Production Technology-I (MEPC-18)

th
B. Tech (ME) 4 Semester

Unit: 3
Analysis of Machining Processes
Prof. Hari Singh
Mech. Engg. Dept.
NIT Kurukshetra
 CALCULATION OF MACHINING TIMES
 The basic relationship for determining the machining time for any machining operation is that the cutting
time in minutes is equal to the distance the tool is fed, in mm, divided by the feed in mm/min, i.e.
𝐿
𝑇𝑚 = , per cut or per pass
𝐹
where 𝑇𝑚 = cutting time in minutes
𝐿 = Total tool travel in mm
𝐹 = Feed of tool in mm/min
The distance a tool is fed to make a cut (L) is the sum of the distance the tool travels while cutting the
material plus its APPROACH distance plus its overtravel.
The approach is the distance a tool is fed from the time it touches the workpiece until it is cutting to the
full depth. Approach distance for a DRILL is the length of its point which is about one-fourth the diameter
of the standard drill. The approach of most of the single point cutting tools is negligible.
“Overtravel” is the distance the tool is fed while it is not cutting. It is the distance over which the tool
idles before it enters and after it leaves the cut. This distance is calculated for face milling and slotting,
but in other cases like drilling or turning, it is taken as 0.8 to 6.0 mm.
 Figure shows cutting operation on a lathe. At position
1, the feed is engaged. The tool travels to position 2,
when it contacts the job. The distance 2-3 is approach
i.e. the total travel before it starts cutting the
required depth of material.
So total cutting distance = (2-3) + (3-4)
 The distance (4-5) is tool overtravel, so that the tool Fig: Cutting operation on lathe
completely clears the job. The distance (1-2) is also
the tool overtravel and this is provided so that the tool contacts the job smoothly and not with
a jerk. So,
Total tool travel = length of job + approach + two overtravels
Now, F = f x N, where f: feed rate, mm/rev N: rpm of work or cutter
1000 V
N= , where V: cutting speed, m/min D: diameter of workpiece in mm
πD
𝐿 π DL
Thus 𝑇𝑚 = fN = 1000 fV
Drilling and Boring:
 The basic principle and procedure of estimation of
machining time in drilling and boring are almost same as
that of turning operation.

L′h = Lh + A + O + C
𝐷
C = cot 𝜌 where D= Diameter of the hole i.e. drill
2
= Half of the drill point angle
π D(Lh +A+O+C)
𝑇𝑐 = ; f: mm/rev
1000 f Vc
 In the same way, 𝑇𝑐 is estimated in boring also. Only the portion ‘C’ is not
included.
 For blind hole, only overrun ‘O’ is excluded.
Fig: Boring operation
Machining time in Shaping and Planing:
L′w
 Total machining time, Tc = min
Ns .S0
L′w = total length of travel of job = W + A′ + O′
where W: width of the job
A’, O’: approach and overrun
Ns : Number of strokes per min
S0 : feed of the job, mm/stroke
𝑁𝑠
Ns has to be determined from 𝑉𝑐 = [𝐿𝑐 1 + 𝑄 ] m/min
1000
where, 𝑉𝑐 = Cutting Velocity, m/min
𝐿𝑐 = Stroke length, mm = 𝐿𝑤 + A + O and 𝐿𝑤 = Length of workpiece
𝑄 = Quick return ratio = (time of return stroke)/ time of cutting stroke
1000 Vc
 Ns =
𝐿𝑐 1+𝑄
Example:
 𝐿𝑤 = 100 mm, A = 5, O = 5, W = 60mm, A’ = O’ = 2, Q = 2/3, 𝑉𝑐 = 40 m/min, S0 = 0.2
mm/stroke
1000 Vc 1000 (40)
 Ns = = = 200
𝐿𝑐 1+𝑄 (100+5+5) 1+2/3

L′w 60+2+2
Then Tc = = Tc = = 1.6 min
Ns .S0 200 x 0.2

 Machining times of planing operations are determined in the same way, because the only
difference is that in planing machine, cutting strokes and feed travels are imparted to the job
and the tool respectively, just opposite to that of shaping machine.
Machining time in Milling Operations:
 There are different types of milling operations done by different types of milling cutters:
• Plain milling by slab milling cutter mounted on arbour
• End milling by solid but small end mill cutter being mounted in the spindle through collet
• Face milling by large face milling cutter being directly fitted in the spindle
 Machining time for plain milling a flat surface
Lc
Tc = min (for job width < cutter length)
Sm
𝐷𝑐
Lc = total length of travel of job = 𝐿𝑤 + A + O +
2
𝐿𝑤 : Length of workpiece, 𝐷𝑐 : Diameter of cutter, mm
S𝑚 : Table feed, mm/min = S0 . Zc . N
where S0 : Feed per tooth, mm/tooth
Zc : Number of teeth of cutter π Dc N
Vc = m/min
1000
N: Cutter speed, rpm
Example:
 Determine Tc for plain milling a rectangular surface of length 100 mm and width 50 mm by an
HSS milling cutter of diameter 60 mm, length 75 mm and 6 teeth. Assume A = O = 5 mm, Vc =
40 m/min and S0 = 0.1 mm/tooth
Lc
 Tc = min
Sm
𝐷𝑐
Lc = 𝐿𝑤 + A + O + = 100 + 5 + 5 + 30 = 140 mm
2

S𝑚 = S0 . Zc . N = 0.1 x 6 x N
1000Vc
where N = = 200 rpm
πDc

S𝑚 = 0.1 x 6 x 200 = 120 mm/min