf"e surf"e of "oted "oted "rbide inserts. Answer. &he "o''on "otin#s re &i, &i7, nd 3l 29.
22.12
'e the the seven seven ele'ents ele'ents of tool tool #eo'etry #eo'etry for sin#le$poin sin#le$pointt "uttin# "uttin# tool. Answer. &he seven ele'ents of sin#le$point tool #eo'etry re (1) b"* r*e n#le, (2) side r*e n#le, () end relief n#le, () side relief n#le, (5) end "uttin# ed#e n#le, () side "uttin# ed#e n#le, nd () nose rdius.
22.1
Why re re "er'i" "er'i" "uttin# "uttin# tools #enerlly #enerlly desi#ned desi#ned !ith ne#tive ne#tive r*e r*e n#les% n#les% Answer. 7er'i"s possess lo! sher nd tensile stren#th but #ood #ood "o'pressive stren#th. :urin# "uttin#, this "o'bintion of properties is best eploited by #ivin# the tool ne#tive r*e n#le to lod the tool in "o'pression.
22.1
-dentify -dentify the lternt lterntive ive !ys !ys by !hi"h !hi"h "uttin# "uttin# tool tool is held held in pl"e pl"e durin# durin# '"hinin#. '"hinin#. Answer. &here re three prin"ipl !ys (1) solid shn*, in !hi"h the "uttin# ed#e is n inte#rl prt of the tool tool shn*, shn*, n e'ple e'ple bein# bein# hi#h hi#h speed speed steel steel toolin#+ toolin#+ (2) br;ed br;ed inserts, inserts, used used for for so'e "e'ented "rbides+ nd () 'e"hni"lly "l'ped inserts, used for 'ost hrd tool 'terils in"ludin# "e'ented "rbides, "oted "rbides, "er'ets, "er'i"s, SP:, nd 7<.
22.15
'e the the t!o t!o 'in "te#ories "te#ories of of "uttin# "uttin# fluid ""ordin# ""ordin# to to fun"tion. fun"tion. Answer. &he t!o fun"tionl "te#ories of "uttin# fluids re (1) "oolnts nd (2) lubri"nts.
22.1
'e the the four four "te#ories "te#ories of "uttin# "uttin# fluid ""ordin# ""ordin# to to "he'istry "he'istry.. Answer. &he four "te#ories of "uttin# fluids ""ordin# to "he'istry re (1) "uttin# oils, (2) e'ulsified oils, () "he'i"l fluids, nd () se'i$"he'i"l fluids.
22.1
Wht re re the prin"ip prin"ipl l lubri"tin lubri"tin# # 'e"hnis's 'e"hnis's by !hi"h "uttin# "uttin# fluids fluids !or*% !or*% Answer. &here re t!o lubri"tin# 'e"hnis's tht re believed to be effe"tive in 'etl "uttin# (1) boundry boundry lubri"ti lubri"tion, on, !hi"h !hi"h involve involvess the for'ti for'tion on of thin fluid fluid fil' to help seprte seprte nd prote"t prote"t the "ont"tin# surf"es+ nd (2) etre'e pressure lubri"tion, in !hi"h thin solid lyer of slt su"h s iron sulfide is for'ed on the tool surf"e to provide lubri"tion.
22.14
Wht re re the 'ethods 'ethods by !hi"h !hi"h "uttin# "uttin# fluids fluids re pplied pplied in '"hinin# '"hinin# opert opertion% ion% Answer. &he 'ost "o''on 'ethod of ppli"tion is floodin#, in !hi"h stedy stre' of fluid is dire"t t the opertion. 9ther 'ethods in"lude 'ist ppli"tion, fluid$hole delivery throu#h the the tool, nd 'nul ppli"tion (e.#., usin# pint brush).
22.1
Why re "uttin# "uttin# fluid filter filter syste's syste's be"o'in be"o'in# # 'ore "o''on, "o''on, nd !ht re re their dvnt# dvnt#es% es% Answer. 7uttin# fluid filter syste's re be"o'in# 'ore "o''on due to the environ'entl prote"tion prote"tion l!s l!s nd nd the need need to prolon# prolon# the life of the fluid fluid before before dispos disposl. l. 3dvnt#es 3dvnt#es of of filter filter syste's in"lude lon#er fluid life, redu"ed disposl "osts, better hy#iene, lo!er '"hine tool 'intenn"e, nd lon#er "uttin# tool life.
22.20
:ry '"hinin# '"hinin# is is bein# "onsid "onsidered ered by '"hine '"hine shops shops be"use be"use of "ertin "ertin proble' proble'ss inherent inherent in the the use of "uttin# fluids. Wht re those proble's sso"ited !ith the use of "uttin# fluids% Answer. 7uttin# fluids be"o'e "ont'inted over ti'e !ith vriety of "ont'innts, in"ludin# tr'p oil, #rb#e, s'll "hips, 'olds, fun#i, nd b"teri. -n ddition to "usin# odors nd helth h;rds, "ont'inted "uttin# fluids do not perfor' their lubri"tin# fun"tion s !ell s !hen they re fresh nd "len.
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
22.21 22.21
Wht Wht re so'e so'e of the ne! prob proble's le's intr introdu odu"ed "ed by '"hin '"hinin# in# dry% dry% Answer. Proble's !ith dry '"hinin# in"lude (1) overhetin# the tool, (2) opertin# t lo!er "uttin# speeds nd produ"tion rtes to prolon# tool life, nd () bsen"e of "hip re'ovl benefits tht re provided by "uttin# fluids in #rindin# nd 'illin#.
Problems 3ns!ers to proble's lbeled (A re listed in n 3ppendi 3ppendi t the b"* of the boo*. Tool Li!e "n# t$e T"%lor E&u"tion
22.1 22.1
(S- unit units) s) =or =or the tool tool life life plot plot of of =i#ure =i#ure 22.5 22.5,, sho! sho! tht tht the 'idd 'iddle le dt dt point point ( " > 10 '/'in, # > > 12 'in) is "onsistent !ith the &ylor eution deter'ined in 8'ple Proble' 22.1. 'olution &ylor eution "l"ulted in 8'ple 22.1 is "# 0.22 > 22. 7onsisten"y !ould be de'onstrted by usin# the vlues fro' the 'iddle dt point ( # > > 12 'in t " > 10 ft/'in) in the eution nd obtinin# the s'e vlue of C s bove (C (C > > 22). 0.22 10(12) > 10(1.0) > 22. &his represents differen"e of less thn 1.2?, !hi"h is "lose enou#h nd !ell !ithin epe"ted rndo' vrition in typi"l tool life dt.
22.2
(S- units) units) -n the tool !er plots plots of =i#ure =i#ure 22., 22., "o'plete "o'plete filure filure of the "uttin# "uttin# tool is indi"te indi"ted d by the end of e"h !er "urve. @sin# "o'plete filure s the "riterion of tool life insted of 0.50 '' fln* !er, the resultin# dt re (1) " > 10 '/'in, # > > 5.5 'in+ (2) " > 10 '/'in, # > > 1.25 'in+ nd () " > 100 '/'in, # > > 'in. :eter'ine the pr'eters n nd C in in the &ylor tool life eution for this dt. 'olution Aet us use the t!o etre'e dt points to "l"ulte the vlues of n nd 7, then "he"* the resultin# eution #inst the 'iddle dt point. (1) 10(5.5) n > C nd () 100() n > C 10(5.5) n > 100() n ln 10 B n ln 5.5 > ln 100 B n ln 5.052 B 1.2 n > .052 B .4501 n 0.00 > 2.100 n n )*22+ 0.22 (1) C > > 10(5.5) > 2. 2,-*. m/min () C > > 100()0.22 > 2. use ver#e C
7he"* #inst dt set (2) 10(1.25) 0.22 > 25.. &his represents differen"e of less thn 0.5?, !hi"h !ould be "onsidered #ood #ree'ent for eperi'entl dt. 0.22 here vs. n > 0.22 in 8'ple 22.1), nd tht the C vlue vlue is hi#her here (C ( C > > 2.4 here vs. C > > 22 in 8'ple 22.1). &he hi#her C vlue vlue here refle"ts the hi#her !er level used to define tool life ("o'plete filure of "uttin# ed#e here vs. fln* !er level of 0.50 '' in 8'ple 22.1). 22.
(A (S- units) -n turnin# tests usin# "oted "rbide tools on lloy steel, fln* !er dt !ere "olle"ted t feed of 0.0 ''/rev nd depth of .0 ''. 3t speed of 125 '/'in, fln* !er > 0.12 '' t 1 'in, 0.2 '' t 5 'in, 0.5 '' t 11 'in, 0.54 '' t 15 'in, 0. t 20 'in, nd 0. '' t 25 'in. 3t speed of 15 '/'in, fln* !er > 0.22 '' t 1 'in, 0. '' t 5 'in, 0.0 '' t 'in, 0.40 '' t 11 'in, nd 0. '' t 1 'in. &he lst vlue in e"h "se is !hen finl tool filure o""urred. () 9n sin#le pie"e of liner #rph pper, plot fln* !er s fun"tion of ti'e for both speeds. @sin# 0.5 '' of fln* !er s the "riterion of tool filure, deter'ine the tool lives for the t!o "uttin# speeds. (b) 9n pie"e of nturl lo#$lo# pper, plot your results fro' prt () () to deter'ine deter'ine the vlues vlues of of n nd C in the &ylor &ool &ool Aife eution. (") 3s "o'prison,
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
"l"ulte the vlues of n nd C in in the &ylor eution solvin# si'ultneous eutions. 3re the resultin# n nd C vlues vlues the s'e% 'olution () nd (b) Student eer"ises. =or prt (), t "1 > 125 '/'in, # 1 > 20. 'in usin# "riterion $% "riterion $% > > 0.5 '', nd t "2 > 15 '/'in, # 2 > 10.0 'in ' in usin# "riterion $% "riterion $% > > 0.5 ''. -n prt (b), vlues of C nd nd n 'y vry due to vritions in the plots. &he vlues should be pproi'tely the s'e s those obtined in prt (") belo!. belo!.
(") &!o eutions (1) 125(20.) n > C , nd (2) 15(10.0) n > C (1) nd (2) 125(20.) n > 15(10.0) n ln 125 B n ln 20. > ln 15 B n ln 10.0 .424 B .0155 n > 5.105 B 2.02 n 0.12 n > 0.2 n )*,.0+ (1) C > > 125(20.) 0.4 > 0. C +)+*+- m/min (2) C > > 15(10.0) 0.4 > 0. 22.
(S- units) units) Solve Proble' Proble' 22. e"ept e"ept tht tht the tool life "riterion "riterion is is 0.50 0.50 '' of of fln* fln* lnd lnd !er !er rther rther thn 0.5 ''. 'olution () nd (b) Student eer"ises. =or prt (), t "1 > 125 '/'in, # 1 > 1.0 'in usin# "riterion $% "riterion $% > > 0.50 '', nd t "2 > 15 '/'in, # 2 > 5. 'in usin# "riterion $% "riterion $% > > 0.50 ''. -n prt (b), vlues of C nd nd n 'y vry due to vritions in the plots. &he vlues should be pproi'tely the s'e s those obtined in prt (") belo!. belo!.
(") &!o eutions (1) 125(1.0) n > C , nd (2) 15(5.) n > C (1) nd (2) 125(1.0) n > 15(5.) n ln 125 B n ln 1.0 > ln 15 B n ln 5. .424 B 2.5 n > 5.105 B 1.224 n 0.421 n > 0.2 n )*,20(1) C > > 125(1.0) 0.4 > 21.1 C 201*1 m/min (2) C > > 15(5.) 0.4 > 21.15 22.5
(@S7S units) units) 3 series of turnin# turnin# tests usin# "e'ented "e'ented "rbide "rbide tools on 'ediu' 'ediu' "rbon "rbon steel steel !ere "ondu"ted to "olle"t fln* !er dt. =eed > 0.010 in/rev nd > depth of "ut > 0.125 in. 3t speed of 50 ft/'in, fln* !er > 0.005 in t 1 'in, 0.004 in t 5 'in, 0.012 in t 11 'in, 0.0.015 in t 15 'in, 0.021 in t 20 'in, nd 0.00 in t 25 'in. 3t speed of 50 ft/'in, fln* !er > 0.00 in t 1 'in, 0.01 in t 5 'in, 0.02 in t 'in, 0.0 in t 11 'in, nd 0.00 in t 1 'in. &he lst vlue in e"h "se is !hen finl tool filure o""urred. () 9n sin#le pie"e of liner #rph pper, plot fln* !er s fun"tion of ti'e. @sin# 0.020 in of fln* !er s the "riterion of tool filure, deter'ine the tool lives for the t!o "uttin# speeds. (b) 9n pie"e of nturl lo#$lo# pper, plot your results fro' prt () to deter'ine the vlues of n nd C in in the &ylor &ool &ool Aife eution. (") 3s "o'prison, "l"ulte the vlues of n nd C in in the &ylor eution solvin# si'ultneous eutions. 3re the resultin# n nd C vlues vlues the s'e% 'olution3 ()
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
@sin# the #rph, t 50 ft/'in the tool lst bout -*2 min+ t 50 ft/'in, it lsts 10*) min. (b) &he points re #rphed in 8"el nd the line "onne"tin# the t!o points is etended to the is.
C is is red fro' the C$inter"ept nd is pproi'tely 40 ft/'in. &he slope, n, "n be deter'ined by t*in# the ln of the & the & nd y nd y "oordintes "oordintes of ny 2 points nd deter'inin# DC/DE. -t is positive be"use be"use the &ylor tool tool life life eution eution is is derived derived ssu'in# ssu'in# the slope slope is ne#tive. ne#tive. @sin# @sin# the the points points (1,40) nd (1,50) the slope is bout 0.22. (") :ependin# on the vlues of tool life red fro' the fln* !er #rph, the vlues of n nd C !ill !ill n n vry. &!o &!o eutions (1) 50(1.0) > C , nd (2) 50(.2) > C 8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
(1) nd (2) 50(1.0) n > 50(.2) n ln 50 B n ln 1.0 > ln 50 B n ln .2 5.45 B 2. n > .102 B 1.425 n 1.11 n > 0.251 (1) C > > 50(1.0) 0.22 > (2) C > > 50(.2) 0.22 > 22.
n )*22+ C -44 !t/min
(@S7S units) units) Solve Proble' Proble' 22.5 e"ept e"ept the tool life !er !er "riterion "riterion is 0.015 0.015 in in of fln* !er. !er. Wht Wht "uttin# speed should be used to #et 20 'inutes of tool life% 'olution3 Fedin# the ti'e of tool filure on the =ln* Wer vs &i'e plot yields the follo!in# dt points. points. ote ote the vlues vlues of of n nd C !ill !ill "hn#e bsed on the esti'tes for ti'e of filure. "1 > 50 ft/'in, # 1 > 15 'in nd "2 > 50 ft/'in, # 2 > .2 'in
&!o eutions (1) 50(15.0) n > C , nd (2) 50(.2) n > C (1) nd (2) 50(15.0) n > 50(.2) n ln 50 B n ln 15.0 > ln 50 B n ln .2 5.45 B 2.041 n > .102 B 1.51 n 1.20 n > 0.251 n )*104 0.1 (1) C > 50(15.0) > 5 C 04 !t/min (2) C > > 50(.2) 0.1 > 5 &o "hieve 20 'in of tool life " > C /# n > 5/20 0.1 > 5/1.405 > ,,) !t/min 22.
(S- units) units) &urnin# &urnin# tests usin# "e'ented "e'ented "rbide "rbide toolin# toolin# resulted resulted in 1$'in tool life t t "uttin# "uttin# speed > .4 '/s nd 22$'in tool life t speed > 2.0 '/s. () =ind the n nd C vlues vlues in the &ylor &ylor &ool Aife eution. (b) Proe"t ho! lon# the tool !ould lst t speed of 1.0 '/s. > 1.0 'in, then C 'olution () =or dt (1) # > +*. m/s 2.. m/min =or dt (2) " > 2 '/s > 120 '/'in 120(22) n > 244 22n > 244/120 > 2. n ln 22 > ln 2. n )*2., .010 n > 0.455 0.24 &he tool life eution is "# > 244 (b) 3t " > 1.0 '/s > 0 '/'in 0(# 0(# )0.24 > 244 (# )0.24 > 244/0 > .4 # > > (.4) 1/0.24 > (.4).51 > 2+ min
22.4
(A (S- units) &he follo!in# dt !ere "olle"ted durin# tool life tests in turnin# (1) !hen "uttin# speed > 100 '/'in, tool life > 'in+ (2) !hen "uttin# speed > 5 '/'in, tool life > 5 'in. () :eter'ine the n nd C vlues vlues in the &ylor &ool Aife eution. <sed on your eution, "o'pute (b) the tool life for speed of 110 '/'in, nd (") the speed "orrespondin# to tool life of 20 'in. 'olution () &!o eutions (1) 100() n > C nd (2) 5(5) n > C . 100()n > 5(5)n ln 100 B n ln > ln 5 B n ln 5 .052 B 2.12 n > .15 B .555 n .052 $ .15 > (.555 H 2.12) n n )*212 0.24 > 1.541 n C > 100()0.225 > 100(1.5) C 10*, m/min 0.212 7he"* C > > 5(5) > 5(2.12) > 15. @se C > > 15. &he tool life eution is "# 0.212 > 15
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
(b) 110 # 0.212 > 15 # 0.212 > 150/110 > 1.5 # > > 1.5 1/0.212 > 1.5 .1 > *4 min (") "(20)0.212 > 15 " > 15/(20) 0.212 > 15/1.44 > .+ m/min 22.
(@S7S units) units) &ool life life tests tests on on lthe hve result resulted ed in the follo!i follo!in# n# dt dt (1) (1) t "uttin# "uttin# speed speed of of 50 ft/'in, the tool life !s 5.2 'in+ (2) t "uttin# speed of 250 ft/'in, the tool life !s 50 'in. () :eter'ine the pr'eters n nd C in in the &ylor tool life eution. (b) <sed on the n nd C vlues, !ht is the li*ely tool 'teril used in this opertion% (") @sin# your eution, "o'pute the tool life tht "orresponds to "uttin# speed of 00 ft/'in. (d) 7o'pute the "uttin# speed tht "orresponds to tool life # > > 10 'in. &!o eutions (1) 50(5.2) n > C nd (2) 250(50) n > C 'olution () '# n > C + &!o 50(5.2)n > 250(50) n 50/250 > (50/5.2) n 1.0 > (.15) n ln 1.0 > n ln .15 n )*1+0 0.5 > 2.2 n 0.11 C ++4* C > > 50(5.2) > 50(1.245) 7he"* C > > 250(50)0.11 > 250(1.1) > .4 @se C > > 4. &he tool life eution is "# 0.1 > 4 ft/'in (b) 7o'prin# these vlues of n nd C !ith !ith those in &ble 22.2, the li*ely tool 'teril is hi#h speed steel. 1/n (") 3t " > 00 ft/'in, # > > (C (C /")1/n > (4/00) 1/0.1 > (1.).11 > 1+*4 min
(d) =or # > > 10 'in, " > C /# n > 4/10 0.1 > 4/1.0 > ,1. !t/min 22.10
'" hined in f"e (A (@S7S units) 3 22$in lon# by .0$in !ide "st iron re"tn#ulr blo"* is '"hined 'illin# opertion usin# .0$in di'eter "utter !ith 12 "rbide inserts. &he "utter pth is "entered over the !idth of the blo"*. =eed > 0.004 in/tooth nd depth of "ut > 0.0 in. 3t "uttin# speed of 500 ft/'in, the tool lsts for seven blo"*s. 3t "uttin# speed of 250 ft/'in, the tool lsts for blo"*s. blo"*s. :eter'ine :eter'ine n nd C in in the &ylor &ool &ool Aife eution. &he eution !ill be used to opti'i;e "uttin# speed in f"e 'illin# opertion tht '"hines the surf"es of en#ine blo"*s nd en#ine heds in the uto'otive industry. -#nore the effe"t of the ppro"h distn"e #iven by 8ution (22.14). >"/I ) > 'olution3 ( 1 >" ) > 500(12)/.0I > 14. rev/'in f r r > (fn > (fnt > > 14.(0.004)(12) > 0.5 in/'in # m > * > *// f f r r > > 22/0.5 > 0.20 'in # 1 > # # m > (0.20) > 5.0 'in !hen "1 > 500 ft/'in ( 2 > 250(12)/.0I > 15.15 rev/'in f r r > (fn > (fnt > > 15.15(0.004)(12) > 15.24 in/'in # m > 22/15.24 > 1. 'in # 2 > # # m > (1.) > .4 'in !hen "2 > 250 ft/'in n > ln (" ("1/"2)/ln(# )/ln(# 2/# 1) > ln (500/250)/ln (.4/5.0) > 0./2.5> )*2-4 n C > "# > 500(5.0 ) 0.2 > 500(1.5) > 4-0*. !t/min 7he"* C > "# n > 250(.4 ) 0.2 > 250(.0) > .4 &he tool life eution is "# 0.2 > .4
22.11 22.11
(S- units) units) -n produ"ti produ"tion on turnin# turnin# opertion opertion,, the !or* prt di'eter di'eter > 102 102 '' nd len#th > 00 '' lon#. 3 feed of 0.2 ''/rev is used in the opertion. -f "uttin# speed > .0 '/s, the tool 'ust be
8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
22$1
Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
"hn#ed every 5 !or* prts+ but if "uttin# speed > 2.0 '/s, the tool "n be used to produ"e 22 pie"es bet!een bet!een tool "hn#es. "hn#es. :eter'ine :eter'ine the the &ylor &ylor &ool Aife Aife eution eution for for this ob. 'olution (1) # m > (102 '')(00 '')/(.0 10 ''/s)(0.2 '') > 1. s > 2. 'in # > > 5(2.) > 1. 'in
(2) # m > (102 '')(00 '')/(2.0 10 ''/s)(0.2 '') > 2. s > .104 'in # > > 22(.104) > 0.4 'in (1) " > '/s > 140 '/'in (2) " > 2 '/s > 120 '/'in (1) 140(1.) n > C (2) 120(0.4) n > C 140(1.) n > 120(0.4) n ln 140 B n ln(1.) > ln 120 B n ln(0.4) 5.12 B 2.1 n > .45 B .50 n 5.12 $ .45 > (.50 $ 2.1) n n )*21 0.05 > 1.44 n 0.215 C ,1- m/min C > > 140 (1.) 0.215 7he"* C > 120(0.4 ) > 120(2.) > 1 &he tool life eution is "# 0.215 > 1 22.12
(@S7S/S(@S7S/S- units) units) &he &he &ylor &ylor euti eution on for "ertin "ertin set of of test "onditions "onditions is "# .25 > 1000, !here the @.S. "usto'ry units re used ft/'in for " nd 'in for # . 7onvert this eution to the euivlent &ylor eution in the -nterntionl Syste' of @nits ('etri"), !here " is in '/se" nd # is is in se". Jlidte the 'etri" eution usin# tool life > 1 'in. &ht is, "o'pute the "orrespondin# "uttin# speeds in ft/'in nd '/se" usin# the t!o eutions. 0.25 'olution "# 0.25 > 1000(# 1000( # ref ref ) C > > 1000 ft/'in for 1.0 'in tool life+ ft/'in "onverts to '/s s (1000 ft/'in)(0.04'/ft)(1 'in/0 s) > 5.04 '/s # ref > 1 'in > 0 s. ref > 0.25 (# ref > (0)0.25 > 2.41 ref ) &he "onverted vlue of C > > 5.04(2.41) > 1.1 &he "onverted eution is vT )*2 1+*1+5 !here " > '/s nd # > > s.
7he"* both eutions t # > > 1 'in > 0 s. 0.25 @S7@ " > 1000/1 > 1000/2 > 500 ft/'in S- " > 1.1/0 0.25 > 1.1/5.5 > 2.5 '/s 7he"* (500 ft/'in)( 0.04'/ft)(1 'in/0 s) > 2.5 '/s 22.1
K.8.:.
(S- units) units) 3 series of turnin# turnin# tests tests re perfor'ed perfor'ed to deter'in deter'inee the pr'ete pr'eters rs n, m, nd + nd + in in the epnded version of the &ylor eution, 8ution (22.). &he follo!in# dt !ere obtined durin# the tests (1) "uttin# speed > 1. '/s, feed > 0.22 ''/rev, tool life > 10 'in+ (2) "uttin# speed > 1. '/s, feed > 0.22 ''/rev, tool life > 'in+ nd () "uttin# speed > 1. '/s, feed > 0.2 ''/rev, tool life > 4 'in. () :eter'ine n, m, nd + nd + . (b) @sin# your eution, "o'pute the tool life !hen the "uttin# speed is 1.5 '/s nd the feed is 0.24 ''/rev. 'olution &hree eutions to be solved si'ultneously (1) (1. 0)(10) n(0.22)m > + > + n m (2) (1. 0)() (0.22) > + > + n m () (1. 0)(4) (0.2) > + > +
(1) nd (2) ln 11 B n ln 10 B m ln 0.22 > ln 4 B n ln B m ln 0.22 ln 11 B n ln 10 > ln 4 B n ln 8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
22$1
Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
.2 B 2.02 n > .5 B .4501 n 0.5 > 1.54 n
n )*2+
(1) nd () ln 11 B 0.25 ln 10 B m ln 0.22 > ln 11 B 0.25 ln 4 B m ln 0.2 0.5 B m ($1.511) > 0.50 B m ($1.1) m )*1+$0. m > $0.05 1-)*4 (1) + (1) + > > 11(10)0..25(0.22)0.1 >11(1.544)(0.401) > K
(b) " > 1.5 '/s, f '/s, f > 0.24 ''/rev (1.5 0)(# 0)( # )0.25(0.24)0.1 > 10. 0(&)0.25(0.40) > 10. (# )0.25 > 2.151 # > > 2.151 1/0.25 > 22*4 min 22.1
(@S7S units) units) 8ution 8ution (22.) in in the tet tet reltes reltes tool life life to speed speed nd feed. feed. -n series series of turnin# turnin# tests "ondu"ted to deter'ine the pr'eters n, m, nd + nd + , the follo!in# dt !ere "olle"ted (1) " > 00 ft/'in, f ft/'in, f > > 0.010 0. 010 in/rev, # > > 10 'in+ (2) " > 00 ft/'in, f ft/'in, f > > 0.010 in/rev, in/rev, # > > 5 'in+ nd () " > 00 ft/'in, f ft/'in, f > > 0.015 0. 015 in/rev, # > > 4 'in. :eter'ine n, m, nd + nd + . Wht is the physi"l interprettion of the "onstnt + "onstnt + % 'olution &hree eutions to be solved si'ultneously (1) 00(10) n(0.010)m > + > + n m (2) 00(5) (0.010) > + () 00(4) n(0.015)m > + > +
(1) nd (2) ln 00 B n ln 10 B m ln 0.010 > ln 00 B n ln 5 B m ln 0.010 ln 00 B n ln 10 > ln 00 B n ln 5 5.15 B 2.02 n > 5.04 B .555 n n )*2204 0.24 > 1.252 n (1) nd () ln 00 B n ln 10 B m ln 0.010 > ln 00 B n ln 4 B m ln 0.015 n ln 10 B m ln 0.010 > n ln 4 B m ln 0.015 0.22(2.02) B m ($.052) > 0.22(2.0) 0.22(2.0) B m ($.1) 0.22(2.02 $ 2.0) > m($.1 B .052) 0.0512 > 0.055 m m )*12-+ (1) + (1) + > > 00(10)0.22(0.010)0.12 > 00(1.1)(0.554) > . (2) + (2) + > > 00(5)0.22(0.010)0.12 > 00(2.22)(0.554) > . () + () + > > 00(4) 0.22(0.015)0.12 > 00(1.12)(0.5441) > .
K ,40*,
&he "onstnt + "onstnt + represents represents the "uttin# speed (ft/'in) for 1.0 'inute tool life t feed rte of 1.0 in/rev. &his feed is of "ourse n etrpoltion nd not rel possible feed vlue. 22.1 22.15 5
(S(S- uni units ts)) &he n nd C vlues vlues in &ble 22.2 re bsed on feed rte of 0.25 ''/rev nd depth of "ut > 2.5 ''. :eter'ine ho! 'ny "ubi" '' of steel !ould be re'oved for e"h of the follo!in# tool 'terils, if 10$'in tool life !ere reuired in e"h "se () plin "rbon steel, (b) hi#h$speed steel, (") "e'ented "rbide, nd (d) "er'i". @se of spredsheet "l"ultor is re"o''ended. > 20 '/'in 'olution () Plin "rbon steel n > 0.10, C > 0.1 " > 20/10 > 20/1.25 > 15.44 '/'in , -, > 15.44(10 )(0.25)(2.50) > .244(10 ) ''/'in =or 10 'in, 'etl re'oved > 10(.244)(10 ) > 00*2..(1), mm, (b) 6SS n > 0.125, C > > 0 '/'in 0.125 " > 0/10 > 0/1. > 52.51 '/'in , -, > 52.51(10 )(0.25)(2.50) > 2.421(10 ) ''/'in
8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
=or 10 'in, 'etl re'oved > 10(2.421(10 )) > ,2.*21(1), mm, (") 7e'ented "rbide n > 0.25, C > > 500 '/'in 0.25 " > 500/10 > 500/1.4 > 241.215 '/'in , -, > 241.215(10 )(0.25)(2.50) > 15.5(10 ) ''/'in =or 10 'in, 'etl re'oved > 10(15.5(10 )) > 1544*0(1), mm, (d) 7er'i" n > 0.0, C > > 000 '/'in 0. " > 000/10 > 000/.41 > 5.54 '/'in , -, > 5.54 (10 )(0.25)(2.50) > 0.4(10 ) ''/'in =or 10 'in, 'etl re'oved > 10(0.4 (10 )) > +54)0*.4(1), mm, 22.1
(S- units) units) 3 series of of 10$''$di'eter 10$''$di'eter holes holes hve been been drilled drilled throu#h throu#h 0$'' thi"* thi"* "st iron pltes pltes to deter'ine the tool life t t!o "uttin# speeds. 3t surf"e speed of 25 '/'in, the hi#h$speed steel drill lsted for holes. 3t 5 '/'in, the drill lsted for five holes. =eed > 0.04 ''/rev. :eter'ine the vlues of n nd C in in the &ylor tool life eution for the dt, !here "uttin# speed " is epressed in '/'in, nd tool life # is is epressed in 'in. -#nore effe"ts of drill entrn"e nd eit fro' the hole. 7onsider the depth of "ut to be e"tly 0 '', "orrespondin# to the plte thi"*ness. '/'in, ( > > (25)(10 )/(10) > rev/'in 'olution (1) " > 25 '/'in, ( f r r > > (0.04)() > . ''/'in # m > 0 ''/(. ''/'in) > 0.1 'in =or holes, # > > (0.1 'in) > 20. 'in =or'ultin# the dt s "# n > C , !e hve 25(20.) n > C (2) " > 5 '/'in, ( '/'in, ( > > (5)(10)/(10) > 111 rev/'in f r r > > (0.04)(111) > 4.1 ''/'in # m > 0 ''/(4.1 ''/'in) > 0. 'in =or 5 holes, # > > 5(0. 'in) > 1.4 'in =or'ultin# the dt s "# n > C , !e hve 5(1.4) n > C Settin# (1) > (2) 25(20.) n > 5(1.4) n ln 25 B n ln 20. > ln 5 B n ln 1.4 .214 B .01 n > .555 B 0.5144 n 2.5124 n > 0. C > > 25(20.) 0.1 > 25(1.500) > .5 C > > 5(1.4) 0.1 > 5(1.01) > .5 &he tool life eution is "# 0.1 > .5
22.1
n )*1,+ C ,4* m/min
(A (S- units) &he outside di'eter of "ylinder 'de of titniu' lloy is to be turned. &he strtin# di'eter > 00 '', nd the len#th > 1100 ''. =eed > 0.5 ''/rev, nd depth of "ut > 2.5 ''. &he "ut !ill be 'de !ith "e'ented "rbide tool !hose &ylor tool life pr'eters re n > 0.2 nd C > > 50. @nits for the &ylor eution re 'in for tool life nd '/'in for "uttin# speed. 7o'pute the "uttin# speed tht !ill llo! the tool life to be 10? lon#er thn the '"hinin# ti'e for this prt.
> 1.10# 1.10# m, !here # m > '"hinin# ti'e per pie"e nd # > > tool 'olution -n this proble' !e !nt # > life. )*/ )*/ f" nd f" nd # > > (C (C /")1/n # m > (00)(1100)(10$)/0.5(10 $)" > /" /" > (" (")$1 1/.2 .1 .1 $.1 # > > (50/" (50/ ") > (50/" (50/") > 50 (") > 115(10 4)(" )(")$.1 Settin# 1.10# 1.10 # m > # 1.10()" 1.10() "$1 > 115(10 4)(" )(")$.1 ".1 > 0.21(10 4) " > L0.21(10 4)1/.1 > L0.21(10 4)0.154 > 22) m/min 8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
22$1
Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
C$e67 # m > /(220) > 1. 'in # > > (50/220) 1/.2 > (2.055) .1 > 1. 'in, !hi"h is 10? lon#er thn # m
22.14
(@S7S units) units) &he &he outside outside di'eter di'eter of roll roll for rollin# rollin# 'ill 'ill is to to be turned. turned. -n the the finl pss, pss, the the strtin# di'eter > 2.25 in nd the len#th > 4.0 in. =eed > 0.0125 in/rev, nd depth of "ut > 0.125 in. 3 "e'ented "rbide "uttin# tool is to be used, nd the pr'eters of the &ylor tool life eution for this setup re n > 0.25 nd C > > 100. @nits for the &ylor eution re 'in for tool life nd ft/'in for "uttin# speed. -t is desirble to operte t "uttin# speed so tht the tool !ill not need to be "hn#ed "hn#ed durin# durin# the the "ut. :eter'ine :eter'ine the "uttin# "uttin# speed speed tht !ill '*e '*e the the tool life eul eul to the ti'e ti'e reuired to "o'plete the turnin# opertion. 'olution -n this proble' !e !nt # m > # , !here # m > '"hinin# ti'e per pie"e nd # > > tool life. )*/12 )*/12 f" nd f" nd # > > (C (C /")1/n # m > (2.25)(4.0)/12(0.0125) (2.25)(4.0)/12(0.0125)"" > 2,4.4/" 2,4.4/" > 2,4.4(" 2,4.4( ")$1 1/.25 .0 .0 $.0 & > (100/" (100/ ") > (100/" (100/") > 100 (") > 2.451(10 12)(" )(")$.0 Settin# # m > & 2,4.4(" 2,4.4( ")$1> 2.451(1012)(" )(")$.0 ".0 > 1.0422(10 4) " > L1.0422(10 4)1/ > L1.0422(10 4)0. > +4-*- !t/min C$e67 # m > 2,4.4 (.5) $1> 55.5 'in # > > (100/.5) 1/.25 > (100/.5) .0 > 55.5 'in
22.1
(S- units) units) &he &he !or* prt prt in turnin# turnin# operti opertion on is 44 '' '' in di'eter di'eter nd 550 550 '' lon#. lon#. 3 feed feed of 0.0 ''/rev is used in the opertion. -f "uttin# speed > . '/s, the tool 'ust be "hn#ed every three !or* prts+ but if "uttin# speed > 2.2 '/s, the tool "n be used to produ"e 1 prts bet!een tool "hn#es. =ind the "uttin# speed tht !ill llo! one tool to be used for bt"h si;e of 0 prts, !hi"h is the si;e of the net order for these prts. 'olution (1) " (1) " > > . '/s > 14 '/'in # m > (0.044 ')(0.55 ')/(14 '/'in)(0.0000 ') > 2.5 'in # > > (2.5) > .4 'in (2) " > 2.2 '/s > 12 '/'in # m > (0.044 ')(0.55 ')/(12 '/'in)(0.0000 '') > .4 'in # > > 1(.4) > 5. 'in
(1) 14(.4) n > C (2) 12(5.) n > C 14(.4) n > 12(5.) n ln 14 B n ln(.4) > ln 12 B n ln(5.) 5.244 B 2.0 n > .44 B .4 n 5.244 H .44 > (.4 H 2.0) n n )*2). 0.05 > 1. n 0.204 C > > 14(.4) C > > 02. ,)2*7he"* 12(5.) 0.204 > 02.5 7lose enou#h. use C
Set # > > 0 # m 0.204 "# > 02., # 0.204 > 02./" 02./", # > > (02./" (02./ ")1/0.204 > (02./" (02./ ").405 > 4.25(10) 11/".405 # m > (0.044)(0.55)/0.0000 " > 50.4/" 50.4/" 11 .405 4.25(10) /" > 0(50.4/" 0(50.4/ ") > 20,2./" 20,2./ " 11 .405 4.25(10) /" > 20,2. ".405 > 4.25(10) 11/20,2. > 1,0,0 " > (1,0,0) 1/.405 > (1,0,0) 0.224 > 1))*2 m/min 8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
7he"* # m > 50.4/100.2 > 5.0 'in, 0# 0 # m > 202. 'in .405 .405 # > > (02./100.2) > (.02) > 202.5 'in (7lose enou#hN) 22.20
(@S7S units) units) -n produ"t produ"tion ion turnin# turnin# opertio opertion, n, the steel steel !or* prt hs .5 in di'eter di'eter nd nd is 1.5 1.5 in lon#. =eed > 0.012 in/rev, nd depth of "ut > 0.100 in. -f "uttin# speed > 00 ft/'in, the tool 'ust be "hn#ed "hn#ed every every four four !or* prts+ prts+ but if if "uttin# "uttin# speed speed > 25 25 ft/'in, ft/'in, the tool "n "n be used used to produ"e produ"e 15 pie"es bet!een tool "hn#es. 3 ne! order for 25 pie"es hs been re"eived but the di'ensions of the !or* prt hve been "hn#ed. &he ne! di'eter > .5 in, nd the ne! len#th > 15.0 in. &he !or* 'teril nd toolin# re'in the s'e, nd the feed nd depth re lso un"hn#ed, so the &ylor &ool Aife eution deter'ined for the previous !or* prts is vlid for the ne! prts. :eter'ine the "uttin# speed tht !ill llo! one "uttin# tool to be used for the ne! order. (1) " > > 00 ft/'in 'olution (1) " # m > (.5 in)(1.5 in)/(00 12 in/'in)(0.012 in) > .25 'in # > > (.25) > 1.14 'in (2) " > 25 ft/'in # m > (.5 in)(1.5 in)/(25 12 in/'in)(0.012 in) > .2 'in # > > 15(.2) > .1 'in (1) 00(1.14) n > C (2) 25(.1) n > C 00(1.14) n > 25(.1) n ln 00 B n ln(1.14) > ln 25 B n ln(.1) 5.1 B 2.4 n > 5.1 B .50 n 5.1 $ 5.1 > (.50 $ 2.4) n n )*22) 0. > 1. n 0.2205 C > > 00 (1.14) C > > 4.4 (ft/'in) 7he"* 25(.1) 0.2205 > 4., use C 4+.*- Set # > > 25 # m 0.2205 "# > 4.5, # 0.2205 > 4.5/" 4.5/", # > > (4.5/" (4.5/")1/0.2205 > (4.5/" (4.5/").55 # > > 10.414(10) 12/".55 =or the ne! prt di'ensions, # m > (.5 in)(15 in)/(12" in)/(12 " in/'in)(0.012 in) > 115./ " 10.414(10) 12/".55 > 25(115./" 25(115./ ") > 24.25/" 24.25/ " 10.414(10) 12/".55 > 24.25 ".55 > 10.414(10) 12/24.25> ,41,0. " > (,41,0.) 1/.55 > (,41,0.) 0.242 > 2-4*)2 !t/min 7he"* # m > 115./2.025 > .24 'in, 25 # m > 10.2 'in # > > (4.5/2.025) .55 > (2.40) .55 > 10.2 'in
22.21
(A (S- units) &he M"hine Shop hs re"eived n order to turn three lloy steel "ylinders. &he strtin# di'eter > 250 '', nd the len#th > 25 ''. =eed > 0.0 ''/rev, nd depth of "ut > 2.5 ''. 3 "oted "rbide "uttin# tool !ill be used !hose &ylor tool life pr'eters re n > 0.25 nd C > 00, !here the units re 'in for tool life nd '/'in for "uttin# speed. 7o'pute the "uttin# speed tht !ill llo! the tool life to be ust eul to the "uttin# ti'e for the three prts. 'olution -n this proble' !e !nt # # m > # , !here # m > '"hinin# ti'e per pie"e nd # > > tool life. )*/ )*/ f" nd f" nd # > > (C (C /")1/n # m > (250)(25)(10 $)/0.0(10 $)" > 1.25/" 1.25/ " > 1.25 (" ( ")$1 # m > (1.25 (" ( ")$1) > 04.(" 04.(")$1 # > > (00/" (00/ ")1/.25 > (00/" (00/").0 > 00.0(")$.0 > 2.01(10 11)(" )(")$.0
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
Settin# # # m > # 04." 04."$1 > 2.01(1011)(" )(")$.0 ".0 > 2.01(10 11) > 4,1,15 " > (4,1,15) 1/.0 > ,-*4 m/min # m > 04./5. > 1.2 'in C$e67 # # > > (00/5.) 1/.25 > (1.11) .0 > 1.2 'in Toolin8 A99li6"tions
22.22
6i#h$speed 6i#h$speed steel steel is the the tool 'teril 'teril tht tht is spe"ifi spe"ified ed for "ertin "ertin finish finish turnin# turnin# opertion opertion in the lthe se"tion of the '"hine shop. &he trouble is tht tool life is 'u"h shorter thn the fore'n thin*s it should be. 3 lubri"nt type "uttin# fluid is used in the opertion, nd the '"hine opertor "o'plins of fu'es e'ntin# fro' the fluid. () 3nly;e the proble' nd (b) re"o''end so'e "hn#es tht 'i#ht be 'de to solve the proble'. 'olution3 () 6i#h speed steel is vulnerble to te'perture filure !hen "uttin# too fst in "ontinuous '"hinin# opertion li*e turnin#. Short tool life nd fu'es "o'in# fro' the lubri"nt type "uttin# fluid support the notion tht "uttin# speed is too hi#h.
(b) Fe"o''endtions bsed on &ble 22. (1) redu"e "uttin# speed to redu"e "uttin# te'perture+ (2) use "oolnt type "uttin# fluid rther thn lubri"nt be"use te'perture filure see's to be the proble', not #rdul !er+ () redu"e feed nd/or depth+ nd () use "rbide or "er'i" tool 'teril insted of hi#h speed steel in this finish turnin# opertion. 22.2
Spe"ify the 3S- 7$#rde 7$#rde or #rdes #rdes (71 throu# throu#h h 74 in &ble &ble 22.5) 22.5) of "e'ented "e'ented "rbide "rbide for for e"h of the follo!in# situtions () "uttin# the threds on the inlet nd outlet of lr#e brss vlve, (b) turnin# the di'eter of hi#h "rbon steel shft fro' .2 in to .5 in, (") '*in# finl f"e 'illin# pss usin# usin# shllo! shllo! depth depth of "ut "ut nd feed on on titniu' titniu' prt, prt, nd nd (d) borin# borin# out out the "ylind "ylinders ers of n n lloy steel uto'obile en#ine blo"* prior to honin#. 'olution3 ()
(b) 6i#h "rbon steel li'its "hoi"e to #rdes 75 throu#h 74. 3 lr#e 'ount of 'teril is bein# re'oved so it is rou#hin# "ut. 75 or 7 "ould be used, dependin# on the finish reuired fter the pro"ess pro"ess is "o'plete "o'plete.. (") &itniu' li'its the "hoi"e of #rdes to 71 throu#h 7. S'll feed nd depth of "ut indi"te finish pss. :ependin# on the finish reuire'ents, 7 or 7 !ould be sele"ted. (d) 3lloy steel li'its the "hoi"e of #rdes to 75 throu#h 74.
&he '"hine '"hine shop shop li'its li'its the nu'ber nu'ber of "e'ented "e'ented "rbide "rbide #rdes #rdes to four four for invento inventory ry "ontrol "ontrol purposes. purposes. &he &he "he'i"l "he'i"l "o'posit "o'positions ions of of these these #rdes #rdes re s follo!s follo!s Grde Grde 1 "ontins "ontins 5? W7 W7 nd 5? 7o+ Grde 2 "ontins 42? W7, ? 7o, nd 1? &i7+ Grde "ontins 40? W7, 10? 7o, nd 10? &i7+ nd Grde "ontins 4? W7 nd 11? 7o. () Whi"h #rdes !ould be suitble for '"hinin# "st iron% (b) Whi"h #rde should be used for finish turnin# of unhrdened steel% (") Whi"h #rde should be used for rou#h 'illin# of lu'inu'% (d) Whi"h #rde should be used for finish turnin# of brss% =or e"h "se, eplin your re"o''endtion. 'olution () M"hinin# "st iron. 7st iron is in"luded !ith !ith the non$steel #rdes. Spe"ify #rde 1 for finishin# nd #rde for rou#hin#.
(b) =inish turnin# of unhrdened steel. Spe"ify steel$"uttin# #rde suitble for finishin#. &his is #rde !ith &i7 nd lo! "oblt. 7hoose #rde 2. 8"erpts fro' this !or* 'y be reprodu"ed by instru"tors for distribution on not$for$profit bsis for testin# or instru"tionl purposes only to students enrolled in "ourses for !hi"h the tetboo* hs been dopted. Any other reproduction reproduction or translation of this work work beyond that permitted by Sections 107 or 108 of the 1976 United States Copyriht Act without the permission of the copyriht owner is unlawful!
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
(") Fou#h 'illin# of lu'inu'. Spe"ify non$steel rou#hin# #rde. &his is #rde !ith no &i7 nd hi#h "oblt. 7hoose #rde . (d) =inish turnin# of brss. Spe"ify non$steel finishin# #rde. &his is #rde !ith no &i7 nd lo! "oblt. 7hoose #rde 1. 22.25
Aist the the -S9 F51$15(8 F51$15(8)) #roup (letter (letter nd "olor "olor in &ble &ble 22.) 22.) nd !hether !hether the nu'ber nu'ber !ould be to!rd the lo!er or hi#her end of the rn#es for e"h of the follo!in# situtions () 'illin# the hed #s*et surf"e of n lu'inu' "ylinder hed of n uto'obile ("ylinder hed hs hole for e"h "ylinder nd 'ust be very flt nd s'ooth to 'te up !ith the blo"*), (b) rou#h turnin# hrdened steel shft, (") 'illin# fiber$reinfor"ed poly'er "o'posite tht reuires pre"ise finish, nd (d) 'illin# the rou#h shpe in die 'de of steel before it is hrdened. 'olution3 () 3lu'inu' !ould be the O (red) #roup. Millin# the surf"e !ith lr#e holes in it !ill "rete sho"* lodin# on the tool. &his !ill reuire hi#her tou#hness.
(b) 6rdened steel shft !ould indi"te #roup P (blue). Fou#h "ut !ould reuire hi#her tou#hness so "hoose hi#her nu'ber (") 7o'posite is non'etlli" nd !ould use #roup O (red). Pre"ise '"hinin# !ould reuire hi#h hrdness (lo!er nu'ber). (d) Steel !ould indi"te the P (blue) #roup. Fou#h 'illin# !ould indi"te hi#her tou#hness nd thus hi#h nu'ber. 22.2
3 turnin# turnin# opertion opertion is perfor'ed perfor'ed on steel steel shft !ith !ith di'eter di'eter > 12 12 '' (5.0 in) nd len#th len#th > 41 '' (2 in). 3 slot or *ey!y hs been 'illed lon# its entire len#th. &he turnin# opertion redu"es the shft di'eter. =or e"h of the follo!in# tool 'terils, indi"te !hether it is resonble "ndidte to use in the opertion () plin "rbon steel, (b) hi#h$speed steel, (") "e'ented "rbide, (d) "er'i", nd (e) sintered poly"rystlline di'ond. =or e"h 'teril tht is not #ood "ndidte, #ive the reson !hy it is not. 'olution &he len#th!ise slot results in n interrupted "ut, so tou#hness is i'portnt in the tool 'teril.
() Plin "rbon steel not e"ono'i"l be"use of lo! "uttin# speeds. (b) 6SS this is resonble "ndidte+ it hs #ood tou#hness for the interrupted "ut. (") 7e'ented "rbide this is resonble "ndidte+ it 'ust be steel "uttin# #rde !ith hi#h tou#hness (hi#h "oblt "ontent). (d) 7er'i" this is not #ood "ndidte be"use of its lo! tou#hness+ it is li*ely to fr"ture durin# interrupted "uttin#. (e) Sintered poly"rystlline di'ond SP: is not suitble for "uttin# steel. Cuttin8 :lui#s
22.2
(@S7S units) units) -n 'illin# 'illin# operti opertion on !ith !ith no "oolnt, "oolnt, "uttin# "uttin# speed of of 500 ft/'in ft/'in is used. used. &he &he "urrent "uttin# "onditions (dry) yield &ylor &ool &ool Aife eution pr'eters of n > 0.25 nd C > > 100 (ft/'in). When "oolnt is used in the opertion, the "uttin# speed "n be in"resed by 20? nd still 'intin the s'e tool life. 3ssu'in# n does not "hn#e !ith the ddition of "oolnt, !ht is the resultin# "hn#e in the vlue of C % 'olution3 =ind the present tool life # (1/n) "# n > C + # > > (C (C /")(1/n
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
# > > (100/500) (1/.25) > 2.0.0 > 5. 'in 3fter "oolnt, the ne! "uttin# speed !ould be 500(1B.20) > 00 -f the tool life stys the s'e, C > > "# n > 00(5.) .25 > 150 ? in"rese in C > > (150$100)/100 > 2); ote When vie!in# vie!in# the lo#$lo# lo#$lo# plot plot of the &ylor &ylor &ool Aife Aife "urve, "urve, it is is stri#ht stri#ht line. Sin"e Sin"e n, the slope, is not ffe"ted by the "oolnt, the "oolnt effe"tively rises the line on the #rph. Fisin# the "urve so tht it in"reses the vlue of " by "ertin per"ent#e !ill in"rese C by by the s'e per"ent#e. per"ent#e. &his &his is true indepen independent dent of the vlues vlues of of n nd C . 22.24
(A (S- units) -n turnin# opertion usin# hi#h$speed steel toolin#, "uttin# speed > 100 '/'in. &he &ylor tool life eution hs pr'eters n > 0.125 nd C > > 120 ('/'in) !hen the opertion is perfor'ed perfor'ed dry. dry. When "oolnt "oolnt is used in in the opertion, opertion, the the vlue of C is is in"resed by 15?. :eter'ine the per"ent in"rese in tool life tht results if the "uttin# speed is 'intined t 100 '/'in. 'olution :ry 100(# 100( # )0.125 > 120 # > > (120/100) 1/.125 > (1.2) 4 > . 'in With "oolnt 100(# 100( # )0.125 > 120(1 B 15?) > 120(1.15) > 14 1/.125 # > > (14/100) > (1.4)4 > 1.15 'in -n"rese > (1.15 H .)/. > 2.0 > 2)-;
22.2
(@S7S units) units) 3 produ"tion produ"tion turnin# turnin# opertio opertion n on plin "rbon "rbon steel steel !or*pie"e !or*pie"e nor'lly nor'lly opertes opertes t "uttin# speed of 125 ft/'in usin# hi#h$speed steel toolin# !ith no "uttin# fluid. &he pproprite n nd C vlues vlues in the &ylor eution re #iven in &ble 22.2 in the tet. -t hs been found tht the use of "oolnt type "uttin# fluid !ill llo! n in"rese of 25 ft/'in in the speed !ithout ny effe"t on tool life. -f it "n be ssu'ed tht the effe"t of the "uttin# fluid is si'ply to in"rese the "onstnt C by 25, 25, !ht !ould !ould be be the in"rese in"rese in tool tool life life if the the ori#inl ori#inl "uttin# "uttin# speed of of 125 ft/'in !ere used used in the opertion% 'olution =ro' &ble 22.2, n > 0.125 nd C > > 200 for dry "uttin#. With "uttin# fluid, C > > 200 B 25 > 225. :ry t " > 125 ft/'in, # > > (200/125) 1/.125 > (1.)4 > 2.5 'in With "uttin# fluid t " > 125 ft/'in, # > > (225/125) 1/.125 > (1.4)4 > 110.2 'in -n"rese > (110.2 $ 2.5)/2.5 > 1*-- 1-*-;
22.0
7e'ented 7e'ented "rbide "rbide "uttin# "uttin# inserts inserts re used used in produ" produ"tion tion 'illin# 'illin# operti opertion on to re'ove re'ove si#nifi"n si#nifi"ntt 'ounts of 'etl fro' steel snd "stin#. &his rou#hin# opertion is perfor'ed t lo! "uttin# speed, hi#h depth nd feed, nd no "uttin# fluid is used. &he proble' is tht the inserts !er out rpidly, nd the fore'n believes tht se'i"he'i"l fluid should be used to redu"e "uttin# te'perture. () 3nly;e the proble' nd (b) re"o''end so'e "hn#es tht 'i#ht be 'de to solve the proble'. 'olution () &he proble' is e"essive !er on the "rbide toolin# tht results fro' the brsive nture of snd "stin#s 'de of steel.
(b) Fe"o''endtions Surely "uttin# fluid !ould be benefi"il, but se'i"he'i"l fluid !ould better ddress ddress te'perture te'perture proble's proble's thn !er !er proble's. proble's. 3 lubri"nt lubri"nt type type "uttin# "uttin# fluid fluid should should be be used to 'iti#te the !erin# "tion of the !or* 'teril on the tool. -f lubri"nt is not ttr"tive, then n e'ulsifible oil should be used !ith perhps less !ter thn usully re"o''ended to in"rese the lubri"tin# ulities of the fluid. 9ther "hn#es tht 'i#ht help in"lude redu"in# speed nd feed. 22.1
(S- units) units) 3 hi#h speed speed steel .0 .0 '' t!ist drill drill is bein# bein# used in produ"t produ"tion ion drillin# drillin# opertion opertion on on 'ild steel. 3 "uttin# oil is pplied by the opertor by brushin# the lubri"nt onto the drill point nd
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Solutions for Fundamentals of Modern Manufacturing , 5/e (published by Wiley) MPGroover 2012
flutes prior to e"h hole. &he "uttin# "onditions re speed > 25 '/'in, feed > 0.10 ''/rev, nd hole depth > 2 ''. &he fore'n sys tht the speed nd feed re ri#ht out of the hndboo* for this !or* 'teril. evertheless, he sys, the "hips re "lo##in# in the flutes, resultin# in fri"tion het, nd the drill bit is filin# pre'turely due to overhetin#. () 3nly;e the proble' nd (b) re"o''end so'e "hn#es tht 'i#ht be 'de to solve the proble'. 'olution () &here re severl proble's here. =irst, the depth$to$di'eter rtio is 2 > 1, !hi"h is #reter thn the 1 tht is usully re"o''ended. 3s "onseuen"e the "hips produ"ed in the hole re hvin# diffi"ulty eitin#, thus "usin# overhetin# of the drill. Se"ond, the 'nul 'ethod of pplyin# the "uttin# oil 'y not be prti"ulrly effe"tive. &hird, !ith overhetin# s proble', the "uttin# oil 'y not be re'ovin# het fro' the opertion effe"tively.
(b) Fe"o''endtion &he 1 depth$to$di'eter rtio is #iven, reuire'ent of the drillin# opertion, nd !e ssu'e it "nnot be "hn#ed. &he t!ist drill 'i#ht be operted in pe"*$drillin# 'ode to solve the "hip "lo##in# proble'. Pe"*$drillin# 'ens drillin# for distn"e pproi'tely eul to one drill di'eter, then retr"t the drill, then drill so'e 'ore, et". 3 t!ist drill !ith fluid hole "ould be used to 'ore effe"tively deliver the "uttin# fluid to the drill point to help etr"t the "hips. =inlly, n e'ulsified oil 'i#ht be tried in the opertion, one !ith #ood lubri"tin# ulities, s substitute for the "uttin# oil. Sin"e overhetin# is proble', it '*es sense to try "oolnt.
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