The time required to produce a given quantity of parts includes the initial setup time and the cycle time for each part. The setup time is composed of the time to setup the turning machine, plan the tool movements (whether performed manually or by machine), and install the fixture device into the turning machine. The cycle time can be divided into the following four times:
Selection of Cutting Conditions. Product Design Consideration. Turning & Related Operations. Turning – a machining process in which a single-point tool remove material from the surface of a rotating work piece. MRR vfd f L T f Nf D D d D v N. R m r o f o = = = − = = 2. People often question how many threads should, or are allowed to protrude beyond a nut. Airsoft gun jams on semi auto pistols. Inspectors especially seem to love counting threads. While it is not a 'standard', per se, the Naval Ships' Technical Manual, Chapter 075 Fasteners lists some good, common-sense rules for thread protrusion.
Load/Unload time
- The time required to load the workpiece into the turning machine and secure it to the fixture, as well as the time to unload the finished part. The load time can depend on the size, weight, and complexity of the workpiece, as well as the type of fixture.Cut time
- The time required for the cutting tool to make all the necessary cuts in the workpiece for each operation. The cut time for any given operation is calculated by dividing the total cut length for that operation by the feed rate, which is the speed of the tool relative to the workpiece.Idle time
- Also referred to as non-productive time, this is the time required for any tasks that occur during the process cycle that do not engage the workpiece and therefore remove material. This idle time includes the tool approaching and retracting from the workpiece, tool movements between features, adjusting machine settings, and changing tools.Tool replacement time
- The time required to replace a tool that has exceeded its lifetime and therefore become to worn to cut effectively. This time is typically not performed in every cycle, but rather only after the lifetime of the tool has been reached. In determining the cycle time, the tool replacement time is adjusted for the production of a single part by multiplying by the frequency of a tool replacement, which is the cut time divided by the tool lifetime.
Following the turning process cycle, there is no post processing that is required. However, secondary processes may be used to improve the surface finish of the part if it is required. The scrap material, in the form of small material chips cut from the workpiece, is propelled away from the workpiece by the motion of the cutting tool and the spraying of lubricant. Therefore, no process cycle step is required to remove the scrap material, which can be collected and discarded after the production.
Cutting parameters
In turning, the speed and motion of the cutting tool is specified through several parameters. These parameters are selected for each operation based upon the workpiece material, tool material, tool size, and more.
- Cutting feed - The distance that the cutting tool or workpiece advances during one revolution of the spindle, measured in inches per revolution (IPR). In some operations the tool feeds into the workpiece and in others the workpiece feeds into the tool. For a multi-point tool, the cutting feed is also equal to the feed per tooth, measured in inches per tooth (IPT), multiplied by the number of teeth on the cutting tool.
- Cutting speed - The speed of the workpiece surface relative to the edge of the cutting tool during a cut, measured in surface feet per minute (SFM).
- Spindle speed - The rotational speed of the spindle and the workpiece in revolutions per minute (RPM). The spindle speed is equal to the cutting speed divided by the circumference of the workpiece where the cut is being made. In order to maintain a constant cutting speed, the spindle speed must vary based on the diameter of the cut. If the spindle speed is held constant, then the cutting speed will vary.
- Feed rate - The speed of the cutting tool's movement relative to the workpiece as the tool makes a cut. The feed rate is measured in inches per minute (IPM) and is the product of the cutting feed (IPR) and the spindle speed (RPM).
- Axial depth of cut - The depth of the tool along the axis of the workpiece as it makes a cut, as in a facing operation. A large axial depth of cut will require a low feed rate, or else it will result in a high load on the tool and reduce the tool life. Therefore, a feature is typically machined in several passes as the tool moves to the specified axial depth of cut for each pass.
- Radial depth of cut - The depth of the tool along the radius of the workpiece as it makes a cut, as in a turning or boring operation. A large radial depth of cut will require a low feed rate, or else it will result in a high load on the tool and reduce the tool life. Therefore, a feature is often machined in several steps as the tool moves over at the radial depth of cut.
Operations
During the process cycle, a variety of operations may be performed to the workpiece to yield the desired part shape. These operations may be classified as external or internal. External operations modify the outer diameter of the workpiece, while internal operations modify the inner diameter. The following operations are each defined by the type of cutter used and the path of that cutter to remove material from the workpiece.
- External operations
Cutting A Thread (project 2)the Mechanics
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- Internal operations
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