1

Technical University - Sofia

IMS I
Course Work




Sava Savchev
221206016
143B

2

Contents:
Task...3
1. Production analysis..4
2. Determining type of production.4
3. Determining type of process...4
4. Selecting a billet...4
5.Milling operations.6
5.1. Choosing milling machine...6
5.2. Face milling...6
5.3. Side milling9
5.4. Thread milling..12
6. Drilling.15
7. Total servicing time.18
8. Price.19
9. Operation sheet...20
10. Reference...20

3


Task: Body
4

1. Production analysis
Designing such kind of body requires to be very precise in material
shaping because of the high density of the used material. In order to
have fast and high quality production, it has to be chosen minimum
amount of types of machining according to the required operations.
2. Determining the type of production
2009 has 257 working days(8 working hours a day). We must
make 50 000 bodies a year.
First we should find our type of production using the coefficient k:
k =
6u 2S7 8
4 Suuuu
= u.62
We find that our production is mass.(mass production k=1-2)
In order to calculate the time limit for production of the whole lot
of 50 000 bodies, the following formula has to be used:
I =
Su uuu
2S7 8
= 24 boJics pcr bour;
I =
1
24
= u.u42 bours = 2.S2minor onc boJy.
3. Determining the type of processes
Operation
1 Selecting a billet
2
Milling:
-face milling (cutting off the billet);
-shoulder milling;
-thread milling;
3 Drilling

4. Selecting a billet
In the course work we have to choose the right material in order to
have high strength, low cost and low machining expenses.
The material for this part must have high yield strength, so we
choose Aluminum alloy 7075 T6 with ultimate tensile strength of
503MPa. The billet is of flat type with dimensions 63.5x127 mm and
5

length 116 mm. This billet is only for determining the required time for
the operations because of the almost exact dimensions.




6

5. Milling Operations
5.1. Choosing Milling Machine
The material of the body and the big length of the cuts require
milling machine with higher power. That is why we choose X.Mill 900 B
with the following specifications:
Travel x-axis 800 mm;
Travel y-axis 500 mm;
Travel z-axis 550 mm;
Table 1050x500 mm;
Power 15 kW;
Spindle speed 8000 rpm;
5.2. Face milling
First thing that has to be done is to cut the billet in order to reach
the exact dimensions of the body. In order to do that there must be done
two facing operations: 63.5 mm 54 mm and 127 mm 120 mm. For
the operation we choose:

Tool:
CoroMill Century Arbor R590-100Q32A-11M



Maximum ap depends on the type of the insert.



Parameter Value
Dc 100 mm
l1 50 mm
dmm 32 mm
No. of teeth zn 6
Kr 90
7

Insert:
R/L590-110504H-NL

a) First we should mill to 120 mm, because then the second facing
will have smaller length. In order to decrease the power we will cut in
two passes each with half of the working engagement (58 mm):
ap = 7 mm - depth of cut;
ae = 58 mm working engagement;
L = 63.5 mm length;
Dc = 100 mm cutting diameter;
zn = 6 number of teeth;
hex = 0.2 mm (Coromant);
Vc = 325 m/min cutting speed (Coromant);
Kr = 90 fz = hex = 0.2 mm;
HB = 150 hardness Brinell;
K = 2.2 (Coromant);
The given cutting speed is for HB = 130, so we will have to multiply it
with coefficient taken from the Coromant catalogue and for hardness
bigger with 20 units it is equal to 0.91:
Vc = 325x0.91 = 300 m/min;
n =
I
c
1uuu
n
c
= 9SS rpm-spinJlc spccJ;
:
]
=
z
z
n
n = 1146 mm min- ccJ spccJ;
I
c
=
I
:
]
= u.uSS min = S.S scc -mocbining timc;
Parameter Value
max ap 10 mm
iW 11.5 mm
la 11 mm
bs 2.2 mm
r 0.4 mm
8

P
c
=
o
p
o
c
:
]
K
1uu uuu
= 1u.2 kw-powcr consumption;

For the second pass the data will be the same, so we can say that
the first face milling will be done for approximately 6.6 seconds.



b) For the second facing we will use the same tool and insert,
which makes the parameters almost the same. The only difference is in
the depth of cut and the length. Otherwise we will have the same
cutting, spindle and feed speed.For this face milling again we will make
two passes in order to have smaller power consumption.
ap = 9.5 mm;
ae = 58 mm;
L = 120 mm;
n = 955 rpm;
vf = 1146 mm/min;
K=2.2;

I
c
=
I
:
]
= u.11 min = 6.6 scc -mocbining timc;
P
c
=
o
p
o
c
:
]
K
1uu uuu
= 1S.9 kw-powcr consumption;

9

For the total time we must again multiply by two, because the
second pass is the same and we can see that the total machining time for
the second facing is 13.2 seconds.



5.3. Side milling
Specific instruction for this operation is the fixing of the detail,
which must be 45 according to the tool in order to have the right
dimensions.
In order to make the right choice for the tool and the insert we
must calculate simple geometric problem:
A

17 mm

B 17 mm C

As we can see the triangle is right with angles 45-45-90. If we draw
the altitude from the angle which is 90 , it will also be a meridian for
ABC. From the Pythagorean theorem we find AC:
AC
2
= AB
2
+BC
2
= 17
2
+17
2
= 24; AC = 12 mm
Altitude is also equal to 12 mm.


10

Tool:
CoroMill 331 Bore with keyway N331.32 160S40RM




Insert:
N331.1A-04 35 05H-PL

ap = 12 mm;
ae = 22 mm;
L = 24 mm;
zn = 6;
hex = 0.1fz = 0.1 mm(Kr=90);
K = 2.7;
Vc = 380 m/minVc = 380x0.91=346m/min(HB=130+20);
n =
I
c
1uuu
n
c
= 11u2 rpm;
:
]
= z
n
n
z
= 882
mm
min
;
Parameter Value
Dc 100 mm
ap 12 mm
No. of teeth zn 8
Kr 90
ar 25
Parameter Value
iW 9.5 mm
la 4.6 mm
bs 0.2 mm
r 0.5 mm
s 3.5 mm
11

I
c
=
I
:
]
= u.u27 min = 1.6 scc
P
c
=
o
p
o
c
:
]
K
1uu uuu
= 6.S kw

This is the time for one of the side millings. Because they are four
we have to multiply four times Tc and we find the total machining time
to be Tc = 1.6x4 = 6.4 seconds.






12

5.4. Thread milling
In order to do threads we can use also milling. It is cheaper and
faster than to do it with special machine. Coromant offers wide variety
of thread milling tools which will satisfy our task.
a) Our first thread milling is the two holes (top and bottom) with
dimensions:M12x1.25.
Tool:
CoroMill Plura R217.14C095125AK26N





ae = 25 mm;
ap = 25 mm;
Dc = 9.5 mm;
zn = 4;
Vc = 280 m/min, but adjusted for too life 240 min Vc = 56 m/min ;
fz = 0.65 mm;
L = 25 mm;
Dth = 12;
K = 2.2;

n =
I
c
1uuu
n
c
= 1877 rpm;
:
]m
= z
n
n
z
= 488u
mm
min
;
Parameter Value
Dc 9.5 mm
ap 26.2 mm
No. of teeth zn 4
l1 40 mm
l2 80 mm
Pitch 1.25
dmm 10
13

:
]
= :
]m
_

th
-
c

th
] = 1u16
mm
min
;
I
c
=
I
:
]
= u.u2S min = 1.S scc
P
c
=
o
p
o
c
:
]
K
1uu uuu
= 1S.9 kw

The total machining time for the two thread holes is 3 seconds.








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b) The second thread milling must be with dimensions:M6
Tool:
CoroMill Plura R217.13C048000AC10N







ae = 18 mm;
ap = 18 mm;
Dc = 4.8 mm;
zn = 3;
Vc = 280 m/min, but adjusted for too life 240 min Vc = 56 m/min ;
fz = 0.65 mm;
L = 18 mm;
Dth = 6;
K = 2.2;

n =
I
c
1uuu
n
c
= S71S rpm;
:
]m
= z
n
n
z
= 7244
mm
min
;
:
]
= :
]m
_

th
-
c

th
] = 14Su
mm
min
;
I
c
=
I
:
]
= u.u12 min = u.72 scc
Parameter Value
Dc 4.8 mm
ap 22 mm
No. of teeth zn 3
l1 21 mm
l2 57 mm
Pitch 0
dmm 6
15

P
c
=
o
p
o
c
:
]
K
1uu uuu
= 1u.SS kw

The total machining time for 12 holes of this size is Tc =0.72x12=8.6 sec.


6. Drilling
We have to drill two big holes with diameter 40 mm. This cant be
done with milling tools and we have to have special drilling devices.
Machine:
BO 90 CNC
travel x-axis = 700 mm;
travel y-axis = 510 mm;
travel z-axis = 800 mm
table size = 630x630 mm;
spindle speed = 6000 rpm;
power = 11 kW;
16

Tool:
CoroDrill 880 3xDc 880-D4000C6-03





Insert:
880-07 04 06H-C-GR


Dc = 40 mm;
ap = 116 mm;
Kcx0.4 = 1000;
zn = 2;
Kr = 88;
fn = 0.15;
Vc=300m/min;
fz=0.075;
L=116 mm;
n =
I
c
1uuu
n
c
= 2Suu rpm;
:
]
= n
n
= S7S
mm
min
;
K
]z
=
K
c
0.4

z
sinK

= 1Suu;
I
m
=

c

n
K
]z
o
p
2uuu [1 -
o
p

= 86u
N
m
;
Parameter Value
Dc 40 mm
No. of teeth zn 2
l1s 175 mm
l3s 124 m
l4 120 mm
D5m 63 mm
Parameter Value
d1 4 mm
iC 12.35
s 4 mm
r 0.6
17

P
c
=

c
I
c
K
]z

n
24u 1uuu
= 9.6 kw;
F
]
= u.S

c
2

n
K
]z
sinK

= 1949 N;
I
c
=
I
:
]
= u.S1 min = 18.6 scc

The total machining time for the drilling of two holes is 37.2 sec.

This is the last operation of shaping the body. As we can see it is
the slowest. This is because of the big length of the holes. After we
finished calculating the operations we can see the body in its final shape:



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7. Total servicing time
Milling:
1.Face milling - 127120 2 times(2 passes):
- time for fixing the detail 0.20 min
- approach of the tool 0.004 min
- face milling 0.11 min
Total servicing time for the first facing 0.354 min
2.Face milling 63.554 2 times:
- time for fixing the detail 0.20 min
- approach of the tool 0.004 min
- face milling 0.22 min
Total servicing time for the second facing 0.424 min
3. Side milling 4 times:
- fixing the detail (45) 0.30 min
- approach of the tool 0.004 min
- side milling 0.108 min
Total servicing time for the side milling 0.412 min
4.Thread milling M12x1.25 2 times
- fixing the detail 0.20 min
- approach of the tool 0.004 min
- thread milling 0.05 min
Total servicing time for the 1
st
thread milling 0.254 min

5.Thread milling M6 12 times
- fixing the detail 0.20 min
- approach of the tool 0.004 min
- thread milling 0.144 min
Total servicing time for the 2
nd
thread milling 0.348 min

Total time for milling = 1.792 = 1.8 min

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Drilling 40 2 times
- fixing the detail 0.20 min
- approach of the tool 0.004 min
- drilling 0.62 min

Total servicing time for the drilling 0.824 min

Total time for drilling = 0.824 min

Because the milling and the drilling machines will be working
together, we choose the longer time 1.8 min, which in our case is the
so called bottleneck. So the making of the product is much faster then it
has to be. This gives us the opportunity for even more tool life
considerations, workers time for rest and etc.

8. Price
Material cost for one body is 66.65$, which is only useful material.
We have to make 24 bodies per hour and we have two workers one
worker on each machine. Their salary is 1$ per hour. One piece weight
3.14 kg and the volume of the all body is V=439000 mm
3
with density
2.81 g/cm
3
. From this we can find:
Salary expenses: 2$/24=0.08$ per body;
Price for one body: 66.65$ + 0.08$=66.73$;









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9. Operation sheet
Operation
No.
Name of
the
Operation
Machine
tools
Cutting tools
Cutting
Speed
[m/min]
Feed
[mm/rev]
Depth
of cut
[mm]
Passes
Tc
[min]
Total
Time
[min]
1
Face
milling
X.Mill 900
B
CoroMill
Century
Arbor R590-
100Q32A-
11M
300 0,2 7 2 0,11 0,354
2
Face
milling
X.Mill 900
B
CoroMill
Century
Arbor R590-
100Q32A-
11M
300 0,2 9.5 2 0,22 0,424
3
Side
milling
X.Mill 900
B
CoroMill 331
Bore with
keyway
N331.32
160S40RM
346 0,1 12 2 0,108 0,412
4
Thread
milling
X.Mill 900
B
CoroMill
Plura
R217.14C0951
25AK26N
56 0,65 18 2 0,005 0,254
5
Thread
milling
X.Mill 900
B
CoroMill
Plura
R217.13C0480
00AC10N

56 0,65 25 12 0,144 0,348
6 Drilling
BO 90
CNC
CoroDrill 880
3xDc 880-
D4000C6-03
300 0.15 116 4 0,62 0.824
10. Reference
www.knuth.de
www.coromant.sandvik.com
Manual for exercises in machine building technology G.Getev,
A. Georgiev - publisher Tehnika Sofia, 1980