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Economics of Machining 1

The document discusses economics of machining and cutting speed optimization. It explains that increasing cutting speed increases metal removal rate but decreases tool life. There is an economic cutting speed that minimizes total cost by balancing these factors. The document provides equations for calculating machining cost, tooling cost, and total cost per part based on cutting speed. It derives equations for the optimum cutting speed and tool life that minimize total cost per part and maximize production rate. Sample exercises are provided to calculate these values for a given machining problem.

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rudrayadav030101
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1K views12 pages

Economics of Machining 1

The document discusses economics of machining and cutting speed optimization. It explains that increasing cutting speed increases metal removal rate but decreases tool life. There is an economic cutting speed that minimizes total cost by balancing these factors. The document provides equations for calculating machining cost, tooling cost, and total cost per part based on cutting speed. It derives equations for the optimum cutting speed and tool life that minimize total cost per part and maximize production rate. Sample exercises are provided to calculate these values for a given machining problem.

Uploaded by

rudrayadav030101
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 12

ECONOMICS OF MACHINING

Production Technology
10/19/2023

ECONOMIC CUTTING SPEED


 Increase of cutting
speed
 Metal removal rate
(MRR) is increased
 Tool life is decreased
 Increase in MRR will
lower the direct cost of
metal removal
 Decrease in tool life will
increase cost of
servicing and replacing
worn-out tools
 What is the combined
effect of these two? 2
10/19/2023

ECONOMIC CUTTING SPEED


 The main objective of metal-
cutting economics is to
achieve the optimum
conditions, that is, the
minimum cost while
considering the principal
individual costs: machining
cost, tool cost, tool-changing
cost, and handling cost.
 The range between the two
optimum speeds is known as
the high-efficiency machining
range 3
10/19/2023

 The two most important parameter in economics of


machining are the minimum cost per part and the
maximum production rate.
 The total cost per piece consists of four items:
 Cp=Machine setup cost + Machining cost + Job
handling cost + Tooling cost

4
10/19/2023

MACHINING COST
L
For turning operation (single pass) Tm  min
f N
where l  Length of bar to be turned (mm)
f  Feed rate (mm per rvolution)
N  Spindle speed (rpm)
1000 V
but N 
D
where V  Cutting speed (surface speed of workpiece in m/min)
D  Diameter of workpiece (mm)
 DL
 Tm  min
1000 f V
Cost of machining  Cm Tm
where Cm  Machine rate including labour cost 5
10/19/2023

JOB HANDLING AND TOOLING COSTS


Job handling cost  CmTl
where Tl  Time of loading and unloading (min)
Note : Job handling cost does not depend on machining parameters
Tooling cost
(i) Throw - away carbide tips :
Cost of insert
Cost per cutting edge of tool C t 
No. of cutting edges per insert
(ii) Braced carbide tips :
Cost of tool
Ct   Cost of each regrind
No. of times tool can be reground
Tm
 Tool cost per job  C t
T
where T  tool life in minutes 6
10/19/2023

CUTTING SPEED FOR MINIMUM COST


Tm Tm
Total machining cost C p  CmTm  CmTl  Cm Ts  Ct
T T
 Tm  Tm
C p  Cm Tm  Tl  Ts   Ct
 T  T
 DL
But Tm 
1000 f V

Assuming feed to be constant and having no influence


n
C 
From Taylor' s tool life equation T   
V 
7
10/19/2023

CUTTING SPEED FOR MINIMUM COST


C p
For minimum cost, 0
V

Optimum cutting speed :


C
Vopt  n
 1  Ct  
  1 Ts  
 n  Cm 
Optimum tool life :
 1  Ct 

Topt    1 Ts 
 n  Cm 
8
10/19/2023

EXERCISE 1
 A batch of 1000 steel components are to be rough machined using a
feed of 0.2 mm/rev. The size of component is 100 mm diameter and 250
mm length. The cost data is as follows:
 Cost per cutting edge of throw-away carbide insert = Rs. 50
 Resetting time per cutting edge = 1 min
 Total machining rate (including operator wages) = Rs. 300 per hr
 The Taylor’s tool life equation V T0.25 = 650 where is V in m/min and

T in min.
 Calculate:
i. Optimum cutting speed for minimum cost
ii. Optimum tool life
iii. Total production cost, assuming that loading and unloading time is
2 min per component and initial setup time is 2 hrs
iv. Total production time for the entire batch of 1000 components
9
10/19/2023

CUTTING SPEED FOR MAXIMUM PRODUCTION RATE


Total machining time
Ttotal  Machining time  Job handling time  tool setting time
Tm
Ttotal  Tm  Tl  Ts
T
Rate of production is the reciprocal of Ttotal
1
Rp 
Tm
Tm  Tl  Ts
T
Assuming feed to be constant and having no influence
n
C 
From Taylor' s tool life equation T   
V  10
10/19/2023

CUTTING SPEED FOR MAXIMUM PRODUCTION RATE


Rp
For maximum production rate 0
V
Substituti ng the value of V and differenti ating
Optimum cutting speed :
C
Vopt  n
 1  
 n  1Ts 
  
Optimum tool life :
1 
Topt    1Ts
n 
11
10/19/2023

EXERCISE 2
 Repeat exercise 1 using maximum production rate
as the optimization criterion.
 Calculate:
i. Optimum cutting speed for minimum cost
ii. Optimum tool life
iii. Total production cost, assuming that loading and
unloading time is 2 min per component and initial
setup time is 2 hrs
iv. Total production time for the entire batch of 1000
components
(Ans: 493.9 m/min, 3 min, Rs. 29150, 3180 min)
12

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