INDUSTRIAL ENGINEERING

STELLENBOSCH UNIVERSITY
Manufacturing Processes 244
Tutorial 9: Economic Consideration in Machining & Non-traditional
Machining (Model Answers)

1. A high-speed steel tool is used to turn a steel workpart that is 295 mm long and 75 mm in
diameter. The parameters in the Taylor equation are: n = 0.15 and C = 80 (m/min) for a feed
of 0.5 mm/rev. The operator and machine tool rate = $29.00/hr, and the tooling cost per
cutting edge = $3.90. It takes 2.1 min to load and unload the workpart and 3.40 min to
change tools.
i) Determine (a) cutting speed for maximum production rate, (b) tool life in min of
cutting, and (c) cycle time and cost per unit of product.
ii) Determine (a) cutting speed for minimum cost, (b) tool life in min of cutting, and (c)
cycle time and cost per unit of product.

Solution option 1:
i) (a) Co = $30/hr = $0.50/min
vmax = 75/[(1/0.13 - 1)(3.5)].13 = 75/[6.692 x 3.5].27 = 49.8 m/min
(b) Tmax = (75/49.8)1/.13 = (1.506)7.692 = 23.42 min
(c) Tm = DL/fv = (80)(300)/(.4 x 49.8 x 103) = 3.787 min
np = 23.42/3.787 = 6.184 pc/tool life Use np = 6 pc/tool life
Tc = Th + Tm + Tt/np = 2.0 + 3.787 + 3.5/6 = 6.37 min/pc.
Cc = 0.50(6.37) + 4.00/6 = $3.85/pc
Solution option 2:
iii) (a) Co = $30/hr = $0.50/min
vmin = 75[0.50/((1/0.13 - 1)(.50 x 3.5 + 4.00))].13 = 75[.50/(6.692 x 5.75)].13 = 42.6 m/min
(b) Tmin = (75/42.6)1/.13 = (1.76)7.692 = 76.96 min
(c) Tm = DL/fv = (80)(300)/(.4 x 42.6 x 103) = 4.42 min/pc.
np = 76.96/4.42 = 17.41 pc/tool life Use np = 17 pc/tool life
Tc = Th + Tm + Tt/np = 2.0 + 4.42 + 3.5/17 = 6.63 min/pc.
Cc = 0.50(6.63) + 4.0/17 = $3.55/pc

2. Disposable and regrindable tooling are to be compared. The same grade of cemented carbide
tooling is available in two forms for turning operations in a certain machine shop: disposable
inserts and brazed inserts. The parameters in the Taylor equation for this grade are: n = 0.25
and C = 300 (m/min) under the cutting conditions considered here. For the disposable
inserts, price of each insert = $6.00, there are four cutting edges per insert, and the tool
change time = 1.0 min (this is an average of the time to index the insert and the time to
replace it when all edges have been used). For the brazed insert, the price of the tool =
$30.00 and it is estimated that it can be used a total of 15 times before it must be scrapped.
The tool change time for the regrindable tooling = 3.0 min. The standard time to grind or
 regrind the cutting edge is 5.0 min, and the grinder is paid at a rate = $20.00/hr. Machine
time on the lathe costs $24.00/hr. The workpart to be used in the comparison is 375 mm
long and 62.5 mm in diameter, and it takes 2.0 min to load and unload the work. The feed =
0.30 mm/rev. For the two tooling cases, with the objective of minimizing cost, compare (a)
cutting speeds for minimum cost, (b) tool lives, (c) cycle time and cost per unit of
production. Which tool would you recommend?
Solution: Disposable inserts: (a) Co = $24/hr = $0.40/min, Ct = $6/4 = $1.50/edge
vmin = 300[0.40/((1/0.25 - 1)(0.40 x 1.0 + 1.50))].25 = 300[0.40/(3 x 1.9)].25 = 154.4 m/min
(b) Tmin = (1/0.25 - 1)(0.4 + 1.5)/0.4 = 3(1.9/0.4) = 14.25 min
(c) Tm = (62.5)(375)/(0.30)(10-3)(154.4) = 1.59 min/pc
np = 14.25/1.59 = 8.96 pc/tool life Use np = 8 pc/tool
Tc = 2.0 + 1.59 + 1.0/8 = 3.72 min/pc.
Cc = 0.40(3.72) + 1.50/8 = $1.674/pc
Regrindable tooling: (a) Co = $24/hr = $0.40/min, Ct = $30/15 + 5($20/60) = $3.67/edge
vmin = 300[0.40/((1/0.25 - 1)(0.40 x 3.0 + 3.67))].25 = 300[0.40/(3 x 4.87)].25 = 122.0 m/min
(b) Tmin = (1/0.25 - 1)(0.4 x 3 + 3.67)/0.4 = 3(4.87/0.4) = 36.5 min
(c) Tm = (62.5)(375)/(0.30)(10-3)(122) = 2.01 min/pc
np = 36.5/2.01 = 18.16 pc/tool life Use np = 18 pc/tool
Tc = 2.0 + 2.01 + 3.0/18 = 4.18 min/pc
Cc = 0.40(4.18) + 3.67/18 = $1.876/pc
Disposable inserts are recommended. Cycle time and cost per piece are less.
3. Why are the nontraditional material removal processes important?
Answer. Reasons for importance of nontraditional material removal processes are (1) the
need to shape new metal alloys and non-metals that are difficult to machine by conventional
processes; (2) the requirement of unusual and complex workpart geometries; and (3) the
need to avoid surface damage which is often associated with conventional machining.
4. How does increasing discharge current affect metal removal rate and surface finish in
electric discharge machining?
Answer. As discharge current increases, metal removal rate increases and surface finish is
degraded.
5. Name the four principal steps in chemical machining.
Answer. The four steps are (1) cleaning, (2) masking, (3) etching, and (4) demasking.
6. The frontal working area of the electrode in an ECM operation is 2000 mm2. The applied
current = 1800 amps and the voltage = 12 volts. The material being cut is nickel (valence =
2). (a) If the process is 90% efficient, determine the rate of metal removal in mm 3/min. (b) If
the resistivity of the electrolyte = 140 ohm-mm, determine the working gap. You are given
that C = 3.42 x 10-2 mm3/A-s
Solution:

From Eq. (19.6) RMR = frA = (CI/A)A = CI = (3.42 x 10-2 mm3/A-s)(1800 A)

= 6156 x 10-2 mm3/s = 61.56 mm3/s = 3693.6 mm3/min
At 90% efficiency RMR = 0.9(3693.6 mm3/min) = 3324.2 mm3/min
(b) Given resistivity r = 140 ohm-mm, I = EA/gr in Eq. (19.2). Rearranging, g = EA/Ir
 g = (12 V)(2000 mm2)/(1800 A)(140 ohm-mm) = 0.095 mm
7. An electric discharge machining operation is performed on two work materials: tungsten and
tin. Determine the amount of metal removed in the operation after one hour at a discharge
current of 20 amps for each of these metals. Use metric units and express the answers in
mm3/hr. You are given that the melting temperatures for tungsten and tin are 3410C and
232C, respectively
Solution:
For tungsten, using Eq. (19.7), RMR = KI/Tm1.23 = 664(20)/(34101.23) = 13,280/22,146
= 0.5997 mm3/s = 2159 mm3/hr
For tin, RMR = KI/Tm1.23 = 664(20)/(2321.23) = 13,280/812 = 16.355 mm3/s = 58,878 mm3/hr
8. Chemical milling is used in an aircraft plant to create pockets in wing sections made of an
aluminum alloy. The starting thickness of one workpart of interest is 20 mm. A series of
rectangular-shaped pockets 12 mm deep are to be etched with dimensions 200 mm by 400
mm. The corners of each rectangle are radiused to 15 mm. The part is an aluminum alloy
and the etchant is NaOH. Use Tables in your textbook to determine the penetration rate and
etch factor for this combination. Determine (a) metal removal rate in mm 3/min, (b) time
required to etch to the specified depth, and (c) required dimensions of the opening in the cut
and peel maskant to achieve the desired pocket size on the part. You are given that the
penetration rate = 0.025 mm/min and the etch factor = 1.75.
Solution:
(a) Neglecting the fact that the initial area would be less than the given dimensions of 200
mm by 400 mm, and that the material removal rate (RMR) would therefore increase during
the cut as the area increased, area A = 200 x 400 – (30 x 30 - (15)2) = 80,000 – 193 =
79,807 mm2
RMR = (0.025 mm/min)(79,807 mm2) = 1995.2 mm3/min
(b) Time to machine (etch) Tm = 12/0.025 = 480 min = 8.0 hr.
(c) Given Fe = 1.75, undercut u = d/Fe = 12/1.75 = 6.86 mm
Maskant opening length = L – 2u = 400 – 2(6.86) = 386.28 mm
Maskant opening width = W – 2u = 200 – 2(6.86) = 186.28 mm
Radius on corners = R – u = 15 – 6.86 = 8.14 mm

End