Cutting time calculation

Example of Cutting time Calculation

TURNING
CUTTING SPEED (Vc) vc (m/min) Cutting Speed
Dm (mm) Workpiece Diameter
π (3.14) Pi
n (rpm) Main Axis Spindle Speed

Problem
What is the cutting speed when main axis spindle speed is 700 rpm and external
diameter is Ø50? Substitute π=3.14,

Answer
Substitute π =3.14, Dm=50, n=700 into the formula.

vc= (π×Dm×n)÷1000 = (3.14×50×700)÷1000 = 110 (m/min)

Cutting speed is 110 m/min.

 Example of Cutting time Calculation
TURNING
FEED (f) f (mm/rev.) Feed per revolution
l (mm/min) Cutting length per Min
n (rpm) Main Axis Spindle Speed

Problem
What is the feed per revolution when main axis spindle speed is 500 rpm and cutting
length per minute is 120mm/min ?

Answer
Substitute n=500, I=120 into the formula

f= l÷n= 120÷500= 0.24 (mm/rev)

The answer is 0.24 mm/rev.

 Example of Cutting time Calculation
TURNING
CUTTING TIME (Tc) Tc (min) Cutting Time
lm (mm) Workpiece Length
l (mm/min) Cutting Length per Min.

Problem
What is the cutting time when 100 mm workpiece is machined at 1,000 rpm, with
feed=0.2 mm/rev?

Answer
First, calculate the cutting length per min. from the feed and spindle speed
l= f×n = 0.2×1000 = 200 (mm/min)

Substitute the answer above into the formulae.

Tc= lm÷l = 100÷200 = 0.5(min)
0.5×60=30(sec.) The answer is 30 seconds.
 THEORETICAL FINISHED SURFACE ROUGHNESS (h)
TURNING

h (µm) Finished Surface Roughness

f (mm/rev.) Feed per Revolution
Re (mm) Insert Corner Radius
Problem
What is the theoretical finished surface roughness when the insert corner radius is
0.8mm and feed is 0.2 mm/rev ?

Answer
Substitute f=0.2 mm/rev, R=0.8 into the formulae.
h= f2÷(8×Re)×1000 = 0.22 ÷ (8×0.8)×1000 = 6.25µm
The theoretical
Manufacturing, finished
Engineering surface
& Technology, Fifthroughness isKalpakjian
Edition, by Serope 6 µm and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Example of Cutting Power Calculation
Turning

CUTTING POWER in TURNING (Pc) Pc (kW) Actual Cutting Power

ap (mm) Depth of Cut
f (mm/rev) Feed per Revolution
vc (m/min) Cutting Speed.
Kc (MPa) Specific Cutting Force
η (Machine Coefficient)

Problem
What is the cutting power required for machining mild steel at cutting speed 120m/min
with depth of cut 3mm and feed 0.2mm/rev (Machine coefficient 80%)?

Answer
Substitute the specific cutting force Kc=3100MPa into the formula.

Pc= (3×0.2×120×3100)÷(60×103×0.8) = 4.65(kw)

Specific Cutting Force
Turning speed and cutting speed
 Example of Cutting time Calculation
FACE MILLING

CUTTING SPEED (vc) vc (m/min) Cutting Speed

D1 (mm) Cutter Diameter
π (3.14) Pi
n (rpm) Main Axis Spindle Speed

* Divide by 1,000 to change to m from mm.

Problem
What is the cutting speed when main axis spindle speed is 350 rpm and cutter diameter
is 125 mm ?

Answer
Substitute π=3.14, D1=125, n=350 into the formulae.

vc= (π×D1×n)÷1000 = (3.14×125×350)÷1000 = 137.4(m/min)

The cutting speed is 137.4 m/min.

 Example of Cutting time Calculation
FACE MILLING

FEED PER TOOTH (fz)

fz (mm/tooth) Feed perTtooth
z Tooth/Insert Number
vf (mm/min) Table Feed per Min.
n (rpm) Main Axis Spindle Speed
f (Feed per Revolution f = z x fz)

Problem
What is the feed per tooth when the main axis spindle speed is 500 rpm, insert number is
10, and table feed is 500 mm/min?

Answer
Substitute the above figures into the formulae.

fz= vf÷(z×n) = 500÷(10×500) = 0.1mm/tooth

The answer is 0.1mm/tooth.

 Example of Cutting time Calculation
FACE MILLING

TABLE FEED (vf) vf (mm/min) Table Feed per Min.

z Insert Number
fz (mm/tooth) Feed per Tooth
n (rpm) Main Axis Spindle Speed

Problem
What is the table feed when feed per tooth is 0.1mm/tooth, insert number is 10, and main
axis spindle speed is 500 rpm?

Answer
Substitute the above figures into the formulae.

vf= fz×z×n = 0.1×10×500 = 500 mm/min

The table feed is 500 mm/min.

 Example of Cutting time Calculation
FACE MILLING

CUTTING TIME (Tc) Tc (min) Cutting Time

vf (mm/min) Table Feed per Min.

L (mm) Total Table Feed Length

(Workpiece Length l + Cutter Diameter D1)

Problem
What is the cutting time required for finishing 100 mm width and 300 length surface of a
cast iron (GG20) block when cutter diameter is ø200, the number of inserts is 16, the
cutting speed is 125m/min, and feed per tooth is 0.25 mm. (spindle speed is 200 rpm)

Answer
Calculate table feed per min vf=0.25×16×200=800mm/min
Calculate total table feed length. L=300+200=500mm

Substitute the above answers into the formulae.

Tc= 500÷800 = 0.625(min)
0.625×60=37.5(sec). The answer is 37.5 sec.
 Example of Cutting Power Calculation
MILLING

CUTTING POWER in MILLING (Pc) Pc (kW) Actual Cutting Power

ap (mm) Depth of Cut
ae (mm) Cutting Width
vf (mm/min) Table Feed per Min.
Kc (MPa) Specific Cutting Force
η (Machine Coefficient)

Problem
What is the cutting power required for milling tool steel at cutting speed 80m/min. With
depth of cut 2mm, cutting width 80mm, and table feed 280mm/min by ø250 cutter with 12
insert. Machine coefficient 80%.

Answer
First, calculate spindle speed in order to obtain feed per tooth.
n= 1000vc÷ π D1=(1000×80)÷(3.14×250) = 101.91 rpm

Feed per Tooth

fz = vf÷(z×n) = 280 ÷ (12×101.9) = 0.228mm/tooth

Substitute the specific cutting force into the formulae.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Pc=ISBN
(2×80×280×1800)÷(60×10 6×0.8) = 1.68kw
0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Milling Feed & Cutting speed
Sebuah benda berdiameter 34 mm dan panjang 150 mm akan dibubut sebagian
menjadi diameter 24 x 100 mm seperti gambar di bawah ini. Jika kecepatan
potong Vc= 30 m/menit, feeding f=0.2 mm/putaran, kedalaman pemakanan ap
= 1 mm, specific cutting force Kc= 3100 dan efisiensi mesin 75%, tentukan
waktu pengerjaan dan daya/power yang dibutuhkan.

Spindle speed
n= 1000vc÷ π D1=(1000×30)÷(3.14×34) = 281 rpm

Cutting length per Min l= f×n = 0.2×281 = 56.2 (mm/min)

Cutting time
Tc= lm÷l = 100÷56.2 x 5 = 9 (min)

Cutting power
Pc= (1×0.2×30×3100)÷(60×103×0.75) = 18,600/4,5000 = 0.413(kw)
Sebuah benda berdiameter 34 mm dan panjang 300 mm akan dibubut menjadi poros
bertingkat seperti gambar di bawah ini. Jika kecepatan potong Vc= 120 m/menit,
feeding ( f ) = 0.3 mm/putaran, kedalaman pemakanan ( ap ) = 1 mm, specific cutting
force ( Kc ) = 3100 dan efisiensi mesin 85%, tentukan waktu pengerjaan dan
daya/power yang dibutuhkan.

Spindle speed 1
n= 1000vc÷ π D1=(1000×120)÷(3.14×34) = 1124 rpm

Cutting length per Min l= f×n = 0.3×1124 = 337.2 (mm/min)

Cutting time
Tc 1 = lm / l = (200 x 5) / 337.2 = 2.97 (min)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Spindle speed
n= 1000vc÷ π D1=(1000×120)÷(3.14×24) = 1592 rpm

Cutting length per Min l= f×n = 0.3×1592 = 477.7 (mm/min)

Cutting time
Tc2 = lm / l = (100 x 7) / 477.7 = 1.4 (min)

Tc = Tc1 + Tc2
= 2.97+ 1.4 = 4.37 (min)

Cutting power

Pc= (1×0.3×120×3100) / (60×103×0.85) = 2.18 (kw)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Sebuah part seperti gambar di bawah ini dikerjakan di mesin milling dengan
kecepatan potong ( Vc ) = 120 m/menit, feeding per insert ( fz ) = 0.2 mm, Jika
dimensi stockmaterial adalah 200 x 300 x 55 mm dan cutting tool yang digunakan
adalah :
- Face mill cutter Ø50 mm dengan jumlah flute/insert= 8.
- End mill cutter Ø10 mm dengan jumlah flute/insert= 4.
a. Jika kedalaman pemakanan maksimum 2 mm dan step over 50% diameter cutter,
tentukan waktu permesinan
b. Hitung machining cost per part jika diketahui machining cost/jam = Rp 300.000,
setup cost/jam = Rp 100.000, loading cost/jam = Rp 50.000, dan tooling cost
adalah 5% dari total cost. Dari data diketahui bahwa waktu setup adalah 5 menit
dan waktu loading adalah 2 menit.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Facing:
Spindle speed .
n= 1000vc / π D1=(1000×120) / 3.14×50) = 764rpm

Table Feed
Vf = fz x z× n = 0.2 x 8 × 764 = 1222 mm/min

Cutting time
Tc= L / Vf = (350 x3x9)/1222 = 7.7 min

Groove Milling:
Spindle speed .
n= 1000vc / π D1=(1000×120) / 3.14×10) = 3821rpm

Table Feed
Vf = fz x z× n = 0.2 x 4 × 3821 = 3057 mm/min

Cutting time
Tc= L / Vf = (310 x10x20)/3057 = 20.3 min

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Total Cutting time
Tc= Tc1 + Tc2 = 7.7 + 20.3 = 28 min

Machining cost per part

Cp = Cm + CS + Cl + Ct
= (( (300,000x 28) + (100,000x5) + (50,000x2) ) / 60 ) x 100/95
= (Rp 8,400,000 + Rp 500,000 + 100,000) /60) x 100/95
= Rp 9,000,000 /60 x 100/95
= Rp 157,895

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Sebuah pocket berukuran 160x60x20 mm dikerjakan dengan mesin milling dengan
kecepatan potong Vc 80 m/menit, feeding per insert fz = 0.2 mm, cutter yang digunakan
adalah end mill Ø20 mm dengan jumlah flute/insert= 4.
a. Jika kedalaman pemakanan maksimum 2 mm dan step over 6 mm, tentukan waktu
permesinan
b. Hitung machining cost per part jika diketahui machining cost/jam = Rp 300.000, setup
cost/jam = Rp 100.000, loading cost/jam = Rp 50.000, dan tooling cost adalah 5%
dari total cost. Dari data diketahui bahwa waktu setup adalah 5 menit dan waktu
loading adalah 2 menit
Spindle speed .
n= 1000vc÷ π D1=(1000×80)÷(3.14×20) = 1274 rpm

Table Feed
Vf = fz x z× n = 0.2 x 4 × 1274 = 1019.2 mm/min

Cutting time
Tc= L / Vf = (160 x10x10)/1019.2 = 15.7 min

Machining cost per part

Cp = Cm + CS + Cl + Ct
= (( (300,000x15.7) + (100,000x5) + (50,000x2) ) / 60 ) x 100/95
= Rp 93,159
 Example of Cutting time Calculation
DRILLING

CUTTING SPEED (vc) vc (m/min) Cutting Speed

D1 (mm) Cutter Diameter
π (3.14) Pi
n (rpm) Main Axis Spindle Speed

* Divide by 1,000 to change to m from mm.

Problem
What is the cutting speed when main axis spindle speed is 1350 rpm and drill diameter is
12mm ?

Answer
Substitute π =3.14, D1=12, n=1350 into the formulae

vc =(π ×D1×n)÷1000 =(3.14×12×1350)÷1000=50.9m/min

The cutting speed is 50.9m/min.

 Example of Cutting time Calculation
DRILLING

FEED od the Main Spindle (vf) vf (mm/min) Feed Speed of the

Main Spindle (Z axis)
f (mm/rev) Feed per Revolution
n (rpm) Rotational Speed of the Main
Spindl

Problem
What is the spindle feed (vf) when feed per revolution is 0.2mm/rev and main axis spindle
speed is 1350 rpm?

Answer
Substitute f=0.2, n=1350 into the formulae

vf = f×n = 0.2×1350 = 270mm/min

The spindle feed is 270mm/min

.
 Example of Cutting time Calculation
DRILLING
CUTTING TIME (Tc) Tc (min) Drilling Time
n (rpm) Spindle Speed
ld (mm) Hole Depth
f (mm/rev) Feed per Revolution
i Number of Holes.

Problem
What is the drilling time required for drilling a 30mm length hole in alloy steel at a cutting
speed of 50m/min and feed 0.15mm/rev ?

Answer
Spindle Speed
n = (50×1000)÷(15×3.14) = 1061.57 rpm

Tc= (30×1)÷(1061.57×0.15) = 0.188

= 0.188×60 = 11.3sec.
 Time To Produce One Part

The time required to produce one part is

Where
Ni is the number of parts machined per insert,
Nf is the number of parts that can be produced per insert face,
Tl is the loading time
Tm is machining time
Tc is the time required to change the insert,
Ti is the time required to index the insert, and
.
 Total Machining Cost Per Piece

In machining a part by turning, the total machining cost per piece, Cp,
is given by

Cp = Cm + CS + Cl + Ct (25.1)

Where
Cm = Machining cost
CS, = Cost of setting up for machining-including mounting the cutter,
setting up fixtures, and preparing the machine tool for the operation
Cl = Cost of loading, unloading, and machine handling
Ct = Tooling cost, often only about 5% of the total cutting operation.

Consequently, using the least expensive tool is not always an effective

Way of reducing machining costs
 The machining cost

The machining cost is given by

Cm = Tm(Lm + Bm) (25.2)

Where
Tm is the machining time per piece,
Lm is the labor cost of production personnel per hour, and
Bm is the burden rate, or overhead charge, of the machine-
including depreciation, maintenance, indirect labor, and the like.
The setup cost is a fixed
figure in dollars per piece.
 The loading, unloading, and machine-handling
cost

The loading, unloading, and machine-handling cost is

Cl = Tl(Lm + Bm), (25.3)

where
Tl is the time involved in loading and unloading the part, in changing
speeds and feed rates, and so on.
Lm is the labor cost of production personnel per hour, and
Bm is the burden rate, or overhead charge, of the machine-including
depreciation, maintenance, indirect labor, and the like.
 The tooling cost

The tooling cost is

where
Ni is the number of parts machined per insert,
Nf is the number of parts that can be produced per insert face,
Tc is the time required to change the insert,
Ti is the time required to index the insert, and
Di is the depreciation of the insert in dollars.