MIAE 311

Tutorial 2
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Q- Assume you are in-charge of the production development for a drilling process to produce the
holes of 10 +0.25/-0.05 mm diameter. For process development, you have taken the average diameter
as the nominal value. If the following data are the measured values after drilling, then:

a) find UCLx, LCLx, USL, LSL,UCLR, LCLR, grand mean, grand R, Cp, D and Cpk.
b) Plot the variation of sample mean along with UCLx, LCLx, USL, LSL, process nominal and
grand mean.
c) Plot the variation of sample R along with UCLR, LCLR and grand R
d) Comment about the process whether it is in control or not. 3
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Hint : Based on the sample size the supplementary values for the above calculation can be taken from the table below
table accordingly.

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Figure 12.10 about
the values

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Chapter 20 (11th Edition)

Fundamentals of Machining/Orthogonal Machining

• What variables must be considered in understanding a machining process?

- The input parameters or independent variables for the process include the cutting speed, feed, depth of cut, the
cutting tool geometry, cutting tool material, and the cutting fluid.
- The input parameters determine the process outputs or dependent variables and process performance, e.g.,
material removal rate, machining time, tool wear, finished surface roughness, surface integrity (finished surface
and subsurface deformation state), cutting zone temperature, cutting forces, chip formation and machine tool
dynamics.
- Other process variables may be constrained to be not completely defined or fixed. There may or may not be
complete control over such process characteristics such as the work material, machine tool, work holding device.
 Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal Machining

• Which of the seven basic chip formation processes are single

point, and which are multiple points? See Figure 20-2.

- Single point include turning, facing, boring, shaping, planing, fly

cutter milling, some modes of deep hole drilling, and other
variations of lathe operations such as cutoff, recessing plunge, or
form turning.
- The rest of the machining processes are multiple-point and
include drilling, milling, broaching, sawing, filing, and many
forms of abrasive machining.
Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal Machining
Problem 1
1. For a turning operation, you have selected an HSS tool and
turning a hot rolled free machining steel, Bhn = 300. Your
depth of cut will be 0.150 in.The diameter of the workpiece is 1
inches.
a. What speed and feed would you select for this job?
b. Using a speed of 105 sfpm and a feed of 0.015, calculate the
rpm for this operation.
c. Calculate the metal removal rate.
d. Calculate the cutting time for the operation with a length of
cut of 4 in. and 0.10-in. allowance.
Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal Machining

a. Speed = 105 sfpm

Feed = 0.015 ipr
Values selected from Figure 20-4

Problem 1
Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal
Machining

b. Speed = 105 sfpm

Feed = 0.015 ipr
Spindle rpm = Ns = 12 v / πD = (12)(105) /
(3.14)(1) = 401
Where D is the diameter of the workpiece

c. MRR = 12 V fr d = (12)(105)(0.015)(0.150)
= 1.9845

Problem 1
Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal
Machining
d. Length of cut = 4 inches
Allowance = 0.10
Tm = (L + allowance) / (fr Ns) = (4 + 0.10) /
[(0.015) ( 410)] = 0.68 min

Problem 1
Chapter 20 (11th Edition)

Fundamentals of
Machining/Orthogonal Machining
Problem 2
2. For a slab milling operation using a 5-in.-diameter, 11-tooth
cutter (see Figure 20-6), the feed per tooth is 0.005 in./tooth with
a cutting speed of 100 sfpm (HSS steel).
Calculate the rpm of the cutter and the feed rate (fm) of the table,
then calculate the metal removal rate, MRR, where the width of
the block being machined is 2 in. and the depth of cut is 0.25 in.
Calculate the time to machine (Tm) a 6-in.-long block of metal
with this setup. Suppose you switched to a coated-carbide tool, so
you increase the cutting speed to 400 sfpm. Now recalculate the
machining time (Tm) with all the other parameters the same.
 Diameter, D = 5 inches
Chapter 20 (11th Edition) n = 11 tooth cutter
Feed per tooth = 0.005 in/tooth
V = 100 sfpm (HSS steel)
Fundamentals of W = 2 inches
Machining/Orthogonal d = DOC = 0.25 in.
Machining L = 6 in

• Ns = 12 v / πD where D is the diameter of the cutter

= (12) (100) / (3.14) (5)
= 76 rpm

• Fm = ft n Ns = (0.005) (11) (76) = 4.2 in/min

• MRR = W d fm = (2) (0.25) (4.2) = 2.1 in3/min

• Tm = L + LA/fm = (6 + 1.6 )/ 4.2 = 1.8 minutes

• LA = [ 0.25 (11 – 0.25) ]1/2 = 1.6

Problem 2
 Diameter = 5 inches
Chapter 20 (11th Edition) 11 tooth cutter
Feed per tooth = 0.005 in/tooth
V = 400 sfpm
Fundamentals of W = 2 inches
Machining/Orthogonal D = DOC = 0.25 in.
Machining L = 6 in

Part 2 – recalculation
V = 400 sfpm
Ns = 305.6 rpm
Fm = 16.8 inches per minute
MRR = 8.4 cubic inches per minute
Tm = 0.45 minutes

Problem 2