7.1.

Two thousand bars 80 mm in diameter and 300 mm long must he

turned down to 65 mm diameter for 150 mm of their length. The surfacefinish and accuracy requirements are such that a heavy roughing cut
(removing most of the material) followed by a light-finishing cut are
needed. The roughing cut is to be taken at maximum power. The lightfinishing cut is to be taken at a feed of 0. 13 mm, a cutting speed of 1. 5
m/s, and at maximum power. If the lathe has a 2-kW motor and an
efficiency of 50%, calculate the total production time in kiloseconds (ks)
for the batch of work. Assume that the specific cutting energy for the work
material is 2.73 GJ/m , the time taken to return the tool to the beginning of
the cut is 15 s, and the time taken to load and unload a workpiece is 120
s.
3

7.6. In a slab-milling operation, the cutter has 20 teeth and is 100 mm in

diameter. The rotational frequency of the cutter is 5 s , the workpiece
feed speed is 1.3 mm/s. the working engagement (depth of cut) is 6 mm.
and the back engagement (width of the workpiece) is 50 mm. The
relationship between the maximum undeformed chip thickness ac and
the specific cutting energy p in gigajoules per cubic meter (GJ/m ), for the
work material is
1

max

Estimate
a. The maximum metal removal rate
b. The maximum power, in kilowatts (kW), required at the cutter

7.15. A designer has specified a surface finish on turned shafts of 0.4-pm

arithmetical mean when a surface finish of 1.6 pm would suffice. Estimate
the cost of this mistake when 2000 shafts are to be produced with a tool
with a rounded corner if the machining time per component = 600 s, the
number of components produced between tool regrinds = 4, the cost of a
sharp tool = $2.00, the machine and operator rate = $00033/s, the toolchanging time = 120 s, and the nonproductive time per component = 240
s.
In all of the questions below use the data from Tables 10.1 through 10.7 for material
costs, material properties, cycle time calculations, and machine hourly rates. Where needed
assume a die-making rate of $40/h.

10.1. The rotor assembly housing shown in Figure 10.12 is to be die cast
using Aluminum Alloy A360. The part is 13 cm high. The large diameter is
20 cm, which steps down to 17.5 cm at the midpoint. The bottom of the
housing is open and the top has a large hole of 12.5 cm diameter in the
center surrounded by 1.5-cm diameter holes. The part has a uniform wall
thickness value of 2.50 mm. It has an estimated weight of 584 g. Taking
account of the through holes, it has a projected, A , of 170.3 cm .
p

a. Determine the appropriate cold chamber machine, from Table

10.4, on which to cast the part using a single-cavity die.
b. Estimate the die-casting cycle time and use it to obtain the
estimated die-casting process cost.
c. Estimate the time and process cost for trimming.
d. Estimate the material cost.