Turning formulas

1. A cylindrical stainless steel rod with length L=150 mm, diameter D0 = 12 mm is being reduced in diameter to Df =11 mm by turning on a lathe. The spindle rotates at N = 400 rpm, and the tool is travelling at an axial speed of =200 mm/min

Calculate: a. The cutting speed V (maximum and minimum) b. The material removal rate MRR c. The cutting time t d. The power required if the unit power is estimated to 4 w.s/mm3

SOLUTION:

a. The maximum cutting speed is at the outer diameter D0, and is obtained from the expression

V = D0 N

Thus, Vmax = () (12) (400) = 15072 mm/min

The cutting speed at the inner diameter Df is

Vmin = () (11) (400) = 13816 mm/min

b. From the information given, the depth of cut is d = (12 11) / 2 = 0,5 mm

and the feed is f = / f = 200 / 400 = 0,5 mm/rev

thus the material removal rate is calculated as

MRR = () (Davg) (d) (f) (N) = () (11,5) (0,5) (0,5) (400) = 3611 mm3/min = 60,2 mm3/s

c. The cutting time is t = l / (f. N) = (150) / (0,5) (400) = 0,75 min

d. The power required is Power = (4) (60,2) = 240,8 W

2. The part shown below will be turned in two machining steps. In the first step a length of (50 + 50) = 100 mm will be reduced from 100 mm to 80 mm and in the second step a length of 50 mm will be reduced from 80 mm to 60 mm. Calculate the required total machining time T with the following cutting conditions:

Cutting speed V=80 m/min, Feed is f=0.8 mm/rev, Depth of cut = 3 mm per pass.

SOLUTION: V=80 m/min f=0.8 mm/rev

The turning will be done in 2 steps. In first step a length of (50 + 50) = 100 mm will be reduced from 100 mm to 80 mm and in second step a length of 50 mm will be reduced from 80 mm to 60 mm.

3. The shaft shown in the figure below is to be machined on a lathe from a 25mm bar. Calculate the machining time if speed V is 60 m/min., turning feed is 0.2mm/rev, drilling feed is 0.08 mm/rev and knurling feed is 0.3 mm/rev.

Turning, drilling, knurling SOLUTION:

Step 2 Turn 20 mm from 25 mm

min 29.0764x 2.0

45N x f

L Tm ===

4. A batch of 800 workpieces is to be produced on a turning machine. Each workpiece with length L=120mm and diameter D=10mm is to be machined from a raw material of L=120mm and D=12mm using a cutting speed V=32 m/min and a feedrate f=0.8 mm/rev. How many times we have to resharpen or regrind the cutting tool? In the Taylors expression, use constants as n=1.25 and C=175.