Turning Question

1- For a turning operation with 1000 rpm spindle speed and 0.2 mm/rev feed rate

(a) Calculate the linear speed of the tool.

(b) Calculate the cutting speed
(c) If the Taylor tool life equation is 250=VT0.5 (V: m/min, T:min) calculate the tool life.
(d) If the operation reduces 100 mm diameter bar to 90 mm diameter in one pass and
the length of the bar is 300 mm, calculate the machining time.
(e) Calculate the number of parts that the tool can manufacture?

ANSWER:

(a) Vlin  fn  1000 * 0.2  200mm / min  0.2m / min

(b) Vc  Dn   100 *1000  314m / min

2
 400 
(c) 400  314T 0.5 T    1.62 min
 314 

L 300
(d) T   1.5 min
Vlin 200

(e) The tool can manufacture only 1 part at this cutting speed.

Turning and Related Operations

2- A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an

engine lathe. Cutting conditions are as follows: cutting speed is 2.30 m/s, feed is 0.32
mm/rev, and depth of cut is 1.80 mm. Determine (a) cutting time, and (b) metal
removal rate.
Solution: (a) N = v/(πD) = (2.30 m/s)/0.200π = 3.66 rev/s
fr = Nf = 6.366(.3) = 1.17 mm/s
Tm = L/fr = 700/1.17 = 598 s = 9.96 min

Alternative calculation using Eq. (22.5), Tm = 200(700)π/(2,300 x 0.32) = 597.6 sec =

9.96 min
3 3
(b) RMR = vfd = (2.30 m/s)(10 )(0.32 mm)(1.80 mm) = 1320 mm /s

3- In a production turning operation, the foreman has decreed that a single pass must
be completed on the cylindrical workpiece in 5.0 min. The piece is 400 mm long and
 150 mm in diameter. Using a feed = 0.30 mm/rev and a depth of cut = 4.0 mm, what
cutting speed must be used to meet this machining time requirement? Solution:
Starting with Eq. (22.5): Tm = πDoL/vf.
Rearranging to determine cutting speed: v = πDoL/fTm
-3 3
v = π(0.4)(0.15)/(0.30)(10 )(5.0) = 0.1257(10 ) m/min = 125.7 m/min
4- A facing operation is performed on an engine lathe. The diameter of the cylindrical
part is 6 in and the length is 15 in. The spindle is set to rotate at a cutting speed of
180 rev/min. The depth of cut is 0.110 in and the feed is 0.008 in/rev. Assume the
cutting tool moves from the outer diameter of the workpiece to exactly the center at
a constant velocity. Determine (a) the velocity of the tool as it moves from the outer
diameter towards the center and (b) the cutting time.
Solution: (a) fr = fN = (0.008 in/rev)(180 rev/min) = 1.44 in/min
(b) L = distance from outside to center of part = D/2; Tm = L/fr = D/(2fr) = 6/(2 x 1.44) =
2.083 min
5- A tapered surface is to be turned on an automatic lathe. The workpiece is 750 mm
long with minimum and maximum diameters of 100 mm and 200 mm at opposite
ends. The automatic controls on the lathe permit the surface speed to be maintained
at a constant value of 200 m/min by adjusting the rotational speed as a function of
workpiece diameter. Feed = 0.25 mm/rev and depth of cut = 3.0 mm. The rough
geometry of the piece has already been formed, and this operation will be the final
cut. Determine (a) the time required to turn the taper and (b) the rotational speeds
at the beginning and end of the cut.
3
Solution: (a) RMR = vfd = (200 m/min)(10 mm/m)(0.25 mm)(3.0 mm) = 150,000
3
mm /min
2 2 0.5
Area of frustrum of cone A = π(R1 + R2){h + (R1 – R2) }
Given R1 = 100 mm, R2 = 50 mm, and h = 750 mm,
2 2 0.5 0.5 2
A = π(100 + 50){750 + (100 – 50) } = 150π(565,000) = 354,214 mm
2
Given depth of cut d = 3.0 mm, volume cut V = Ad = (354,214 mm )(3.0 mm) =
3
1,062,641 mm
3 3
Tm = V/RMR = (1,062,641 mm )/(150,000 mm /min) = 7.084 min

(b) At beginning of cut (D1 = 100 mm), N = v/πD = 200,000/100π = 636.6 rev/min
At end of cut (D2 = 200 mm), N = 200,000/200π = 318.3 rev/min

6- In the taper turning job of previous Problem 22.4, suppose that the automatic lathe
with surface speed control is not available and a conventional lathe must be used.
Determine the rotational speed that would be required to complete the job in exactly
the same time as your answer to part (a) of that problem.
Solution: At a constant rotational speed and feed, feed rate fr is constant and Eqs.
(22.3) and (22.4) can be used. Combining, Tm = L/Nf and then rearranging to obtain
rotational speed N = L/fTm
 Given L = 750 mm, f = 0.25 mm/rev, and Tm = 7.084 min from Problem 22.3,
N = 750/(0.25)(7.084) = 423.5 rev/min
7- A workbar with 4.5 in diameter and 52 in length is chucked in an engine lathe and
supported at the opposite end using a live center. A 46.0 in portion of the length is to
be turned to a diameter of 4.25 in one pass at a speed of 450 ft/min. The metal
3
removal rate should be 6.75 in /min. Determine (a) the required depth of cut, (b) the
required feed, and (c) the cutting time.
Solution: (a) depth d = (4.50 - 4.25)/2 = 0.125 in
(b) RMR = vfd; f = RMR/(12vd) = 6.75/(12 x 450 x 0.125) = 0.010 in
f = 0.010 in/rev
(c) N = v/πD = 450 x 12/4.5π = 382 rev/min
fr = 382(0.010) = 3.82 in/min

Tm = 46/3.82 = 12.04 min

Drilling Question

1- The following part with 6 holes having 10 mm diameter is going to be manufactured

by drilling. The depth of the holes is 10 mm. The feed rate of 0.2 mm/rev and the
spindle speed of 2000 rpm are used during machining. If the Taylor Equation
constants for the tool is C=80 and n=0.25 calculate the number of parts that can be
produced without changing the drill.

ANSWER:

Vlinear  0.2(mm / rev)  2000(rev / min)  400mm / min

Since the hole depth is 10 mm the drilling time for one hole is:

t  10 / 400  0.025 min  1.5s

There are 6 holes therefore the drilling time for one part is:

td  6  t  9 s

From Taylor Equation the time that the drill can cut without flank wear can be calculated as:
(note that velocity should be the cutting speed in calculating the Taylor tool life
Vc  dn   10  2000  62831mm / min  63m / min

VcT n  C  T  C / Vc   80 / 63  2.6 min  156s

1/ n 1 / 0.25

Since 9 seconds is needed in order to manufacture 1 part, 156/9=17 parts can be

manufactured without changing the drill.