Name: ‫محمد فتحى عبدالعظيم عمران‬

Sec. 4
Sheet 8
Q1) A cylindrical stainless steel rod with a length of 200 mm, and a
diameter of 20 mm is reduced in diameter to 15 mm by turning on
a lathe. The spindle rotates at 350 rpm, and the tool travels at an
axial speed of 180 mm/min.
Calculate:
a. The cutting speed V (maximum and minimum).
c. The cutting time t.
Data:
L= 200 mm - d1= 20 mm – d2= 15 mm - n= 350 rpm – v= 180 mm/min
SOLVE:
Vmin= PI*d1*n/1000 = 3.14*20*350/1000 = 21.98 m/min
Vmax= PI*d2*n/1000=3.14*15*350/1000 = 16.49 m/min
Tm= L/v = 200/180 = 1.11 min

Q2) The part shown below will be turned in two machining steps. In
the first step, a length of (50 + 50) = 100 mm will be reduced from
Ø100 mm to Ø80 mm, and in the second step, a length of 50 mm
will be reduced from Ø80 mm to Ø60 mm. Calculate the required
total machining time T with the following cutting conditions:
Cutting speed V=80 m/min, Feed is f = 0.8 mm/rev, Depth of cut =
3 mm per pass.
Step 1:
1. Calculate the cutting speed in revolutions per minute (RPM): RPM = (Cutting
Speed (m/min) * 1000) / (π * Diameter (mm)) RPM = (80 * 1000) / (π * 80) ≈
318.31 RPM
2. Calculate the feed rate in millimeters per minute (mm/min): Feed Rate = Feed
(mm/rev) * RPM Feed Rate = 0.8 * 318.31 ≈ 254.65 mm/min
3. Calculate the machining time for Step 1: Time (minutes) = Length (mm) / Feed
Rate (mm/min) Time = 100 / 254.65 ≈ 0.393 minutes
Step 2:
4. Calculate the RPM for Step 2 (using the new diameter of 60 mm): RPM = (80
* 1000) / (π * 60) ≈ 424.41 RPM
5. Calculate the feed rate for Step 2: Feed Rate = 0.8 * 424.41 ≈ 339.53 mm/min
6. Calculate the machining time for Step 2: Time = 50 / 339.53 ≈ 0.147 minutes
Total machining time:
7. Add the machining times for both steps: Total Time = 0.393 + 0.147 ≈ 0.54
minutes
Therefore, the required total machining time T for both steps is approximately 0.54
minutes.

Q3) Calculate the cutting time in turning operation for steel bar with 85
mm diameter and 144 mm length to 69 mm diameter. Given that: feed
= 0.5 mm/rev., cutting speed = 28 m/min., permissible depth of cut = 4
mm

1. Calculate the required depth of cut:

Since the permissible depth of cut is 4 mm and the final diameter is 69 mm, the
required depth of cut is:

(Initial diameter - Final diameter) / 2 = (85 mm - 69 mm) / 2 = 8 mm

2. Calculate the number of passes:

To achieve the required depth of cut (8 mm) while respecting the permissible depth
of cut (4 mm), you need multiple passes. Divide the required depth by the
permissible depth:

Number of passes = Required depth / Permissible depth = 8 mm / 4 mm = 2 passes

3. Calculate the cutting speed in revolutions per minute (RPM):

RPM = (Cutting speed * 1000) / (π * Diameter)

RPM = (28 m/min * 1000) / (π * 85 mm) ≈ 105.6 RPM

4. Calculate the feed rate in millimeters per minute (mm/min):

Feed Rate = Feed * RPM

Feed Rate = 0.5 mm/rev * 105.6 RPM ≈ 52.8 mm/min

5. Calculate the machining time per pass:

Machining time (per pass) = Length / Feed Rate

Machining time (per pass) = 144 mm / 52.8 mm/min ≈ 2.73 minutes

Since there are 2 passes, multiply the time per pass by the number of passes:

Total Machining Time = 2.73 minutes/pass * 2 passes = 5.46 minutes

Therefore, the total cutting time for the turning operation is approximately 5.46
minutes.

Q4) Evaluate the machining speed and time and feed per tooth for the
slab milling operation according to the following parameters:
Cutter diameter = 110 mm, Cutter speed = 520 r.p.m, Table feed =
110 mm/min, Total machined Length = 450 cm, Number of teeth
in cutter = 9
1. Calculate the Actual Cutting Speed (V_c):

• We know the cutter speed (N) as 520 rpm. However, the actual cutting speed
depends on the cutter diameter (D) and the rotational speed.

V_c = π * N * D / 1000

V_c = π * 520 rpm * 110 mm / 1000

V_c ≈ 181.7 m/min

2. Calculate the Chip Load (Vc):

• Chip load is the thickness of the material removed per tooth per revolution.
We need the table feed (F) and the number of teeth (Z) for this calculation.

Vc = F / (N * Z)

Vc = 110 mm/min / (520 rpm * 9)

3. Calculate the Milling Time (Tm):

• Milling time depends on the total machined length (L) and the table feed (F).

Tm = L / F

Tm = 450 cm / 110 mm/min

Tm ≈ 4.09 minutes

4. Evaluate the Machining Parameters:

• The calculated cutting speed (181.7 m/min) is within a suitable range for slab
milling steel with high-speed steel cutters.

• The chip load (0.023 mm/tooth) is slightly lower than the recommended
range for high-speed steel cutters (0.05 to 0.2 mm/tooth). This might
indicate a conservative feed rate or a high number of teeth on the cutter.

• The milling time (4.09 minutes) is based on the given parameters and can be
further optimized based on specific factors like workpiece material, coolant
usage, and desired surface finish.