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Mechanics of Grinding
f t1 = mm ZN
Where Z = Number of active grains N = rpm of the wheel
Z = DCb '
rg = b ' / t1
f t1 = DNCrg
Power
AfU c W= 60
Force per single grit
'
Cos 1
2
2
l Dd
1 ' ( NDBC ) bmax t1max l = fdB 6
t1max
6f = NDrg C
d D
BfdU c W= W 60
Fc' =
Thermal aspects
Energy spent per unit surface area ground
Fc ND s Bf
Since
s dU c
and
U c = U o (t1av )
0.4
and
t1av
1 = t1max 2
g = U c
vt1max k C
Honing Operation
Lapping
MAF
end cutting edge angle Maximum height of unevenness, when nose radius (r) is used
H max
f2 = 8r
Verification of surface roughness with cutting Speed during turning mild steel bar
R = R1 + R2 + R3 + R4 + R5
R = Total Cost/ piece R1 = Material Cost/ piece R2 = Set up and idle time Cost/ piece R3 = Machining Cost/ piece R4 = Tool changing Cost/ piece R5 = Tool regrinding Cost/ piece 1= Cost/ min of labour and overheads 2= Cost of setting a tool for regrinding 3 = Cost/mm of tool ground ts = Set-up tme and idel time/ piece, min, tm = Machining time/piece, min, tct = Tool changing time, min
R2 = 1ts
Machining cost
R3 = 1t3 = 1
LD
1000 fv
tm R4 = 1 tct T
k T = 1/ n 1/ m v f
T = Tool life
R4 = 1tct
LD
1000 fv
v1/ n 1 f 1/ m 1
= h f tan vs ,
2 + 3 = 2 + 3h f tan s
tm R5 = (2 + 3 h f tan vs ) T
= (2 + 3 h f tan vs )
LD
1000k
A
Vs = Clearance angle
v1/ n 1 f 1/ m 1
If tool cost of new tool is A and the total length that can be reground is B mm , then cost per mm of the tool
3 =
1 + h
B ta n v s
LD
1000 fv
+ 1tct
LD
1000 fv
v1/ n 1 f 1/ m 1 + (2 + 3 h f tan vs )
LD
1000 fv
v1/ n 1 f 1/ m 1
vopt
nk 1 = 1/ m (1 n) f (1tct + 2 + 3 h f tan s )
vopt
nk 1 = 1/ m (1 n) f (1tct + 4 )
mk 1 = 1/ n (1 m)v (1tct + 4 )
m
f opt
Machining force
Fc = 1000U 0 wt10.6
Fc = k1 f 0.6
Power consumption Variation of machining cost with v and f
W = k1vf 0.6
Maximum available power in the machine then limiting cutting speed-feed
vf
0.6
Wlim = k1
tm tt = ts + tm + tct min T
= ts +
LD
1000 fv 1000k
LD
tt v
v = vopt
LD
vopt
nk = 1/ m (1 ) n f tct
SR pr = tt
pr v
=0
v = vopt