Tutorial 3 Solutions 2010
Q1
Tool life tests in turning yield the following data: (1) when cutting speed is 120 m/min,
tool life is 7 min; (2) when cutting speed is 80 m/min, tool life is 28 min. (a) Determine
the n and C values in the Taylor tool life equation. Based on your equation, compute (b)
the tool life for a speed of 110 m/min, and (c) the speed corresponding to a tool life of 15
min.
n n
Solution: (a) Two equations: (1) 120(7) = C and (2) 80(28) = C.
n n
120(7) = 80(28)
ln 120 + n ln 7 = ln 80 + n ln 28
4.7875 + 1.9459 n = 4.3820 + 3.3322 n
4.7875 - 4.3820 = (3.3322 – 1.9459) n
0.4055 = 1.3863 n n = 0.2925
0.2925
C = 120(7) = 120(1.7668) C = 212.0
0.2925
Check: C = 80(28) = 80(2.6503) = 212.0
0.2925
(b) 110 T = 212.0
0.2925
T = 212.0/110 = 1.927
1/0.2925 3.419
T = 1.927 = 1.927 = 9.42 min
0.2925
(c) v (15) = 212.0
0.2925
v = 212.0/(15) = 212.0/2.2080 = 96.0 m/min
Q2
In a production turning operation, the workpart is 125 mm in diameter and 300 mm long.
A feed of 0.225 mm/rev is used in the operation. If cutting speed = 3.0 m/s, the tool must
be changed every 5 workparts; but if cutting speed = 2.0 m/s, the tool can be used to
produce 25 pieces between tool changes. Determine the Taylor tool life equation for this
job.
Solution: (1) Tm = π(125 mm)(0.3 m)/(3.0 m/s)(0.225 mm) = 174.53 s = 2.909 min
T = 5(2.909) = 14.54 min
(2) Tm = π(125 mm)(0.3 m)/(2.0 m/s)(0.225 mm) = 261.80s = 4.363 min
T = 25(4.363) = 109.08 min
(1) v = 3 m/s = 180 m/min
(2) v = 2 m/s = 120 m/min
n
(1) 180(14.54) = C
n
(2) 120(109.08) = C
n n
180(14.54) = 120(109.08)
ln 180 + n ln(14.54) = ln 120 + n ln(109.08)
5.1929 + 2.677 n = 4.7875 + 4.692 n
5.1929 - 4.7875 = (4.692 - 2.677) n
0.4054 = 2.0151 n n = 0.2012
0.2012
C = 180 (14.54) C = 308.43
Q3
The outside diameter of a cylinder made of titanium alloy is to be turned. The starting
diameter is 400 mm and the length is 1100 mm. The feed is 0.35 mm/rev and the depth of
cut is 2.5 mm. The cut will be made with a cemented carbide cutting tool whose Taylor
tool life parameters are: n = 0.24 and C = 450. Units for the Taylor equation are min for
tool life and m/min for cutting speed. Compute the cutting speed that will allow the tool
life to be just equal to the cutting time for this part.
Solution: In this problem we want Tm = T, where Tm = machining time per piece and T =
tool life. Both of these times must be expressed in terms of cutting speed.
1/n
Tm = πDL/fv and T = (C/v)
-6 -3 -1
Tm = π(400)(1100)(10 )/0.35(10 )v = 3949/v = 3949 (v)
1/.24 4.1667 4.1667 -4.1667 8 -4.1667
T = (450/v) = (450/v) = 450 (v) = 1135(10 )(v)
-1 8 -4.3478
Setting Tm = T: 3949 v = 1135(10 )(v)
3.1667 8
v = 0.2874(10 )
8 1/3.1667 8 0.3158
v = {0.2874(10 )} = {0.2874(10 )} = 226.6 m/min
-1
Check: Tm = 3949 (226.6) = 17.4 min
1/.24 4.1667
T = (450/226.6) = (450/226.6) = 17.4 min
Q4
In a milling operation with no coolant, a cutting speed of 500 ft/min is used. The current
cutting conditions (dry) yield Taylor tool life equation parameters of n = 0.25 and C =
1300 (ft/min). When a coolant is used in the operation, the cutting speed can be increased
by 20% and still maintain the same tool life. Assuming n does not change with the
addition of coolant, what is the resulting change in the value of C?
Solution: Find the present tool life T
n (1/n)
vT = C; T = (C/v)
(1/.25) 4.0
T = (1300/500) = 2.60 = 45.7 min
After coolant, the new cutting speed would be 500(1+.20) = 600
n .25
If the tool life stays the same, C = vT = 600(45.7) = 1560
% increase in C = (1560-1300)/1300 = 20%