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Lecture No. 7 Turning Parameters

This document discusses various turning parameters such as depth of cut, feed, cutting speed, spindle speed, cutting time, material removal rate, and torque. It defines each parameter and provides the relevant formulas. Examples are given to demonstrate how to calculate these parameters for given turning operations and solve related numerical problems. Key turning parameters and their impact on machining operations are explored.

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Muhammad Irfan
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888 views

Lecture No. 7 Turning Parameters

This document discusses various turning parameters such as depth of cut, feed, cutting speed, spindle speed, cutting time, material removal rate, and torque. It defines each parameter and provides the relevant formulas. Examples are given to demonstrate how to calculate these parameters for given turning operations and solve related numerical problems. Key turning parameters and their impact on machining operations are explored.

Uploaded by

Muhammad Irfan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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LECTURE NO.

7
Turning Parameters

1
LECTURE OBJECTIVES

 To develop an understanding about different Turning


parameters
 To study how to solve numerical problems

2
Recall: What is turning?
Turning is a machining process performed on a lathe in which a single
point tool removes material from a rotating cylindrical workpiece.

The cutting tool is fed linearly and in a direction parallel to the axis of
rotation of the work piece as shown in the figure below.
Parameters


• Depth
  of cut (d)
 Axial depth of cut
 Radial depth of cut
 Feed (f)
 Feed rate ()
 Cutting speed (v)
 Spindle Speed (N)
 Cutting time (t)
 Material removal Rate (MRR)
 Torque (T)
Depth of cut (d)
• is  the amount of material removed as the work piece revolves on its axis.
It
Its unit is mm or inch.

Formula: d =
where;
d= depth of cut (mm or inches)
= original diameter of work piece (mm or inches)
= final diameter of work piece (mm or inches)
There are two types of depth of cut:
 Axial depth of cut
 Radial depth of cut

Axial depth of cut


The depth of cut which is taken along the
axis of workpiece as in case of
facing is called axial depth of cut
Radial depth of cut:

The depth of cut which is taken along


the radius of workpiece as in case of
tuning operation
Feed (f)

• is  distance the tool travels per unit revolution of the workpiece.
It
Its unit is (mm/rev or in/rev).
Formula f = / N

Schematic illustration of the basic turning operation, showing depth-of-cut, d; feed, f;


and spindle rotational speed, N in rev/min. Cutting speed is the surface speed of the
workpiece at the tool tip.
Feed rate
  ()
• is  the rate at which tool advances into the workpiece.
It
Or
It is the linear speed of the tool along the workpiece length.

Formula: = f.N
= mm/rev . rev/min = mm/min
So its unit is mm/min or inch/min.
Where;
f = feed (mm/rev)
N = spindle speed (rev/min)
Cutting speed (v)
• is  the rate at which the surface of workpiece moves past the cutting tool
It
OR
The speed of workpiece surface relative to edge of cutting tool during a cut.
Formula:
v = π N (for max speed)
v = π N (for avg speed)
Where;
V= cutting speed(m/min or ft/min)
Do = original diameter of workpiece
𝐷𝑎𝑣𝑔 = average diameter of workpiece
N = spindle speed (rev/min)
Unit:
Its unit is m/min or feet/min
Spindle speed (N)
• is  the rotational speed of spindle and work piece in revolution per minute.
It
Formula: N =
Where;
N = spindle speed (rev/min)
v= cutting speed (m/min or feet/min)
Do = original diameter of work piece (mm or in)

The difference between cutting and spindle speed is that cutting speed is linear
velocity covered by work piece whereas the spindle speed is the angular speed
of spindle/work piece.
Cutting time (t)

•   time required for cutting tool to make all the necessary cut in the work
The
piece for each operation.
It is calculated by dividing the total cut length for operation by feed rate.

Formula: t = L / f.N
Unit = = min
Material removal rate (MRR)

• is  the volume of material removed per unit time.


It
For each revolution, we remove a ring shaped layer of material with a
cross section that equals the product of tool travel in 1 revolution and
depth of cut.
Formula cross-sectional area = f × d
volume = f × d × average circumference of ring
= f × d × (2πr)
= f × d × π × Davg ( for 1 revolution)
MRR = f × d × π × Davg × N (for N revolution)
Unit = mm/rev × mm × rev/min × mm
=
Example 1:
A mild steel rod having 50 mm diameter and 500 mm length is to be turned on a lathe.
Determine the machining time to reduce the rod to 45 mm in one pass when cutting
speed is 30 m/min and a feed of 0.7 mm/rev is used.

Given data: D = 50 mm, L = 500 mm, v = 30 m/min, f = 0.7 mm/rev


Substituting the values of v and D in

calculate the required spindle speed as: N = 191 rpm

Machining time
t = L / f.N
= 500 / (0.7×191)
= 3.74 minutes
Example 2
A 150 mm long 12 mm diameter stainless steel rod is to be reduced in diameter to 10 mm
by turning on a lathe in one pass. The spindle rotates at 500 rpm, and the tool is traveling
at an axial speed of 200 mm/min. Calculate the cutting speed, max. material removal rate
and the time required for machining the steel rod.
Given data: L = 150 mm, D1 = 12 mm, D2 = 10 mm, N = 500 rpm, fr = 200 mm/min

v = π×12×500 / 1000
= 18.85 m/min.
MRR = f × d × π × Dmax × N
depth of cut = d = (12 – 10)/2 = 1 mm
f = 200/500 = 0.4 mm/rev
MRR = 3.142×12×0.4×1×500 = 7538.4 mm3/min
t = L / f.N
t = 150/(0.4×500) = 0.75 min.
Example 3

Calculate the time required to machine a work piece 170 mm long, 60 mm diameter to
165 mm long 50 mm diameter. The work piece rotates at 440 rpm, feed is 0.3 mm/rev and
maximum depth of cut is 2 mm. Assume total approach and over travel distance as 5 mm
for turning operation.

Given data: L = 170 mm, D1 = 60 mm, D2 = 50 mm, N = 440 rpm,


f = 0.3 mm/rev, d= 2 mm,
How to calculate the machining time when there is more than one
operation?
Time for Turning:
Total length of tool travel = job length + length of approach and over travel
L = 170 + 5 = 175 mm
Required depth to be cut = (60 – 50)/2 = 5 mm
Since maximum depth of cut is 2 mm, 5 mm cannot be cut in one pass. Therefore, we
calculate number of cuts or passes required.
Number of cuts required = 5/2 = 2.5 or 3 (since cuts cannot be a fraction)
Machining time for one cut = L / (f×N)
Total turning time = [L / (f×N)] × Number of cuts) = 3.97 min
Time for facing:
Now, the diameter of the job is reduced to 50 mm. Recall that in case of facing operations,
length of tool travel is equal to half the diameter of the job. In one pass only 2 mm length
(max. depth of cut) can be reduced.
For 5 mm reduction (170 - 165 mm = 5 mm) 2.5 or 3 pass would be required
That is, L = 25 mm and 3 passes
t = 25/(0.3×440) × Number of cuts
= 0.54 min.
Total time:
Total time for machining = Time for Turning + Time for Facing
= 3.97 + 0.54 = 4.51 min.
Example 4
While turning a carbon steel cylinder bar of length 3 m and diameter 0.2 m at a feed of
0.5 mm/revolution with an HSS tool, one of the two available cutting speeds is to be
selected. These two cutting speeds are 100 m/min and 57 m/min. The tool life
corresponding to the speed of 100 m/min is known to be 16 minutes with n=0.5. The cost
of machining time, setup time and unproductive time together is Rs.1/sec. The cost of one
tool re-sharpening is Rs.20.

Given T1 = 16 minute, v1 = 100 m/minute, v2 = 57 m/minute,


D = 200mm, l = 300 mm, f = 0.5 mm/rev
Consider Speed of 100 m/minute
Number of resharpening required = t1/T1
N1 = (1000 × v) / (π × D) = (1000×100) / (π×200) = 159.2 rpm
t1 = L / (f×N) = 3000 / (0.5 ×159.2) = 37.7 minute
Tool life corresponding to speed of 100 m/minute is 16 minute.
Number of resharpening required = 37.7 /16 = 2.35
or number of resharpenings = 2
Total cost = Machining cost + Cost of resharpening × Number of resharpening
= 37.7×60×1+ 20×2
= Rs.2302
Consider Speed of 57 m/minute
From Taylor’s tool life expression,
we have vTn= C

Using Taylor’s expression T2 = T1 × (v1 / v2)2 with usual notations


= 16 × (100/57)2
= 49 minute
t2 = L / (f×N)
N = (1000 × v) / (π × D)
Repeating the same procedure we get t2 = 66 minute,
number of reshparpening = 66/49 = 1
and total cost = Rs. 3980.
Example 5
From a raw material of 100 mm length and 10 mm diameter,a component having length
100 mm and diameter 8 mm is to be produced using a cutting speed of 31.41 m/min and a
feed of 0.7 mm/rev. How many times we have to resharpen or regrind, if 1000 work-
pieces are to be produced. In the taylor’s expression use constants as n = 1.2 and C = 180

Given D =10 mm, v = 31.41 m/minute


From Taylor’s tool life expression,
we have vTn= C
Substituting the values we get,
(31.40)(T)1.2 = 180
T = 4.28 min
N = (1000 × v) / (π × D) = 1000 rpm
Machining time/piece = L / (f×N) = 100 / (0.7×1000)
= 0.142 minute.
Machining time for 1000 work-pieces = 1000 × 0.142 = 142.86 min
Number of resharpenings = 142.86/4.28
= 33.37 or 33 resharpenings
Example 6:
Determine the angle at which the compound rest would be swivelled for cutting a taper on a
work piece having a length of 150 mm and outside diameter 80 mm. The diameter on the
tapered end of the rod should be 50 mm and the required length of the tapered portion is 80
mm.

Given data: D1 = 80 mm, D2 = 50 mm, L = 80 mm (with usual notations)

tan α = (80-50) / 2×80


or α = 10.62o

The compound rest should be swivelled at 10.62o


Example 7
Write the process sequence to be used for manufacturing the component from raw
material of 175 mm length and 60 mm diameter
The raw material is having size of 175 mm length and 60 mm diameter.
The component shown in Figure is having major diameter of 50 mm, step diameter of 40
mm, groove of 20 mm and threading for a length of 50 mm. The total length of job is 160
mm.
Hence, the list of operations to be carried out on the job are turning, Facing, Step turning,
Thread and Grooving.
A possible sequence for producing the component would be:
1. Turning (reducing completely to 50 mm)
2. Step turning (reducing from 50 mm to 40 mm)
3. Facing (to reduce the length to 160 mm)
4. Thread cutting.
5. Grooving
Example 8:
In a production turning operation, the work piece is 125 mm in diameter and 300 mm long.
A feed of 0.225 mm/rev is used in the operation. If cutting speed = 3.0 m/s, the tool must be
changed every 5 work parts; but if cutting speed = 2.0 m/s, the tool can be used to produce
25 pieces between tool changes. Determine the Taylor tool life equation for this job

Solution:
t = L / (f×N) = L π D / f. V
(1) t1 = π(125 mm)(0.3 m)/(3.0 m/s)(0.225 mm) = 174.53 s = 2.909min
T = 5(2.909) = 14.54 min
(2) t2 = π(125 mm)(0.3 m)/(2.0 m/s)(0.225 mm) = 261.80s = 4.363 min
T = 25(4.363) = 109.08 min
(1) v = 3 m/s = 180 m/min (2) v = 2 m/s = 120 m/min
vTn= C
(1) 180(14.54)n = C
(2) 120(109.08)n = C
180(14.54)n = 120(109.08)n
ln 180 + n ln(14.54) = ln 120 + n ln(109.08)
5.1929 + 2.677 n = 4.7875 + 4.692 n
5.1929 - 4.7875 = (4.692 - 2.677) n
0.4054 = 2.0151 n
n = 0.2012
C = 180 (14.54)0.2012
C = 308.43
Example 9:
Tool life tests in turning yield the following data: (1) when cutting speed is 100 m/min, tool
life is 10 min; (2) when cutting speed is 75 m/min, tool life is 30 min. (a) Determine the n
and C values in the Taylor tool life equation. Based on your equation, compute (b) the tool
life for a speed of 110 m/min, and (c) the speed corresponding to a tool life of 15 min.

Solution: VTn = C
(a) Two equations:
(1): 100(10)n = C
(2): 75(30)n = C
100(10)n = 75(30)n
100/75 = (30/10)n, 4/3 = 3n
ln(4/3)=n ln3
n=ln(4/3)/ln3,
n = 0.26186
C = 100(10)0.26186 C = 182.75
Check: C = 75(30)0.26186 = 182
(b)
110 T0.26186 = 182.75
T = (182.75/110)1/0.26186
= 6.9489 min

(c)
v (15)0.26186 = 182.75
v = 182.75/(15)0.26186
= 89.9 m/min
THANKYOU

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