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Manufacturing Technology (ME461) Lecture-8

This document discusses the basic steps involved in developing a manufacturing process plan, including analyzing part requirements, selecting materials and operations, and determining machining conditions and times. It provides models for determining optimal machining conditions to minimize cost or maximize production rate. These include considering factors like cutting speed, feed rate, depth of cut, tool life equation, and costs of machine operation, tooling, and labor. The document concludes with a numerical problem asking to determine optimum conditions to minimize cost or maximize rate for a given turning operation based on provided tool life data and costs.

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6 views

Manufacturing Technology (ME461) Lecture-8

This document discusses the basic steps involved in developing a manufacturing process plan, including analyzing part requirements, selecting materials and operations, and determining machining conditions and times. It provides models for determining optimal machining conditions to minimize cost or maximize production rate. These include considering factors like cutting speed, feed rate, depth of cut, tool life equation, and costs of machine operation, tooling, and labor. The document concludes with a numerical problem asking to determine optimum conditions to minimize cost or maximize rate for a given turning operation based on provided tool life data and costs.

Uploaded by

candypop8725
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ME-461, Manufacturing

Technology, Lecture 8
Instructor: Shantanu Bhattacharya
GVMM Chair and Professor
Department of Mechanical Engineering
Indian Institute of Technology Kanpur
Email: [email protected]
Tel: 05122596056
Basic steps in developing a process
plan

• This involves a no. of activities like:


1. Analysis of part requirements.
2. Selection of raw work piece.
3. Determining manufacturing operations and their
sequences.
4. Selection of machine tools.
5. Selection of tools, work holding devices, and inspection
equipments.
6. Determining machining conditions (cutting speed, feed and depth of cut)
and manufacturing times (setup time, processing time, and lead time).
Determining Machining Conditions and
Manufacturing times
• Having specified the work-piece material, machine tool, and
cutting tool, the question is what can be controlled to reduce the
cost and increase production rate.
•The controllable variables are cutting speed (v), feed (f), and
depth of cut (d). Jointly, v,f, and d are referred to as machining
conditions. There are a no. of models •Co=specifying optimal
cost rate including
machining conditions out of which the labortwo best
andones are: cost
overhead
rates ($/min.)
•C1= tool cost per cutting
edge, which depends on
type of tool used
•C= constant in tool life
equation
•V= cutting speed in
meters/min.
•f=Feed rate (mm/rev)
•d=depth of cut(mm)
•n= exponent in the tool life
td= time to change a cutting edge equat.
(min.) •t1=non productive time
tac= actual cutting time per piece,
Determining
Machining
Conditions and
Manufacturing
times
Maximum Production
Rate Model
• Another criterion used to determine the
optimal conditions is maximum production
rate which is inversely proportional to the
production time per piece, which is given by:
Manufacturing Lead Time

• Assuming that the lot size is Q


units, then the average lead time
to process these units will be .
• Lead time = major setup time +
TuQ
Numerical Problem
A lot of 500 units of steel rods 30cm long and 6 cm in diameter is
turned on a numerically controlled (NC) lathe at a feed rate of 0.2
mm per revolution and a depth of cut of 1mm. The tool life is given
by:
vT0.20 = 200
The other data are:
Machine labor rate = $10/ hr.
Machine overhead rate = 50% of labor
Grinding labor rate = $10/hr
Grinding overhead rate = 50% of grinding labor
Work peice loading/ unloading time = 0.50 min/ piece
The data related to the tools are:
Brazed inserts
Original cost of the tool = $ 27.96
Grinding Time = 2min.
Tool changing time = 0.50 min. (The tool can be ground only five times
before it is discarded.
Determine the following:
(a)Optimum tool life and optimum cutting speed to minimize the cost
per piece.
(b)Optimum tool life and optimum cutting speed to maximize the
production rate.
Solutions
Solutions
Solutions

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