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Transcript of Shop Computation
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MIRDC-ITS Slide 2
OBJECTIVE
At the end of the course, the participants
shall be able to perform basic computation
in machining.
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MIRDC-ITS Slide 3
COURSE OUTLINE
Introduction to Measurement
Shop Calculations
- Cutting Speed
- Feed
Machine Shop Application
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MIRDC-ITS Slide 4
Measurement
• defined as the estimation of some
attribute of an object, such as its length
or weight, relative to a unit ofmeasurement.
• it is expressed in terms of length,
volume, area, temperature, among
others.
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MIRDC-ITS Slide 5
Systems of Measurement
• English System
• System Internationale (SI) or Metric System
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MIRDC-ITS Slide 6
Systems of Measurement
• English System
grew out of the creative way that people
measured for themselves. Familiar
objects and parts of the body were used
as measuring devices.
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MIRDC-ITS Slide 7
Systems of Measurement
• English System
Length:
12 inches (in) = 1 foot (ft)3 feet = 1 yard (yd)
5280 feet = 1 mile (mi)
Capacity:
3 teaspoons (tsp) = 1 tablespoon (tbsp)
16 tbsp = 1 cup (c)
8 ounces (oz) = 1 c
2 c = 1 pint (pt)
2 pt = 1 quart (qt)4 qt = 1 gallon (gal)
Weight: 16 ounces (oz) = 1 pound (lb)
2000 lb = 1 ton
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MIRDC-ITS Slide 8
Systems of Measurement
• Metric System
developed at the time of the French
Revolution, with standards set for the
meter and kilogram on June 22, 1799.
it was an elegant decimalsystem, where units of like type
were defined by power of ten.
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MIRDC-ITS Slide 9
Systems of Measurement
• SI (Metric System)
Meter (m); Kilogram (kg); Second
(s); Ampere (amp); Kelvin (°K); Mole
(mol); Candela (cd).
From these base units, manyother units are derived.
Ex: Velocity – meter per second
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MIRDC-ITS Slide 10
Conversion of Measurement
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MIRDC-ITS Slide 11
Conversion of Measurement
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MIRDC-ITS Slide 12
Conversion of Measurement
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MIRDC-ITS Slide 13
REVIEW AND EXERCISES
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MIRDC-ITS Slide 14
Convert the following:
Given:
1 cm = 10 mm 1 ft = 12 in
1 m = 100 cm 1 mi = 5280 ft
1 km = 1000 m 1 in = 2.54 cm
1.) 10 ft = ______ m 4.) 27 in = ____ mm
2.) 18 mi = ______ km 5.) 1.5 mi = ____ m
3.) 8 m = _______ ft 6.) 37 km = _____ mi
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MIRDC-ITS Slide 15
MACHINE SHOP COMPUTATION
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MIRDC-ITS Slide 16
Cutting Speed (CS)
• defined as the length or distance which
the tool point of a machine cuts in one
minute.• it is expressed in units of distance
along the work-piece surface per unit of
time (surface feet per minute or meters
per minute).
CS = D N
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MIRDC-ITS Slide 17
Cutting Speed (CS)
where:pi = 3.1416
D = diameter
N = rpm (revolution per minute)
CS = D N
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MIRDC-ITS Slide 18
High-Speed Steel Cutter Carbide Cutter Material ft/min m/min ft/min m/min
Alloy steel 40 –70 12 –20 150 –250 45 –75
Aluminum 500 –1000 150 –300 1000 –2000 300 –600
Bronze 65 –120 20 –35 200 –400 60 –120
Cast iron 50 –80 15 –25 125 –200 40 –60
Mach steel 70 –100 21 –30 150 –250 45 –75
Stnless steel 30 –80 10 –25 100 –300 30 –90
Tool steel 60 –70 18 –20 125 –200 40 –60
Milling Machine Cutting Speeds
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MIRDC-ITS Slide 19
Cutting Speed (CS)
Calculate the cutting speed in ft/min of acutting tool in a lathe that cuts a 5 ½ inch
steel that is revolving at a rate of 150 rpm.
Example No. 1:
Answer: 215.99 ft/min
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MIRDC-ITS Slide 20
Cutting Speed (CS)
What is the cutting speed in m/min of a toolthat cuts a 105 mm stock if the lathe makes
190 rpm?
Example No. 2:
Answer: 62.67 m/min
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MIRDC-ITS Slide 21
RPM Calculation (English)
For optimum use of cutter, proper speed(rpm) must be determined
Diameter of cutter affects the speed
D
xCS
x
xCS
xinncecircumfere
ftCSr 4141633
1214163390
...)()(min/
Calculate speed required to revolve a 3-in. diameterhigh-speed steel milling cutter for cutting machine
steel (CS=90 sf/min).simplified formula
1203
360
3
904
xr min/
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MIRDC-ITS Slide 22
RPM Calculation (Metric)
Formula for r/min of the milling machine using
metric measurement
)()(
x.D(mm)x)(min/
mmDxmCS
DCSxxmCSr 32014163
10001000
simplified formula
Calculate the r/min required for a 75 mm diameter
high-speed steel milling cutter when cutting
Machine steel (CS 30 m/min)
12875
9600
75
32030min/
x
r
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MIRDC-ITS Slide 23
Cutting Speed Rules for Best Results
1. For longer cutter life, use lower CS in
recommended range
2. Know the hardness of the material to be machined3. When starting, use lower range of CS and
gradually increase to higher range
4. Reduce feed instead of increasing the cutter speedfor fine finish
5. Using coolant will generally produce better finish
and lengthen cutter life
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MIRDC-ITS Slide 24
Feed
• defined as the distance the cutting tool
advances along the length of the work
for every revolution.• the feed of an engine lathe is
dependent on the speed of the lead
screw or feed rod.
• expressed in inches per minute /
meters per minute
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MIRDC-ITS Slide 25
Feed
Feed Rate = RPM x Chip Load x No. of Teeth
where:RPM = spindle speed
Chip Load = thickness of material removed
by each cutting edge
No. of Teeth = number of cutting edges/inserts
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MIRDC-ITS Slide 26
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MIRDC-ITS Slide 27
Example No. 1:
Feed
Find the feed in inches per minute using a
3.5 in. diameter, 12 tooth helical cutter to
cut machine steel (CS80)First, calculate proper r/min for cutter:
9153
8044
.
min/
x
D
CSxr
Feed(in/min) = N x CPT x r/min
=12 x .010 x 91
= 10.9 or 11 in/min
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MIRDC-ITS Slide 28
Example No. 2:
Feed
Calculate the feed in millimeters per minute
for a 75-mm diameter, six-tooth helical carbide
milling cutter when machining cast-iron (CS 60)First, calculate proper r/min for cutter:
25675
20019
755
32060320
,min/
x
D
xCSr
Feed(in/min) = N x CPT x r/min
= 6 x .025 x 256
= 38.4 mm/min
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MIRDC-ITS Slide 29
MACHINE SHOP APPLICATIONS
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MIRDC-ITS Slide 30
Taper
A work is said to be tapered when the
dimensions of the cross section of a
piece of work, or a part of a work, isgradually and uniformly increasing or
decreasing from both ends.
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MIRDC-ITS Slide 31
Taper
The taper on a piece of work is formed by
subtracting the diameter of the small
end from the diameter of the large end.
d D
Taper = D - d
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MIRDC-ITS Slide 32
Taper
The taper per inch of a piece of work is
the taper divided by the length in
inches.
d D
L
Taper per inch = D – d
L
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MIRDC-ITS Slide 33
Taper
The taper per foot of a piece of work is the
taper divided by the length in feet.
d D
L
Taper per foot = taper per inch x 12
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THANK YOU.
MIRDC-ITS Slide 34