HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY
FACULTY OF MECHANICAL ENGINEERING
DEPARTMENT OF MANUFACTURING ENGINEERING
---------oOo----------
MANUFACTURING ENGINEERING PROJECT
Project Topic:
“DESIGN THE MANUFACTURING PROCESS FOR
SHAFT SUPPORT”
Instructor: PhD. Ton Thien Phuong
Group Members:
Name
Student ID
Tran Tien Anh
1752083
Ho Viet Cao Cuong
1752119
Lam Hong Dung
1852304
Ho Chi Minh City, 11 September 2021
Manufacturing Engineering Project
PhD. Ton Thien Phuong
CONTENTS
CONTENTS ...............................................................................................................1
FIGURE LIST ............................................................................................................5
TABLE LIST .............................................................................................................7
CHAPTER 1: ANALYZING THE PART AND CALCULATING THE
WORKPIECE ............................................................................................................9
1.1 Technical Analysis And Applications Of The Manufacturing Part .................9
1.2 Dimension And Geometrical Tolerances Analysis ........................................10
1.3 Workpiece Analysis ........................................................................................12
1.3.1 Material Selection .....................................................................................12
1.3.2 Forming Methods Of Workpiece ..............................................................12
1.3.2.1 Hot Rolled Workpiece ........................................................................12
1.3.2.2 Casting Workpiece .............................................................................13
1.3.3 Calculations of Casting Tolerances (CT) And Required Machining
Allowance (RMA) .............................................................................................15
CHAPTER 2: ANALYSYS FOR THE MACHINING PROCESS .......................18
2.1 Analysis For The Machining Surface .............................................................18
2.2 Determine machining process.........................................................................21
2.2.1 Establish Plans ..........................................................................................21
2.2.2 Correlation Analysis Between Surfaces ...................................................23
2.2.3 Plan Selection ...........................................................................................23
2.3 Determining the locating plans for machining operations .............................24
CHAPTER 3: SELECTION OF MACHINES & CUTTING TOOLS ..................32
3.1 Selection For Machines ..................................................................................32
3.1.1 Milling Machine .......................................................................................32
3.1.2 Lathe Machine ..........................................................................................34
3.1.3 Drilling Machine .......................................................................................35
3.2 Selection For Cutting Tools ............................................................................36
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3.2.1 Selection For Tool Holders.......................................................................36
3.2.2 Selecting Cutting Tool For Each Task .....................................................37
3.2.2.1 Task 1: Turing Surfaces 3, 5 ..............................................................37
3.2.2.2 Task 2: face milling surface 1 ............................................................45
3.2.2.3 Task 3: Turning Surfaces 2, 4 and surface 10 ....................................50
3.2.2.4 Task 4: Drilling Holes 11, 13, 15, 17 .................................................57
3.2.2.5 Task 5: Milling Surfaces 12, 16 .........................................................59
3.2.2.6 Task 6: Drilling And Tapping Holes 6, 7, 8, 9: .................................63
3.2.2.7 Tasks 7: Milling Surfaces 14, 18 ........................................................66
3.2.2.9 Task 8: Finishing Boring Surface 3 ....................................................70
CHAPTER 4: DESIGN AND CALCULATION OF FIXTURE ............................73
4.1 Requirements for Designing Fixtures .............................................................73
4.2 Fixture Description .........................................................................................74
4.3 Determining Cutting Force .............................................................................74
4.4 Determining Clamping Force .........................................................................77
4.5 Determining Bolt Tightening Force................................................................78
4.6 Calculation of manufacturing error of fixture ................................................80
4.6.1 Standard error ...........................................................................................80
4.6.2 Clamping error ..........................................................................................80
4.6.3 Error due to wear of fixture ......................................................................80
4.6.4 Adjustment error .......................................................................................81
4.6.5 Mounting error ..........................................................................................81
4.6.6 Manufacturing error ..................................................................................81
CHAPTER 5: PRODUCT PRICE CALCULATION..............................................82
5.1 Cost Of Materials ............................................................................................82
5.2 Processing Costs .............................................................................................82
5.2.1 Insert cost ..................................................................................................82
5.2.2 Tool holder cost ........................................................................................87
5.3 Direct and Indirect Costs ................................................................................88
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5.3.1 Direct cost .................................................................................................88
5.3.2 Indirect cost ..............................................................................................88
5.3.3 Energy cost ...............................................................................................89
REFERRENCES ......................................................................................................90
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ABSTRACT
Manufacturing engineering project is the combination of knowledge of many
previous subjects such as manufacturing engineering 1, 2, 3, manufacturing process,
etc. Nowadays, Mechanical Engineering requires engineers with vast knowledge and
know how to apply the knowledge to solve problems in manufacturing. Through this
project, we will learn how important of manufacturing engineering for engineers and
mechanics to design and operate machines in industry and agriculture.
Our country now is in the development stage. Therefore, demands on
mechanical manufacturing is very important. However, the old-dated technology
which is the main problem led to consequences of ineffective production, so the
modern technologies should be applied in order to increase not only in quality but
also efficiency.
The weakness of this project is that all the calculation is not fully implemented
due to lack of time and learning material. Therefore, this project might have several
mistakes. It would be my pleasure to learn more knowledge from teachers, lecturers
and professors.
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FIGURE LIST
Figure 1.1 Shaft Support Block (Square flange type) ……………………….…8
Figure 1.2 Dimensions Of Shaft Support………………………………….…….9
Figure 1.3 Manufacturing Drawing of Shaft Support…………...……………..…10
Figure 1.4 Mass Of Casting Workpiece…………………………………...……….13
Figure 1.5 Dimension of workpiece in external machining………...…….….….14
Figure 1.6 Dimension of workpiece in internal machining…...………...………15
Figure 1.7 Workpiece Drawing Of Shaft Support……………………………...…16
Figure 2.1 Surface Numbering Drawing……………………….……….….……...17
Figure 3.1 KNUTH Servomill UFM 8V Milling Machine…………….…………31
Figure 3.2 KNUTH V-Turn 410/1500 Universal Lathe……………...………….33
Figure 3.3 EchoENG TC 40 DA drill press…….…………………….……….….34
Figure 3.4 SK40-FMB22-50 taper ……………….................................……….35
Figure 3.5 F-Arbor SK50………….…………………………….…...…………….36
Figure 3.6 CCMT 06 02 08-UM 1515insert (Sandvik)…………………….......41
Figure 3.7 E12Q-SCLCR 06-R boring bar …………………………………...…42
Figure 3.8 131-2512-B rectangular shank ……………………………………...43
Figure 3.9 CNMG 12 04 12-MR 4335 insert (Sandvik) …………………….…43
Figure 3.10 CNMG 12 04 12-WF 1515 insert (Sandvik)……………….….….44
Figure 3.11 DCLNR 2020K 12 tool shank ……………………………………...44
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Figure 3.12 345R-1305M-PM 4340 inserts ……………………………...….…49
Figure 3.13 345-063Q22-13M face Milling Cutter…………………….…..….49
Figure 3.14 CNMG 12 04 12-MR 4335 insert (Sandvik)……….…….………56
Figure 3.15 CNMG 12 04 12-WF 1515 insert (Sandvik)……………...…..…56
Figure 3.16 DCLNR 2020K 12 tool shank…………………………....…...…...57
Figure 3.17 460.1-0550-017A0-XM GC34 drill bit……………….…...….….58
Figure 3.18 N331.1A-11 50 08M-PM4040 insert………………….…........….64
Figure 3.19 L331.52-100S32KM disc milling cutter……………...…….……..65
Figure 3.20 460.1-0420-013A0-XM GC34 drill bit………………........……..66
Figure 3.21 E046M5 tap bit………………………………………………...…….67
Figure 3.22 N331.1A-11 50 08M-PM4040 insert………………………..….…72
Figure 3.23 L331.52-100S32KM disc milling cutter ..……….……………..…73
Figure 3.24 CCMT 09 T3 08-PF 1515 insert (Sandvik)……………...……….75
Figure 3.25 A16R-PCLNR09 boring bar…………………………………...…...76
Figure 3.26 131-2516-B rectangular shank………………………..……......….77
Figure 4.1 Operation Drawing For Disc Milling Faces (12), (16) ..……...…78
Figure 4.2 Different of chip formation of down milling and up milling..........80
Figure 4.3 FBD For Cutting Force In Operation Milling
Faces (12) & (16)………………………………………………………….……...80
Figure 4.4 FBD of workpiece in milling (12), (16) operation…………….…82
Figure 4.5 Clamping Diagram Of Fixture Of Operation 5………..…….…..83
Figure 4.6 Strap Clamp FBD in Operation 5………………….…….………..84
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TABLE LIST
Table 1.1. Analyzing the given face roughness.......................................................10
Table 1.2 Chemical Composition Of S45C……………..…………………...……......11
Table 1.3 Mechanical Properties Of S45C...................................................…......11
Table 1.4 Dimensional Calculation For Casting Workpiece.................................15
Table 2.1 Machining Process For Surfaces 1........................................................17
Table 2.2 Machining Process For Surfaces 2, 4, 10, 14, 17, 20………………......18
Table 2.3 Machining Process For Surface 3………………………………...…........18
Table 2.4 Machining Process For Surface 5…………………………...…….….......18
Table 2.5 Machining Process For Surfaces 6, 7, 8, 9.........................…..............19
Table 2.6 Machining Process For Surfaces 11,13,16,19....…………........…........19
Table 2.7 Machining Process For Surfaces 12, 15, 18, 21……………....….........19
Table 3.1 Servomill UFM 8V Specifications……………………………….….........32
Table 3.2 KNUTH V-Turn 410/1500 Universal Lathe specifications……….......33
Table 3.3 EchoENG TC 40 DA drill press specifications…………………..........34
Table 3.4 SK40-FMB22-50 taper specifications………………………….............35
Table 3.5 F-Arbor SK50 specifications………………...…………….......……...…36
Table 3.6 Specific Cutting Force Kc for turning…………………………………...38
Table 3.7 CCMT 06 02 08-UM 1515 specifications………………...…................41
Table 3.8 E12Q-SCLCR 06-R specifications……………………….…....……......42
Table 3.9 131-2512-B rectangular shank specification………...….…...……......43
Table 3.10 CNMG 12 04 12-MR 4335 specifications………………….........……43
Table 3.11 CNMG 12 04 12-WF 1515specifications……………………...…...…44
Table 3.12 DCLNR 2020K 12 specifications……………………………….......…45
Table 3.13 Specific cutting force Kc for milling……………………...…………...47
Table 3.14 345R-1305M-PM 4340 specifications…………………...…………...49
Table 3.15 345-063Q22-13M milling cutter specification……………….……...50
Table 3.16 CNMG 12 04 12-MR 4335 specifications……………………........…56
Table 3.17 CNMG 12 04 12-WF 1515specifications………….….…….....….…57
Table 3.18 DCLNR 2020K 12 specifications…………………….………....….…57
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Table 3.19 460.1-0550-017A0-XM GC34 drill bit specification………….......……59
Table 3.20 Cutting speed for drilling …………………………………...………..……60
Table 3.21 N331.1A-11 50 08M-PM4040 specification…………………….….……64
Table 3.22 L331.52-100S32KM milling cutter specifications…………….......……65
Table 3.23 460.1-0420-013A0-XM GC34 drill bit specifications….……..……..…66
Table 3.24 E046M5 tap bit specifications……………...…………………….….……67
Table 3.25 Cutting speed for tapping…………………………………...….….………68
Table 3.26 N331.1A-11 50 08M-PM4040 specification……………….….. ….……72
Table 3.27 E046M5 tap bit specifications……………...……………….….…..….…73
Table 3.28 CCMT 09 T3 08-PF 1515 specifications………………...…..…....……75
Table 3.29 A16R-PCLNR09 specifications……………………..……….…...………76
Table 3.30 131-2516-B rectangular shank specification…………..………....……77
Table 5.1 n and C value in Taylor tool life equation………………..…….…...…...87
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CHAPTER 1: ANALYZING THE PART AND CALCULATING
THE WORKPIECE
1.1 Technical Analysis And Applications Of The Manufacturing Part
Shaft support products for linear applications are available as standalone
blocks or as rails. Shaft support blocks are used for end or intermittent support where
loads are light and slight shaft deflection is not a concern. The support blocks are
primarily intended for applications where loading is somewhat light and resulting
deflection between supports does not become an issue.
In linear motion systems with closed linear sets the guiding shafts are mounted
at their ends. Precision shaft support blocks have been developed for these
applications. Shaft support blocks are typically made out of aluminum or ductile
iron, however for higher loads steel is available.
Unlike shaft support rails, blocks do not permit longitudinal passage of opentype ball bushing bearings. Shaft support blocks enable clamping of shafts and
eliminate the need for bolts to maintain shaft position. Shimming is suggested for
high precision applications to eliminate the effect of variations in surface of base or
manufacturing tolerances between supports.
Figure 1.1 Shaft Support Block (Square flange type)
In this project, our manufacturing parts are standard mount shaft support block
(square flange-long sleeve). This type of shaft support uses screws to secure the shaft
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and the long sleeve of this part will enhance the rigidity of the assembling. This is
the most popular type according to Misumi mechanical distributor.
1.2 Dimension And Geometrical Tolerances Analysis
Analyzing the technical requirements:
The part has a big holes D with diameter Ø25 with four through
mounting holes d1 Ø5.5 and 4 tapped holes M5.
According to the working condition and applications, the hole D is the
important dimension of this part which is the working surface and will be
assembled with the shaft. So, it requires high accuracy and low surface
roughness with Ra = 1.6. We select H7 as the tolerance grade for the hole D.
4 mounting holes used for locating the part so that high accuracy is not
necessary. We choose Js12 tolerance.
The perpendicularity of the sleeve and the base flange should not
exceed 0.02.
The bottom surface of the flange, which will be mounted to another
surface should have low surface roughness with Ra = 1.6.
The 4 tapped holes M5 for clamping the shaft is coarse so that we
choose H12 tolerance.
Other dimensions and surfaces without be mentioned will follow js12
tolerance and roughness Ra = 6.3.
Figure 1.2 Dimension Of Shaft Support
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Table 1.1. Analyzing the given face roughness
Dimension
Tolerance
Order of accuracy
D
Ø25+0.021
0
H7
L1
57+0.15
−0.15
js12
D1
Ø33+0.125
−0.125
js12
H
55+0.15
−0.15
js12
T
8+0.075
−0.075
js12
l1
19+0.105
−0.105
js12
M (coarse)
Ø4.2+0.06
−0.0.6
Js12
K
44+0.125
−0.125
js12
d1
Ø5.5+0.12
0
H12
Figure 1.3 Manufacturing Drawing of Shaft Support
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1.3 Workpiece Analysis
1.3.1 Material Selection
In the working process, the shaft supports may be impacted by the
bending stress due to loads acting on the shaft. Therefore, our materials need
a good hardness as well as good ductility because we expect to avoid breaking
our parts. To balance the hardness and ductility of our shaft supports, a
medium carbon steel is approriate for our parts. Beside the mechanical
properties, considering about prices and availability in Vietnamese market,
S45C is the selected material for our workpiece.
S45C is a very common and low-priced materials that can be easily
found in Vietnam. With the Carbon composition about 0.45%, this material
have high ductility and wear resistance. Otherwise, it can withstand high
loads, elasticity withstands strong impacts. With these properties, S45C can
be easily casted, rolled, drawn and machined.
Table 1.2 Chemical Composition Of S45C
Grade
S45C
C
0.42 - 0.48
Chemical Composition
Si
Mn
P (max)
0.15 - 0.35
0.60 - 0.90
0.02
S (max)
0.035
Table 1.3 Mechanical Properties Of S45C
Grade
Yield Point
(N/mm2)
S45C
370 (min)
Mechanical Properties
Tensile Strength
Elongation
2
(N/mm )
(%)
630 - 780
17 (min)
HRC
35-45
1.3.2 Forming Methods Of Workpiece
1.3.2.1 Hot Rolled Workpiece
It is estimated that about 90% of mechanical failures of materials
in service are caused by or at least contributed to by fatigue. [5]
Therefore, fatigue is an important parameter to consider for moving
mechanical components that are expected to last for long periods. The
shaft supports have to serve under the repetitive stresses.
If hot rolled forming method is selected for our workpiece, we
decide to buy square steel bars (bloom) to use as workpieces.
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Because our boundary dimension of our part is 44x44x57 mm,
follow the ASTM A-600 92a Standard [1] to calculate the Required
Machining Allowance (RMA), we can estimate the dimensions of our
hot rolled workpiece is 50x50x65 mm.
Then, we decide to buy the 50x50 square steel bars with the 6
meters length. Therefore, for a 6 meters steel bar, we can cut into 92
workpieces. Our required production is 1000 parts; therefore, we need
to buy at least 11 steel bars to produce 1000 parts. Then, we decide to
buy 13 steel bars. These 2 steel bars are used in case we produce
defective products and in case we need spare parts to use as accessories
when the main parts are broken and need a replacement.
Mass per meter of a 50x50 square steel bar is about 19.63 kg/m
and the price is around 30,000 VND per kilogram (according to many
steel distributors in Vietnam). Therefore, a 6 meters steel bar
(50x50mm) has a price around from 3.5 million VND. Then, 13 steel
bar will cost us approximately 45.5 million VND.
1.3.2.2 Casting Workpiece
Steel castings are solid metal objects produced by filling the void
within a mold with liquid steel. Mechanical properties for cast steel are
generally lower than hot rolled steels, but with the same chemical
composition. Cast steel compensates for this disadvantage with its
ability to form complex shapes in fewer steps.
One of the advantages of cast steel parts is flexible design.
Designers have the largest design choice on the shape and dimensions
of cast steel parts. Especially complex shape and hollow section parts,
we could manufacture cast steel parts with set core special technology.
Secondly, the material of cast steel parts is isotropic and the
overall constitutive property is strong, thus improves the reliability.
And for its small weight and short lead time, it has great advantages on
pricing.
Following ISO 8062:2007 [5], we can preliminarily add 4mm as
the Required Machining Allowance (the detailed calculation will be
considered later) and Dimension Casting Allowance on each side.
Then, we get the mass of the casting workpiece at about 700 grams.
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Figure 1.4 Mass Of Casting Workpiece (Preliminary Modeling
in SOLIDWORKS)
One kilogram of S45C steel cost us 30,000 VND. Then, to
produce one part, the cost of material is 21,000 VND. Our
required production is 1000 pieces but we need the material to
produce 1200 pieces in case our casting parts are defective when
machining and in case we need spare parts to use as accessories
when the main parts are broken and need a replacement. Then
the total cost for material is 25,200,000 VND.
 Conclusions: We select casting as the forming method for our workpiece
because the required machining allowance is much smaller than hot rolled
workpieces which reduce the material requirement and material cost. In
addition, because casting method can produce complex-shape parts, it can
reduce the machining steps for us which is more time-saving for
manufacturing process.
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1.3.3 Calculations of Casting Tolerances (CT) And Required Machining
Allowance (RMA)
As our forming process is casting in sand mold and our type of
production is short-series production, following the recommendation of Steel
Founder’ Society of America and ISO 8062:2007 [5], we select CT14 the
casting tolerance grade (CT) for our parts.
Castings that are to be machined must have sufficient metal stock on all
surfaces requiring machining. For sand casting (hand mold), based on ISO
8062:2007 standard, we select grade K as the RMA grade for our parts.
After selecting the CT grade and RMA grade for our parts. We apply
the formulas in section 8.2 in ISO 8062:2007 [5] to calculate the dimensions
of our workpiece.
Figure 1.5 Dimension of workpiece in external machining
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Figure 1.6 Dimension of workpiece in internal machining
Where CT = 14 and RMA = K, by following these formulas, we get
the result dimensions for our workpiece:
Table 1.4 Dimensional Calculation For Casting Workpiece
Types of
dimensions
External
Internal
Dimensions of
final part
F (mm)
Required
Machining
Allowances
RMA (mm)
Casting
Tolerances
CT (mm)
Workpiece
Dimensions
R (mm)
8
1.4
8
14.8
∅33
1.4
9
40.3
44
2
10
53
57
2
10
66
Hole ∅25
1.4
8
∅18.2
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Figure 1.7 Workpiece Drawing Of Shaft Support
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CHAPTER 2: ANALYSYS FOR THE MACHINING PROCESS
The aim of this chapter is to determine the sequence of machining processes
that ensures accuracy and roughness for our parts. We have to establish different
plans for manufacturing this part, and among them, we analyze and decide which
plan is the most optimal. Furthermore, in this chapter, we also considered the
locational plans for each surface of our part.
Figure 2.1 Surface Numbering Drawing
2.1 Analysis For The Machining Surface
• Surfaces 1
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 6.3
Available Machining Process: Milling, Turning
Table 2.1 Machining Process For Surfaces 1
Stage
Machining process
I
II
Rough Milling
Semi-Finishing Milling
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IT
From To
14
13
Ra
13 12.5
12 6.3
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PhD. Ton Thien Phuong
• Surfaces 2, 4, 10
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 6.3
Available Machining Process: Turning
Table 2.2 Machining Process For Surfaces 2, 4, 10
Stage
Machining process
I
II
Rough Turning
Semi-Finishing Turning
IT
From To
14
13
Ra
13 12.5
12 6.3
• Surface 3
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 7, Ra = 1.6
Available Machining Process: Boring, Drilling
Table 2.3 Machining Process For Surface 3
Stage
Machining process
I
II
III
Rough Boring
Semi-Finishing Boring
Finishing Boring
IT
From To
14
11
9
Ra
11 12.5
9 6.3
7 1.6
• Surface 5
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 1.6
Available Machining Process: Milling, Turning
Table 2.4 Machining Process For Surface 5
Stage
Machining process
I
II
Rough Milling
Semi-Finishing Milling
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IT
From To
14
13
Ra
13 12.5
12 1.6
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PhD. Ton Thien Phuong
• Surfaces 6, 7, 8, 9
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 6.3
Available Machining Process: Drilling, Tapping
Table 2.5 Machining Process For Surfaces 6, 7, 8, 9
Stage Machining process
I
II
Drilling
Tapping
IT
Ra
From To
14
13
13 12.5
12 6.3
• Surfaces 11, 13, 15, 17
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 6.3
Available Machining Process: Drilling
• Table 2.6 Machining Process For Surfaces 11, 13, 15, 17
Stage Machining process
I
Drilling
IT
From To
14
Ra
12 6.3
• Surfaces 12, 14, 16, 18
Initial Surface Quality:
IT 14, Ra = 40
Required Quality:
IT 12, Ra = 6.3
Available Machining Process: Milling
Table 2.7 Machining Process For Surfaces 12, 14, 16, 18
Stage Machining process
I
II
Rough Milling
Finishing milling
20
IT
From To
14
13
Ra
13 12.5
12 6.3
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2.2 Determine machining process
2.2.1 Establish Plans
Plan A:
Plan
Operations Step
Surface
IT
Ra
Process
1
5
13
12.5
Rough Turning
2
5
12
6.3
Semi-Finishing Turning
3
3
11
12.5
Rough Boring
4
3
9
6.3
Semi-Finishing Boring
5
1
13
12.5
Rough Milling
6
1
12
6.3
Semi-Finishing Milling
7
2,4
13
12.5
Rough Turning
8
10
13
12.5
Rough Turning
9
2,4
12
6.3
Semi-Finishing Turning
10
10
12
6.3
Semi-Finishing Turning
4
11
11, 13, 15, 17
12
6.3
Drilling
5
12
12,16
13
12.5
Rough Milling
6
13
12,16
12
6.3
Semi-Finishing Milling
14
6,7,8,9
13
12.5
Drilling
15
6,7,8,9
12
6.3
Tapping
8
16
14,18
13
12.5
Rough Milling
9
17
14,18
12
6.3
Semi-Finishing Milling
10
18
3
7
1.6
Finishing Boring
1
2
3
A
7
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Plan B:
Plan
Operations Step
Surface
IT
Ra
Process
1
5
13
12.5
Rough Milling
2
5
12
6.3
Semi-Finishing Milling
3
1
13
12.5
Rough milling
4
1
12
6.3
Semi-Finishing milling
5
12, 14, 16,
18
13
12.5
Rough milling
6
12, 14, 16,
18
12
6.3
Semi-Finishing milling
7
2,4
13
12.5
Rough Turning
8
2,4
12
6.3
Semi-Finishing Turning
9
3
12
12.5
Rough boring
10
3
9
6.3
Semi-Finishing boring
11
10
13
12.5
Rough Turning
12
10
12
6.3
Semi-Finishing Turning
13
6,7,8,9
13
12.5
Drilling
14
6,7,8,9
12
6.3
Tapping
8
15
11, 13, 15,
17
12
6.3
Drilling
9
16
3
7
1.6
Finishing Boring
1
2
3
B
4
5
6
7
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2.2.2 Correlation Analysis Between Surfaces
• Let the surface (5) to be the reference surface, then boring hole (3).
• Surface (10), (12), (14), (16), (18) are machined perpendicularly to the
surface (5).
• 4 through holes (11), (13), (15), (17) have centers lying on the circle
∅44 which is concentric with the big hole (3). These 4 through holes
pattern a 45° to the vertical and horizontal centerlines of the part.
• Surface (1) has to be perpendicular to surface (2) and to be parallel to
surfaces (4) and (5).
• Holes (6) and (7) have center on the centerline of the workpiece that
perpendicular to surface (5) and holes (8) (9) have centerline
perpendicular to centerline of holes (6) (7)
2.2.3 Plan Selection
Between plan A and plan B, we refer plan A, because if we follow the
technical rules for machining sequences, in case all of the surface have to be
machined, in the first operation, we should select the surface which have least
machining allowance to be the reference surface. Therefore, the surface (5) is
our reference surface. From surface (5), we can milling surfaces (1), (2), (3),
(4).
Then, we select the surface (1) to be the reference surface in operation
2. Then, the surface (5) and edge surface of the base can be machined. And in
the final operation, the most accurate and smoothest surface (surfaces (5) and
(3)) will be accomplishing.
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2.3 Determining the locating plans for machining operations
Locating Plans For Hole (3) and Face (5)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (5): Tz, Rx, Ry
1
Face (3)
- Face (3): Tx, Ty, Rx, Ry
Face (5)
Sufficient condition:
- Face (2): Tx, Ty, Rx, Ry
- Face (1): Tz
Necessary condition:
- Face (5): Tz, Rx, Ry
2
Sufficient condition:
Face (3)
Face (5)
- Face (2): Tx, Ty, Rx, Ry
- Face (4): Tz
 The selected plan: Plan 1
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Locating Plans For Face (1)
Plan Operations
Diagrams
Located surface
Necessary condition:
- Face (1): Tz, Rx, Ry
Sufficient condition:
1
Face (1)
- Face (5): Tz, Rx, Ry
- Face (12): Tx, Ty
Necessary condition:
- Face (1): Tz, Rx, Ry
Sufficient condition:
2
Face (1)
- Face (4): Tz, Rx, Ry
- Face (12): Ty, Rz
 The selected plan: Plan 1
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Locating Plans For Faces (2) and (4)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Step Faces (2) (4): Tx, Ty,
Tz, Rx, Ry
Sufficient condition:
1
- Face (5) : Tz, Rx, Ry
Step Faces
(2) (4)
- Face (12): Ty, Rz
- Face (18): Tx
Necessary condition:
- Step Faces (2) (4): Tx, Ty,
Tz, Rx, Ry
2
Sufficient condition:
Step Faces
(2) (4)
- Face (3): Tx,Ty,Rx, Ry
- Face (5): Tz
 The selected plan: Plan 2
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Locating Plans For Face (10)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (10): Tx, Ty,
Rx, Ry
1
Sufficient condition:
Face (10)
- Face (3): Tx, Ty,
Rx, Ry
- Face (5): Tz
Necessary condition:
- Face (10): Tx, Ty,
Rx, Ry
2
Sufficient condition:
Face (10)
- Face (2): Tx, Ty,
Rx, Ry
- Face (5): Tz
 The selected plan: Plan 1
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Locating Plans For Faces (11), (13), (15), (17)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (11), (13), (15), (17):
Tx, Ty, Rx, Ry, Rz
Face (11)
Face (13)
1
Sufficient condition:
Face (15)
- Face (1): Tz, Rx, Ry
Face (17)
- Face (3): Tx, Ty
- Face (14): Rz
Necessary condition:
- Face (11), (13), (15), (17):
Tx, Ty, Rx, Ry, Rz
Face (11)
2
Face (13)
Sufficient condition:
Face (15)
- Face (3): Tx, Ty, Rx, Ry
Face (17)
- Face (16): Rz
 The selected plan: Plan 1
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Locating Plans For Faces (12), (16)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (12): Ty, Rx, Rz
Face (12)
- Face (16): Ty, Rx, Rz
Face (16)
1
Sufficient condition:
- Face (2): Tx, Ty, Rx, Ry
- Face (14): Rz
Necessary condition:
- Face (12): Ty, Rx, Rz
- Face (16): Ty, Rx, Rz
Sufficient condition:
Face (12)
- Face (1): Tz, Rx, Ry
Face (16)
- Face (3): Tx, Ty
2
- Face (15): Rz
 The selected plan: Plan 2
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Locating Plans For Faces (14), (18)
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (14): Tx, Ry, Rz
Face (14)
- Face (18): Tx, Ry, Rz
Face (18)
1
Sufficient condition:
- Face (2): Tx, Ty, Rx, Ry
- Face (12): Rz
Necessary condition:
- Face (14): Tx, Ry, Rz
Face (14)
2
- Face (18): Tx, Ry, Rz
Face (18)
Sufficient condition:
- Face (1): Tz, Rx, Ry
- Face (3): Tx, Ty
- Face (13): Rz
 The selected plan: Plan 2
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Locating Plans For Faces (6), (7), (8, (9))
Plan Operations
Diagrams
Locating surfaces
Necessary condition:
- Face (6): Tz, Rz, Ty, Ry, Tx, Rx
- Face (7): Tz, Rz, Ty, Ry, Tx, Rx
1
Face (6)
- Face (8): Tz, Rz, Ty, Ry, Tx, Rx
Face (7)
- Face (9): Tz, Rz, Ty, Ry, Tx, Rx
Face (8)
Sufficient condition:
Face (9)
- Face (2): Tx, Ty, Rx, Ry
- Face (5): Tz
- Face (12): Rz
Necessary condition:
- Face (6): Tz, Rz, Ty, Ry, Tx, Rx
- Face (7): Tz, Rz, Ty, Ry, Tx, Rx
2
Face (6)
- Face (8): Tz, Rz, Ty, Ry, Tx, Rx
Face (7)
- Face (9): Tz, Rz, Ty, Ry, Tx, Rx
Face (8)
Sufficient condition:
Face (9)
- Face (5): Tz, Rx, Ry
- Face (3): Tx, Ty
- Face (15): Rz
 The selected plan: Plan 2
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CHAPTER 3: SELECTION OF MACHINES & CUTTING TOOLS
3.1 Selection For Machines
3.1.1 Milling Machine
Requirements when choosing a milling machine:
• In the process with face and parallel surfaces milling, we should
choose the type of vertical milling and horizontal milling.
• Machine with high rigidity.
Then, our selection for milling machine is Servomill UFM 8V
Conventional Milling from KNUTH supplier. This machine can be
used for both horizontal, vertical milling and drilling tasks.
Figure 3.1 KNUTH Servomill UFM 8V Milling Machine
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Table 3.1 Servomill UFM 8V Specifications
Table size
1600 x 320 mm
Table load capacity
450 kg
Number of T-slots
3 positions
T-slots, width
18 mm
T-slots, spacing
80 mm
Table dimensions
1600mm x 320mm
X travel
1300 mm
Y travel
290 mm
Z travel
450 mm
Vertical Spindle Mount
SK40/DIN2080
Horizontal Spindle Mount
SK50/DIN2080
Vertical Spindle Power
5.5 kW
Horizontal Spindle Power
7.5 kW
Vertical Spindle Speed
5000 rpm
Horizontal Spindle Speed
1800 rpm
Quill Feeds
0.04 / 0.08 / 0.15 mm/rev
Quill Stroke
127 mm
Overall Dimension
1900 x 2050 x 2500 mm
Weight
2400 kg
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3.1.2 Lathe Machine
KNUTH V-Turn 410/1500 Universal Lathe is chosen for turning and
boring operations.
Figure 3.2 KNUTH V-Turn 410/1500 Universal Lathe
Table 3.2 KNUTH V-Turn 410/1500 Universal Lathe specifications
Power
5.5 kW
Spindle high speed
550 ÷ 3000 rpm
Spindle low speed
30 ÷ 550 rpm
Travel X axis
210 mm
Travel Y axis
140 mm
Feed X axis
0.025 ÷ 0.85 mm/rev
Feed Y axis
0.05 ÷ 1.7 mm/rev
Tool holder type
WB
Spindle bore
52 mm
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Spindle mount
Camlock D1-6
Spindle taper
MT 6
Size
2400 x 1000 x 1320 mm
Weight
1800 kg
3.1.3 Drilling Machine
EchoENG TC 40 DA drill press is chosen for drilling
Figure 3.3 EchoENG TC 40 DA drill press
Table 3.3 EchoENG TC 40 DA drill press specifications
Drilling capacity
40 mm
Tapping capacity
M22
Table size
500 x 380 mm
Spindle power
1.5 kW
Number of spindle speed
12
Spindle speed
75 ÷ 3200 rpm
Size
670 x 470 x 2100 mm
Weight
430 kg
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3.2 Selection For Cutting Tools
3.2.1 Selection For Tool Holders
As the KNUTH Servo Mill UFM 8V is supported with spindle taper
SK40 for vertical milling and SK50 for horizontal milling, we select the tool
holder for our milling machine as follows:
Figure 3.4 SK40-FMB22-50 taper
Table 3.4 SK40-FMB22-50 taper specifications
Size
SK40
Type
FMB
Name
FMB22-50
L1
50 mm
L2
18 mm
d
22 mm
D
48 mm
G
M10
Weight
1.5 kg
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Figure 3.5 F-Arbor SK50
Table 3.5 F-Arbor SK50 specifications
Size
SK50
L
606 mm
L1
400 mm
d1
32 mm
Weight
6.2 kg
3.2.2 Selecting Cutting Tool For Each Task
3.2.2.1 Task 1: Turing Surfaces 3, 5
• Mounting diagram
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• Cutting condition:
Rough boring surface 3: IT 11, Ra 6.3
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
6.3×8×0.8
1000
= 0.2 mm/rev
CCMT 06 02 08-UM 1515 insert is selected with
85 <vC <290, 0.12<fn<0.4 and 0.5<ap<2.5
Choose cutting speed 𝑣𝑐 = 120 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×120
𝜋×18
= 2122 𝑟𝑝𝑚
 Choose n = 2000 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 2000 × 0.2 = 400 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
2000×18
1000
= 113 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 1.7 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
66
400
= 0.165 min = 9.9 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2700 MPa
𝑃𝑐 =
1.7 × 113 × 0.2 × 2700
60 × 103
= 1.73 kW< 5.5kW machine capacity
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Table 3.6 Specific Cutting Force Kc for turning
Semi finishing boring surface 3: IT 9, Ra 3.2
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
3.2×8×0.8
1000
= 0.14 mm/rev
CCMT 09 T3 08-PF 1515 insert is selected with
150 <vC <310, 0.08<fn<0.27 and 0.15<ap<2
Choose cutting speed 𝑣𝑐 = 155 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×155
𝜋×24
= 2055 𝑟𝑝𝑚
 Choose n = 2000 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 2000 × 0.14 = 280 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
2000×24
1000
Depth of cut: ap = 1 mm, cut 1 time
39
= 150 𝑚/𝑚𝑖𝑛
Manufacturing Engineering Project
PhD. Ton Thien Phuong
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
57
280
= 0.2 min = 12 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 3080 MPa
𝑃𝑐 =
1 × 155 × 0.14 × 3080
60 × 103
= 1.1 kW< 5.5kW machine capacity
Rough turning surface 5: IT 13, Ra 12.5
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
12.5×8×1.2
1000
= 0.35 mm/rev
CNMG 12 04 12-MR 4335 insert is selected with
145 <vC <200, 0.3<fn<0.75 and 1.5<ap<8
Choose cutting speed 𝑣𝑐 = 150 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×150
𝜋×53
= 900 𝑟𝑝𝑚
 Choose n = 900 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 900 × 0.35 = 315 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
900×53
1000
= 150 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 2.4 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
26.5
350
= 0.08 min = 4.8 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2450 MPa
𝑃𝑐 =
2.4 × 150 × 0.35 × 2450
60 × 103
= 5.1 kW < 5.5kW machine capacity
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Semi-Finishing turning surface 5: IT 12, Ra 1.6
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
1.6×8×1.2
1000
= 0.12 mm/rev
CNMG 12 04 12-WF 1515 insert is selected with 45 <vC
<260, 0.1<fn<0.55 and 0.4<ap<4
Choose cutting speed 𝑣𝑐 = 180 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×190
𝜋×53
= 1081 𝑟𝑝𝑚
 Choose n = 1100 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1100 × 0.12 = 132 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1100×53
1000
= 183 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 1 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
26.5
132
= 0.2 min = 12 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 3080 MPa
𝑃𝑐 =
1 × 183 × 0.12 × 3080
60 × 103
= 1.13 kW < 5.5kW machine capacity
• Choosing cutting tool:
Insert for rough boring: CCMT 06 02 08-UM 1515
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Figure 3.6 CCMT 06 02 08-UM 1515insert (Sandvik)
Table 3.7 CCMT 06 02 08-UM 1515 specifications
Blade
length
(LE)
(mm)
5.6
Major
cutting
edge
angle
(KRINS)
95
Tool tip
radius
(RE)
(mm)
0.8
Thickness
(S) (mm)
2.4
Inscribed
circle
diameter (IC)
(mm)
Suitable
material
Suitable
machining
process
6.4
Steel,
stainless
steel
Rough
Boring bar for rough boring: E12Q-SCLCR 06-R
Figure 3.7 E12Q-SCLCR 06-R boring bar
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Table 3.8 E12Q-SCLCR 06-R specifications
Tool
cutting
edge angle
(KAPR)
95
Hand
Right
Shank
height
(H)
Body
diameter
(BD)
Functional
length
(LF)
Functional
width
(WF)
(mm)
(mm)
(mm)
(mm)
11
12
180
9
Minimum
bore
diameter
(DMIN1)
(mm)
Maximum
overhang
(OHX)
Minimum
overhang
(OHN)
Connection
diameter
(DCON)
(mm)
(mm)
(mm)
72
25
16
16
Tool shank for rough boring: 131-2512-B rectangular shank
Figure 3.8 131-2512-B rectangular shank
Table 3.9 131-2512-B rectangular shank specifications
Shank Shank Functional Functional Functional
width height
length
width
height
(B)
(H)
(LF)
(WF)
(HF)
Overall
length
(OAL)
Connection
diameter
(DCON)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
25
25
80
9
12.5
80
12
Insert for rough turning: CNMG 12 04 12-MR 4335
Figure 3.9 CNMG 12 04 12-MR 4335 insert (Sandvik)
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Torque
(Nm)
0.9
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Table 3.10 CNMG 12 04 12-MR 4335 specifications
Blade
length
(LE)
(mm)
Major
cutting
edge
angle
(KRINS)
Tool tip
radius
(RE)
(mm)
11.7
95
1.2
Thickness
(S) (mm)
Inscribed
circle
diameter (IC)
(mm)
Suitable
material
Suitable
machining
process
4.8
12.7
Steel
Rough
Insert for finishing turning: CNMG 12 04 12-WF 1515
Figure 3.10 CNMG 12 04 12-WF 1515 insert (Sandvik)
Table 3.11 CNMG 12 04 12-WF 1515specifications
Blade
length
(LE)
(mm)
11.7
Major
cutting
edge angle
(KRINS)
95
Tool tip
radius Thickness
(RE)
(S) (mm)
(mm)
1.2
4.7625
Inscribed
circle
diameter
(IC) (mm)
Suitable
material
Suitable
machining
process
12.7
Steel,
Stainless
steel
Finishing
Turning tool: DCLNR 2020K 12 (both rough and finishing turning)
Figure 3.11 DCLNR 2020K 12 tool shank
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Table 3.12 DCLNR 2020K 12 specifications
Tool
cutting
edge
angle
(KAPR)
Hand
95
Right
Shank
height
(H)
Shank
width
(B)
Functional Functional Functional Maximum
length
width
height
overhang
(LF)
(WF)
(HF)
(OHX)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
20
20
125
25
20
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3.2.2.2 Task 2: face milling surface 1
• Mounting diagram
• Cutting condition:
Rough milling: IT 13, Ra 12.5
Feed per tooth:
fz max
2
2R
= 2 × √RE 2 − (RE − 3t )
10
= 2 × √0.82 − (0.8 −
2 × 12.5 2
) = 0.4 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 170 <vC <235,
0.16 <fz <0.4 ➔Choose fz = 0.2 mm/tooth
45
Torque
(Nm)
3.9
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Choose cutting speed 𝑣𝑐 = 200 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
=
𝜋𝐷
1000×200
𝜋×63
= 1010 𝑟𝑝𝑚
 Choose n = 1000 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1000×63
1000
= 197 𝑚/𝑚𝑖𝑛
Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.2 × 1000 × 5 = 1000 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
𝑛
=
1000
1000
= 1 mm/rev
Depth of cut: ap = 2.3 mm, cut 2 times
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑣𝑓
=
40.3+63
1000
× 2 = 0.2 min = 12 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×103
According to table 3.13, Kc = 1800 MPa
𝑃𝑐 =
2.3 × 33 × 1000 × 1800
60 × 106
= 2.3 kW < 5.5kW machine capacity
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Table 3.13 Specific cutting force for milling
Semi-Finishing milling: IT 12, Ra 6.3
Feed per tooth:
fz max
2
2R
= 2 × √RE 2 − (RE − 3t )
10
= 2 × √0.82 − (0.8 −
2 × 6.3 2
) = 0.28 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 170 <vC <235,
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0.16 <fz <0.4 ➔Choose fz = 0.16 mm/tooth
Choose cutting speed 𝑣𝑐 = 220 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
=
𝜋𝐷
1000×220
𝜋×63
= 1111 𝑟𝑝𝑚
 Choose n = 1100 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
=𝜋
1000
1100×63
1000
= 218 𝑚/𝑚𝑖𝑛
Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.16 × 1100 × 5 = 880 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
𝑛
=
880
1100
= 0.8 mm/rev
Depth of cut: ap = 1 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑣𝑓
=
40.3+63
880
= 0.12 min = 7.2 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×103
According to table 3.13, Kc = 1800 MPa
𝑃𝑐 =
1 × 33 × 880 × 1800
60 × 106
= 0.9 kW < 5.5kW machine capacity
• Selecting Cutting Tool:
For rough milling, we select insert and cutting tool as follows:
Inserts: 345R-1305M-PM 4340
Figure 3.12 345R-1305M-PM 4340 inserts
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Table 3.14 345R-1305M-PM 4340 specifications
Wiper Blade
Tool tip
Cutting
length
edge
radius (RE) Thickness
angle
(LE)
length
(S) (mm)
(KRINS)
(mm)
(mm) (mm)
2
8.8
45
0.8
5.05
Suitable
material
Suitable
machining
process
Steel, Cast
iron
Rough to
finishing
Milling cutter: 345-063Q22-13M of Sandvik with SK40FMB22-50 taper
Figure 3.13 345-063Q22-13M face Milling Cutter
Table 3.15 345-063Q22-13M milling cutter specification
Cutting
angle
(KAPR)
45
Cutting
diameter Flutes
(DC) (m)
63
Maximum
depth of
cut
(APMX)
(mm)
Connection
diameter
(DCON)
(mm)
Suitable
application
6
22
Medium
5
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3.2.2.3 Task 3: Turning Surfaces 2, 4 and surface 10
• Mounting diagram
• Cutting condition:
Rough turning surface 2: IT 13, Ra 12.5
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
12.5×8×1.2
1000
= 0.35 mm/rev
CNMG 12 04 12-MR 4335 insert is selected with 145
<vC <200, 0.3<fn<0.75 and 1.5<ap<8
Choose cutting speed 𝑣𝑐 = 150 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×150
𝜋×40
= 1193 𝑟𝑝𝑚
 Choose n = 1200 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1200 × 0.35 = 420 𝑚𝑚/𝑚𝑖𝑛
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Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1200×40
= 151 𝑚/𝑚𝑖𝑛
1000
Depth of cut: ap = 1 mm, cut 3 times
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
50
420
× 3 = 0.36 min=21.6 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2450 MPa
𝑃𝑐 =
1 × 151 × 0.35 × 2450
60 × 103
= 2.2 kW< 5.5kW machine capacity
Rough turning surface 4: IT 13, Ra 12.5
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
12.5×8×1.2
1000
= 0.35 mm/rev
CNMG 12 04 12-MR 4335 insert is selected with
145 <vC <200, 0.3<fn<0.75 and 1.5<ap<8
Choose cutting speed 𝑣𝑐 = 150 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×150
𝜋×40
= 1193 𝑟𝑝𝑚
 Choose n = 1200 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1200 × 0.35 = 420 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1200×40
1000
= 151 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 0.4 mm, cut 3 times
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
8
420
× 3 = 0.06 min = 3.6 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2450 MPa
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Manufacturing Engineering Project
𝑃𝑐 =
PhD. Ton Thien Phuong
0.4 × 151 × 0.35 × 2450
60 × 103
= 0.9 kW< 5.5kW machine capacity
Rough turning surface 10: IT 13, Ra 12.5
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
12.5×8×1.2
1000
= 0.35 mm/rev
CNMG 12 04 12-MR 4335 insert is selected with 145
<vC <200, 0.3<fn<0.75 and 1.5<ap<8
Choose cutting speed 𝑣𝑐 = 150 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×150
𝜋×75
= 636 𝑟𝑝𝑚
 Choose n = 700 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 700 × 0.35 = 245 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
700×75
1000
= 165 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 3 mm, cut 3 times
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
15
245
× 3 = 0.18 min=10.8 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2450 MPa
𝑃𝑐 =
3 × 165 × 0.35 × 2450
60 × 103
= 5.3 kW < 5.5kW machine capacity
Semi-Finishing turning surface 2: IT 12, Ra 6.3
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
6.3×8×1.2
1000
= 0.25 mm/rev
CNMG 12 04 12-WF 1515 insert is selected with
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45 <vC <260, 0.1<fn<0.55 and 0.4<ap<4
Choose cutting speed 𝑣𝑐 = 180 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×180
𝜋×36
= 1591 𝑟𝑝𝑚
 Choose n = 1500 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1500 × 0.25 = 375 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1500×36
= 170 𝑚/𝑚𝑖𝑛
1000
Depth of cut: ap = 2.3 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
50
375
= 0.13 min = 7.8 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2570 MPa
𝑃𝑐 =
2.3 × 170 × 0.25 × 2570
60 × 103
= 4.19 kW < 5.5kW machine capacity
Semi-Finishing turning surface 4: IT 12, Ra 6.3
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
6.3×8×1.2
1000
= 0.25 mm/rev
CNMG 12 04 12-WF 1515 insert is selected with
45 <vC <260, 0.1<fn<0.55 and 0.4<ap<4
Choose cutting speed 𝑣𝑐 = 180 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×180
𝜋×36
= 1591 𝑟𝑝𝑚
 Choose n = 1500 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1500 × 0.25 = 375 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
53
𝑛×𝐷𝐶
1000
=𝜋
1500×36
1000
= 170 𝑚/𝑚𝑖𝑛
Manufacturing Engineering Project
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Depth of cut: ap = 1 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
8.15
375
= 0.03 min = 1.8 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2570 MPa
𝑃𝑐 =
1 × 170 × 0.25 × 2570
60 × 103
= 1.8 kW < 5.5kW machine capacity
Semi-Finishing turning surface 10: IT 12, Ra 6.3
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
6.3×8×1.2
1000
= 0.25 mm/rev
CNMG 12 04 12-WF 1515 insert is selected with
45 <vC <260, 0.1<fn<0.55 and 0.4<ap<4
Choose cutting speed 𝑣𝑐 = 180 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×180
𝜋×59
= 971 𝑟𝑝𝑚
 Choose n = 1000 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 1000 × 0.25 = 250 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
1000×59
1000
= 185 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 2 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
15
250
= 0.06 min = 3.6 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 2570 MPa
𝑃𝑐 =
2 × 185 × 0.25 × 2570
60 × 103
= 4 kW < 5.5kW machine capacity
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• Selecting Cutting Tool
Insert for rough turning: CNMG 12 04 12-MR 4335
Figure 3.14 CNMG 12 04 12-MR 4335 insert (Sandvik)
Table 3.16 CNMG 12 04 12-MR 4335 specifications
Blade
length
(LE)
(mm)
Major
cutting
edge
angle
(KRINS)
Tool tip
radius
(RE)
(mm)
11.7
95
1.2
Thickness
(S) (mm)
Inscribed
circle
diameter (IC)
(mm)
Suitable
material
Suitable
machining
process
4.8
12.7
Steel
Rough
Insert for finishing turning: CNMG 12 04 12-WF 1515
Figure 3.15 CNMG 12 04 12-WF 1515 insert (Sandvik)
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Table 3.17 CNMG 12 04 12-WF 1515specifications
Blade
length
(LE)
(mm)
Major
cutting
edge angle
(KRINS)
11.7
95
Tool tip
radius Thickness
(RE)
(S) (mm)
(mm)
1.2
4.7625
Inscribed
circle
diameter
(IC) (mm)
Suitable
material
Suitable
machining
process
12.7
Steel,
Stainless
steel
Finishing
Turning tool: DCLNR 2020K 12 (both rough and finishing
turning)
Figure 3.16 DCLNR 2020K 12 tool shank
Table 3.18 DCLNR 2020K 12 specifications
Tool
Shank Shank Functional Functional Functional Maximum
cutting
height width
length
width
height
overhang Torque
edge
Hand (H)
(B)
(LF)
(WF)
(HF)
(OHX)
(Nm)
angle
(mm) (mm)
(mm)
(mm)
(mm)
(mm)
(KAPR)
95
Right
20
20
125
56
25
20
32
3.9
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3.2.2.4 Task 4: Drilling Holes 11, 13, 15, 17
• Mounting Diagram
• Choosing cutting tool:
Drilling tool: solid carbide drill 460.1-0550-017A0-XM GC34
(Sandvik)
Figure 3.17 460.1-0550-017A0-XM GC34 drill bit
Table 3.19 460.1-0550-017A0-XM GC34 drill bit specification
Point
angle
(SIG)
140
Cutting
diameter
(DC)
(mm)
5.5
Rotational
speed
maximum
(RPMX)
14,469
Chip
flute
length
(LCF)
Usable
length
(LU)
(mm)
Connection
diameter (DCON)
Achievable hole
tolerance
Suitable
material
H9
Steel, cast
iron, hard
material
(mm)
(mm)
17.3
28
57
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• Cutting condition:
Drill holes 11, 13, 15, 17: IT 13
Recommended feed rate according to diameter of drill is:
f = 0.1 mm/rev
Table 3.20 Cutting speed for drilling
Cutting speed: according to table 3.20, choose cutting speed Vc
for medium carbon steel 𝑉𝑐 = 22 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =

1000×𝑣𝑐
𝜋𝐷
=
1000×22
𝜋×5.5
= 1273 𝑟𝑝𝑚
Choose n = 1200 rpm
Penetration rate: 𝑣𝑓 = 𝑛 × 𝑓 = 1200 × 0.1 = 120 𝑚𝑚/𝑚𝑖𝑛
Machining time: T𝒄 =
𝒍𝒎
𝒗𝒇
58
=
𝟖
𝟏𝟐𝟎
= 0.07 min = 4.2 sec
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3.2.2.5 Task 5: Milling Surfaces 12, 16
• Mounting diagram
• Cutting condition:
We use 2 discs milling to machine parallel surfaces
Rough milling: IT 13, Ra 12.5
Feed per tooth:
fz max
2
2R
= 2 × √RE 2 − (RE − 3t )
10
= 2 × √0.82 − (0.8 −
2 × 12.5 2
) = 0.4 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 190 <vC <250,
0.06 <fz <0.3 ➔Choose fz = 0.1 mm/tooth
Choose cutting speed 𝑣𝑐 = 200 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
59
=
1000×200
𝜋×100
= 636 𝑟𝑝𝑚
Manufacturing Engineering Project
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 Choose n = 700 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
700×100
1000
= 220 𝑚/𝑚𝑖𝑛
Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.1 × 700 × 8 = 560 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
560
=
𝑛
700
= 0.8 mm/rev
Depth of cut: ap = 15 mm, distance between 2 discs is 47 mm
𝐿
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝑣𝑓
=
53+100
560
= 0.28 min = 16.8 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×106
According to table 3.13, Kc = 1980 MPa
𝑃𝑐 =
7 × 14.8 × 560 × 1980
60 × 106
= 1.9 kW < 7.5kW machine capacity
Semi finishing milling: IT 12, Ra 6.3
Feed per tooth:
fz max = 2 × √RE 2 − (RE −
= 2 × √0.82 − (0.8 −
2Rt 2
103
)
2 × 6.3 2
) = 0.28 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 190 <vC <250,
0.06 <fz <0.3 ➔Choose fz = 0.06 mm/tooth
Choose cutting speed 𝑣𝑐 = 240 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×240
𝜋×100
= 763 𝑟𝑝𝑚
 Choose n = 750 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
60
=𝜋
750×100
1000
= 236 𝑚/𝑚𝑖𝑛
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Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.06 × 750 × 8 = 360 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
=
𝑛
600
750
= 0.8 mm/rev
Depth of cut: ap = 15 mm, distance between 2 discs is 44 mm
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑣𝑓
=
53+100
360
= 0.425 min = 25.5 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×103
According to table 3.13, Kc = 1980 MPa
𝑃𝑐 =
1.5 × 15 × 360 × 1980
60 × 106
= 0.4 kW < 7.5kW machine capacity
• Selecting cutting tool
Insert: N331.1A-11 50 08M-PM4040 from Sandvik
Figure 3.18 N331.1A-11 50 08M-PM4040 insert
Table 3.21. N331.1A-11 50 08M-PM4040 specification
Corner
Insert Cutting edge
Thickness
Cutting
Suitable
effective
radius
width
Suitable
(S)
angle
machining
(RE)
(W1) length (LE)
material
(KRINS)
process
(mm)
(mm)
(mm)
(mm)
11.5
10.7
90
0.8
61
5
Steel,
Cast iron
Rough to
finishing
Manufacturing Engineering Project
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Milling cutter: L331.52-100S32KM of Sandvik from Sanvik
Figure 3.19 L331.52-100S32KM disc milling cutter
Table 3.22 L331.52-100S32KM milling cutter specifications
Cutting angle
(KAPR)
90
Cutting
diameter (DC)
(mm)
Cutting depth
maximum (CDX)
100
25.5
Connection diameter
(DCON) (mm)
(mm)
62
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3.2.2.6 Task 6: Drilling And Tapping Holes 6, 7, 8, 9:
• Mounting diagram
• Selecting Cutting Tools:
Drilling tool: solid carbide drill 460.1-0420-013A0-XM GC34 from
Sandvik
Figure 3.20 460.1-0420-013A0-XM GC34 drill bit
Table 3.23 460.1-0420-013A0-XM GC34 drill bit specifications
Point
angle
(SIG)
140
Cutting
diameter
(DC)
(mm)
4.2
Rotational
speed
maximum
(RPMX)
18,947
Usable
length
(LU)
(mm)
13.2
63
Chip
flute
length
(LCF)
Connection
diameter
(DCON)
(mm)
Achievable
hole
tolerance
Suitable
material
6
H9
Steel, cast
iron, hard
material
(mm)
24
Manufacturing Engineering Project
PhD. Ton Thien Phuong
Tapping tool: E046M5 - Sandvik
Figure 3.21 E046M5 tap bit
Table 3.24 E046M5 tap bit specifications
Thread
diameter
size
(TDZ)
Thread
diameter
(TD)
(mm)
Premachined
hole
diameter
(PHD)
Thread
pitch
(TP)
Thread
length
(THL)
Usable
length
(LU)
(mm)
(mm)
(mm)
0.8
11.2
22
Connection
diameter
(DCON)
(mm)
Achievable
thread
tolerance
Suitable
material
6H
Steel,
cast iron
(mm)
∅D
M5
5
4.2
5
□
4
• Cutting condition:
Drill holes 6, 7: IT 13
Recommended feed rate according to diameter of tool is:
f = 0.1 mm/rev
Cutting speed: according to table 3.21, choose cutting speed Vc
for medium carbon steel 𝑉𝑐 = 22 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =

1000×𝑣𝑐
𝜋𝐷
=
1000×22
𝜋×4.2
= 1667 𝑟𝑝𝑚
Choose n = 1600 rpm
Penetration rate: 𝑣𝑓 = 𝑛 × 𝑓 = 1600 × 0.1 = 160 𝑚𝑚/𝑚𝑖𝑛
Machining time: T𝒄 =
𝒍𝒎
𝒗𝒇
64
=
𝟒.𝟓×𝟐
𝟏𝟔𝟎
= 0.03 min = 1.8 sec
Manufacturing Engineering Project
PhD. Ton Thien Phuong
Tapping holes 6, 7:
Recommended feed rate according to diameter of tool is:
f = 0.15 mm/rev
Table 3.25 Cutting speed for tapping
Cutting speed: according to table 3.25, choose cutting speed Vc
for medium carbon steel 𝑉𝑐 = 35 𝑓𝑒𝑒𝑡/ min = 10.5 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =

1000×𝑣𝑐
𝜋𝐷
=
1000×10.5
𝜋×5
= 668 𝑟𝑝𝑚
Choose n = 650 rpm
Penetration rate: 𝑣𝑓 = 𝑛 × 𝑓 = 650 × 0.1 = 65 𝑚𝑚/𝑚𝑖𝑛
Machining time: T𝒄 =
𝒍𝒎
𝒗𝒇
65
=
𝟒.𝟓
𝟔𝟓
= 0.07 min = 4.2 sec
Manufacturing Engineering Project
PhD. Ton Thien Phuong
3.2.2.7 Tasks 7: Milling Surfaces 14, 18
• Mounting diagram
• Cutting condition:
We use 2 discs milling to machine parallel surfaces
Rough milling: IT 13, Ra 12.5
Feed per tooth:
fz max = 2 × √RE 2 − (RE −
= 2 × √0.82 − (0.8 −
2Rt 2
103
)
2 × 12.5 2
) = 0.4 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 220 <vC <255,
0.06 <fz <0.3 ➔Choose fz = 0.1 mm/tooth
Choose cutting speed 𝑣𝑐 = 200 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
66
=
1000×200
𝜋×100
= 636 𝑟𝑝𝑚
Manufacturing Engineering Project
PhD. Ton Thien Phuong
 Choose n = 700 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
=𝜋
1000
700×100
1000
= 220 𝑚/𝑚𝑖𝑛
Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.1 × 700 × 8 = 560 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
𝑛
560
=
700
= 0.8 mm/rev
Depth of cut: ap = 15 mm, distance between 2 discs is 47 mm
𝐿
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝑣𝑓
=
53+100
560
= 0.28 min = 16.8 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×103
According to table 3.13, Kc = 1980 MPa
𝑃𝑐 =
3 × 15 × 560 × 1980
60 × 106
= 0.8 kW < 7.5kW machine capacity
Finishing milling: IT 12, Ra 6.3
Feed per tooth:
fz max = 2 × √RE 2 − (RE −
= 2 × √0.82 − (0.8 −
2Rt 2
103
)
2 × 6.3 2
) = 0.28 mm/tootℎ
103
345R-1305M-PM 4340 insert is selected with 220 <vC <255,
0.06 <fz <0.3 ➔Choose fz = 0.06 mm/tooth
Choose cutting speed 𝑣𝑐 = 240 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×240
𝜋×100
= 763 𝑟𝑝𝑚
 Choose n = 750 rpm
Cutting speed: 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
67
=𝜋
750×100
1000
= 236 𝑚/𝑚𝑖𝑛
Manufacturing Engineering Project
PhD. Ton Thien Phuong
Table feed:
𝑣𝑓 = 𝑓𝑧 × 𝑛 × 𝑍 = 0.06 × 750 × 8 = 360 𝑚𝑚/𝑚𝑖𝑛
Feed per revolution: 𝑓𝑛 =
𝑣𝑓
=
𝑛
600
750
= 0.8 mm/rev
Depth of cut: ap = 15 mm, distance between 2 discs is 44 mm
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑣𝑓
=
53+100
360
= 0.425 min = 25.5 sec
𝑎𝑝 ×𝑎𝑒 ×𝑣𝑓 ×𝑘𝑐
60×103
According to table 3.13, Kc = 1980 MPa
𝑃𝑐 =
1.5 × 15 × 360 × 1980
60 × 106
= 0.4 kW < 7.5 kW machine capacity
• Selecting cutting tool
Insert: N331.1A-11 50 08M-PM4040 from Sandvik
Figure 3.22 N331.1A-11 50 08M-PM4040 insert
Table 3.26. N331.1A-11 50 08M-PM4040 specification
Corner
Insert Cutting edge
Thickness
Cutting
Suitable
effective
radius
width
Suitable
(S)
angle
machining
(RE)
(W1) length (LE)
material
(KRINS)
process
(mm)
(mm)
(mm)
(mm)
11.5
10.7
90
0.8
68
5
Steel,
Cast iron
Rough to
finishing
Manufacturing Engineering Project
PhD. Ton Thien Phuong
Milling cutter: L331.52-100S32KM of Sandvik from Sanvik
Figure 3.23 L331.52-100S32KM disc milling cutter
Table 3.27 L331.52-100S32KM milling cutter specifications
Cutting angle
(KAPR)
90
Cutting
diameter (DC)
(mm)
Cutting depth
maximum (CDX)
100
25.5
Connection diameter
(DCON) (mm)
(mm)
69
32
Manufacturing Engineering Project
PhD. Ton Thien Phuong
3.2.2.9 Task 8: Finishing Boring Surface 3
• Mounting diagram
• Cutting condition:
Finishing boring: IT 7, Ra 1.6
Feed per revolution: 𝑓𝑛 = √
𝑅𝑡 ×8×𝑅𝐸
1000
=√
1.6×8×0.8
1000
= 0.1 mm/rev
CCMT 09 T3 08-PF 1515 insert is selected with
150 <vC <310, 0.08<fn<0.27 and 0.15<ap<2
Choose cutting speed 𝑣𝑐 = 160 𝑚/𝑚𝑖𝑛
Spindle speed: 𝑛 =
1000×𝑣𝑐
𝜋𝐷
=
1000×160
𝜋×24
= 2122 𝑟𝑝𝑚
 Choose n = 2100 rpm
Feed rate: 𝑓𝑟 = 𝑛 × 𝑓𝑛 = 2100 × 0.1 = 210 𝑚𝑚/𝑚𝑖𝑛
Cutting speed 𝑣𝑐 = 𝜋
𝑛×𝐷𝐶
1000
=𝜋
2100×24
1000
= 158 𝑚/𝑚𝑖𝑛
Depth of cut: ap = 0.7 mm, cut 1 time
Machining time: 𝑇𝑐 =
Power: 𝑃𝑐 =
𝐿
𝑓𝑟
=
57
210
= 0.27 min = 16.2 sec
𝑎𝑝 ×𝑣𝑐 ×𝑓𝑛 ×𝑘𝑐
60×103
According to table 3.6, Kc = 3080 MPa
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Manufacturing Engineering Project
𝑃𝑐 =
PhD. Ton Thien Phuong
0.7 × 160 × 0.1 × 3080
60 × 103
= 0.57 kW< 5.5kW machine capacity
• Choosing cutting tool:
Insert for both processes: CCMT 09 T3 08-PF 1515
Figure 3.24 CCMT 09 T3 08-PF 1515 insert (Sandvik)
Table 3.28 CCMT 09 T3 08-PF 1515 specifications
Blade
length
(LE)
(mm)
8.9
Major
cutting
edge angle
(KRINS)
95
Tool tip
radius Thickness
(RE)
(S) (mm)
(mm)
0.8
4
Inscribed
circle
diameter
(IC) (mm)
Suitable
material
Suitable
machining
process
9.5
Steel,
Stainless
steel
Finishing
Boring bar for both processes: A16R-PCLNR09
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Manufacturing Engineering Project
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Figure 3.25 A16R-PCLNR09 boring bar
Table 3.29 A16R-PCLNR09 specifications
Tool
cutting
edge
angle
(KAPR)
Hand
95
Right
Shank
height
(H)
Body
diameter
(BD)
Functional
length
(LF)
Functional
width
(WF)
(mm)
(mm)
(mm)
(mm)
20
16
200
11
Minimum
bore
diameter
(DMIN1)
(mm)
20
Maximum
overhang
(OHX)
Minimum
overhang
(OHN)
Connection
diameter
(DCON)
(mm)
(mm)
(mm)
96
33
16
Torque
Tool shank for both processes: 131-2516-B rectangular shank
Figure 3.26 131-2516-B rectangular shank
Table 3.30 131-2516-B rectangular shank specification
Shank Shank Functional Functional Functional
width height
length
width
height
(B)
(H)
(LF)
(WF)
(HF)
Overall
length
(OAL)
Connection
diameter
(DCON)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
25
25
80
10
12.5
80
16
72
(Nm)
3
Manufacturing Engineering Project
PhD. Ton Thien Phuong
CHAPTER 4: DESIGN AND CALCULATION OF FIXTURE
4.1 Requirements for Designing Fixtures
Issues to be noticed when designing fixtures are productivity, quality and
processing cost.
• The fixtures ensures that the positioning and fastening process is fast,
ensuring the shortest machining time.
• The fixtures must contribute to the machining accuracy.
• The price of fixturse should not be too expensive; the structure is
simple and easy to manufacture and assemble; the material must be
easy to find.
• The fixture selected for calculation is the fixture for operation 5 - disc
milling face (12), (16)
Figure 4.1 Operation Drawing For Disc Milling Face (12), (16)
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4.2 Fixture Description
For milling face (12) and (16), we have to fix 3 degrees of freedom, we locate
by hole (3) and face (1) by a round locating pin. Then, we add a clamping force on
the face (5) which will make sure hole (3) and face (1) is fully located.
4.3 Determining Cutting Force
At any instant during the rotation, there is a cutting force component known
as the tangential cutting force, Ft, acting on the edge of the cutter that is tangent to
the cutter body. The magnitude of the tangential force is proportional to the axial
depth of cut, b, the instantaneous chip thickness, t, and is dependent on the type of
material being cut.
There are also components of the cutting force directed from the edge towards
the tool’s center, and along its axis. However, in practice these radial and axial
cutting force components are normally a small fraction of the tangential force; so we
will concentrate only on the tangential cutting force, calling it the cutting force.
It might seem hopelessly complex to calculate cutting forces. Since they vary
continuously during a cut, the workpieces held may vary substantially in size, shape,
and material, and each different part being machined may use many different cutters.
Then, we just consider the maximum force caused produced in our milling process
so that we can determined the appropriate force for clamping.
In the operation that milling faces (12) and (16), the operation was divided in
to rough milling and semi-finishing milling. However, when we consider about the
maximum cutting force occur in this operation, so in this case we just concentrate
on rough milling operation.
Moreover, in conventional milling (up milling), the chip thickness starts at
zero and increases toward the end of the cut. The thick chips and higher temperature
at the exit from cut will cause high tensile stresses that will reduce tool life and often
result in rapid edge failure. It can also cause chips to stick or weld to the cutting
edge, which will then carry them around to the start of the next cut, or cause
momentary edge frittering. Then, the highest cutting force occur when the insert of
the tool cut the highest chip thickness which mean the highest cutting force is
produced when the cutter exit from cut. Then, we will analyze the force of the cutter
impact on the workpiece at the point it exit from cut.
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Manufacturing Engineering Project
PhD. Ton Thien Phuong
Figure 4.2 Different of chip formation of down milling and up milling
Figure 4.3 FBD For Cutting Force In Operation Milling Faces (12) & (16)
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Manufacturing Engineering Project
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As we cutting the part on the faces (12) and (16) by two cutting disc cutting
tools, then axial force can be eliminated. And the maximum cutting force occur in
the rough milling operation.
First, we have to find the maximum power occur in that operation. Following
table 21.2-[10] we can find the specific energy for our operation:
𝑢𝑡 = 6 𝑊𝑠/𝑚𝑚3
Then, we can find the material removal rate (MRR) by equation 24.5-[10]:
𝑀𝑅𝑅 = 𝑤𝑑𝑣 = 15 × 3 × 560 = 25200 (𝑚𝑚3 /𝑚𝑖𝑛)
After that, we can find the maximum power for this operation by [10]:
𝑃 = 6 × 𝑀𝑅𝑅 ×
1
1
= 6 × 25200 ×
= 2520 (𝑊)
60
60
The torque acting on the cutter spindle also can be calculated by noting that
power is the product of torque and the spindle rotational speed (in radians per unit
time). Therefore,
𝑇=
𝑃 2520 × 60
=
= 34.37 (𝑁𝑚)
𝑛
700 × 2𝜋
Then, the maximum cutting force (tangential force) in our operation can be
find by following table 24.1- [10]:
𝐹𝑡 =
𝑇 × 2 34.37 × 2
=
= 687.4 (𝑁)
𝐷
0.1
As the angle of tangential force can only be measured experimentally. Then,
for the most unexpected case, this angle will be 90 degree, which mean tangential
forces have vertical direction.
As our operation is side milling on two faces (12) and (18) which is used 2
disc milling cutters, then the tangential force have to be doubled:
𝐹𝑇 = 2 × 𝐹𝑡 = 2 × 687.4 = 1374.8 N
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Manufacturing Engineering Project
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4.4 Determining Clamping Force
In the operation milling faces (12) and (16), we use the fixture that can create
two clamping forces simultaneously by fastening one bolt and a round pin (shoulder
type) that can create a normal reaction force on face (1). The free body diagram of
clamping force is illustrated in figure 4.4.
Figure 4.4 FBD of workpiece in milling (12), (16) operation
Then to calculate the necessary clamping force (Pc1 and Pc2), we just
concentrate on the normal force N (which is equal to total tangential force 𝐹𝑇 =
1374.8 𝑁).
Equilibrate all of the forces on the Oz axis, we have:
∑ 𝐹𝑧 = 0
N= 𝑃𝑐1 + 𝑃𝑐2
While 𝑃𝑐1 = 𝑃𝑐2 , we have the total necessary clamping force P:
𝑃 = 𝑃𝑐1 + 𝑃𝑐2 = 𝑁 = 1374.8
𝑃𝑐1 = 𝑃𝑐2 =
1374.8
= 687.4 𝑁
2
After getting the necessary clamping force on the workpiece, we multiply
necessary clamping force with a safety factor (SF = 1.5) to get the reality clamping
forces:
𝑃1 = 𝑃2 = 𝑃𝑐1 × 𝑆𝐹 = 687.4 × 2 = 1031.1 𝑁
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Manufacturing Engineering Project
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4.5 Determining Bolt Tightening Force
After getting the clamping force in reality, we can get the bolt tightening force
on the strap clamp fixture by following the figure 4.5 and figure 4.6:
Figure 4.5 Clamping Diagram Of Fixture Of Operation 5
Figure 4.6 Strap Clamp FBD in Operation 5
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First, we have to calculate the elastic forces 𝑠1 and 𝑠2 caused by the springs.
We have the spring parameters as follow:
d = 1.5 mm
D = 13 mm
D1 = 12.25 mm
D2 = 13.75 mm
L = 70 mm
G = 78 × 103 MPa
With :
- d is diameter of material (unit: mm)
- D is coil mean diameter =
D1 +D2
2
(unit: mm)
- D1 is inner diameter of a coil (unit: mm)
- D2 is outer diameter of a coil (unit: mm)
- L is free length (unit: mm)
- G is shear modulus of elasticity (unit: MPa)
The number of active winding can be find by following section 1.1 - [11]:
Na =
L−2×(D2 − 2×d)
d
=
70−2×(13.75−2×1.5)
1.5
=
97
3
≈ 32.333
Then, we select Na = 32.
Then, the spring constant can be found by equation (2), section 1.2.1-[11]
k=
G×d4
8×Na×D3
=
78 × 103 ×1.54
8×32×133
≈ 0.7 N/mm
Then, we can find the elastic force caused by the spring:
𝑠1 = 𝑠2 = 𝑘 × ∆𝑙 = 0.7 × 10 = 7 𝑁
Where:
∆𝑙 is the total change in length of the spring
Following [4], we can find the bolt tightening force acting on the strap
clamp 𝑄1 and 𝑄2 :
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Manufacturing Engineering Project
PhD. Ton Thien Phuong
𝑅𝑐1
𝑃1
26
=
=
𝑄1 − 𝑠1 𝑄1 − 𝑠1 52
 𝑄1 = 𝑄2 = 2 × 𝑃1 + 𝑠1 = 2 × 1031.1 + 7 = 2069.2 𝑁
4.6 Calculation of manufacturing error of fixture
The manufacturing error of fixture is calculated from formula (13, page 35,
equation 7.1)
2
2 +𝜀 2 +𝜀 2 + 𝜀 2 )
𝜀𝑐𝑡 = √𝜀𝑔đ
− (𝜀𝑚
𝑐
𝑘
𝑑𝑐
•
•
•
•
•
•
𝜀𝑐 : standard error
𝜀𝑐𝑡 : fabrication error
𝜀𝑚 : error due to wear of fixtures
𝜀𝑑𝑐 : adjustment error
𝜀𝑘 : clamping error
𝜀𝑔đ : error of mounting
4.6.1 Standard error
Because dimension standards and measurement standards coincide:
=> 𝜀𝑐 = 0
4.6.2 Clamping error
Because clamping force is perpendicular to direction of the machining
surface
=> 𝜀𝑘 = 0
4.6.3 Error due to wear of fixture
Calculated by formula 7.6-[13]
𝜀𝑚 = 𝛽 × √𝑁
𝛽: coefficient depends on structure of the fixtures, we use
locating pin so 𝛽 = 0.3
N: Number of workpieces put on fixture, N = 1000
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PhD. Ton Thien Phuong
𝜀𝑚 = 9 𝜇𝑚
4.6.4 Adjustment error
Erroneous error during assembly, jiggling and adjustment. Adjustment
error depends on the ability of the jig and tool assembler to make
adjustments. However, when designing fixtures, we can take [13, page 49]
𝜀𝑑𝑐 = 10 µm
4.6.5 Mounting error
According to (13, page 36, table 7.3), we get
𝜀𝑔đ = 100 𝜇𝑚
4.6.6 Manufacturing error
2
2 +𝜀 2 +𝜀 2 + 𝜀 2 ) = √1002 − 92 − 02 − 02 − 102 = 99 𝜇𝑚
𝜀𝑐𝑡 = √𝜀𝑔đ
− (𝜀𝑚
𝑐
𝑘
𝑑𝑐
From the result of calculating, we give the technical requirement of the fixture:
• The degree of non-parallelism between the locating surface and the bottom
surface of the jig should not exceed 0.099 mm
• The non-perpendicularity between the center of the locating pin and the
bottom
of the jig is not more than 0.099 mm
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CHAPTER 5: PRODUCT PRICE CALCULATION
Total Product Cost:
𝐴 = 𝐴1 + 𝐴2 + 𝐴3 + 𝐴4 + 𝐴5
With: 𝐴1 : Material cost (VND)
𝐴2 : Processing cost (VND)
𝐴3 : Direct cost (VND)
𝐴4 : indirect cost (VND)
𝐴5 : energy cost (VND)
5.1 Cost Of Materials
- Steel S45C: about 35,000 VND/kg
- Each part weight: 700g = 0.7kg
- Cost of material for 1000 part:
𝐴1′ = 35000 × 0.7 × 1000 = 24500000 VND
- Cost of cutting fluid GB Soluble Cutting Oil 200Liter: 13,000,000 VND
Then, we have the material cost for our manufacturing process:
𝐴1 = 24500000 + 13000000 = 37500000 VND
5.2 Processing Costs
5.2.1 Insert cost
- According to [7, page 594], the total processing cost for a part includes the
costs such as:
* 𝐶ℎ : cost for the time of mounting and removing parts, 𝐶ℎ = 𝐶0 × 𝑇ℎ
* 𝐶𝑚 : cost for processing time, 𝐶𝑚 = 𝐶0 × 𝑇𝑚
* 𝐶𝑐 : cost for the time to change the cutting tool, where n is the
number of parts per tool, 𝐶𝑐 = 𝐶0 ×
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Manufacturing Engineering Project
PhD. Ton Thien Phuong
* 𝐶𝑡 : cost of the cutting tool, where 𝑃𝑡 is the cost of the cutting tool,
𝐶𝑡 =
𝑃𝑡
𝑛
With 𝐶0 : cost of machinery, based on the cost in Vietnamese market
nowadays
𝐶0 = 696000 VND/hr = 11600 VND/min for milling machine
𝐶0 = 568000 VND/hr = 9500 VND/min for turning machine
𝐶0 = 226000 VND/hr = 3800 VND/min for drilling machine
𝑇ℎ : part handling time, [3, table 7.3] (minutes)
𝑇𝑚 : machining time
(minutes)
𝑇𝑡 : tool change time [3, table 7.4]
(minutes)
- Taylor’s Equation for tool life: 𝑽𝒄 × 𝑻𝒏 = 𝑪
With 𝑉𝑐 : cutting speed
𝑇: tool life
(m/mins.)
(mins.)
n and C: representative values in Taylor tool life equation
Table 5.1 n and C value in Taylor tool life equation [7, table 23.2]
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Manufacturing Engineering Project
No. Task
Machined Cutting
surface
tool
PhD. Ton Thien Phuong
Price
n
C
T
np
CCMT
06 02 08UM 1515
248000
0.25 500 383.32 0.39 0.33 1161 0.15
CNMG
12 04 12MR 4335
371000
0.25 500
80.36
0.39 0.08 1004 0.15
1
Rough
Boring
2
Rough
Turning
3
SemiFinishing
Turning
CNMG
12 04 12WF 1515
411000
0.25 500
55.73
0.39
0.2
278
0.15
4
Rough
Milling
345R1305MPM 4340
530000
0.25 500
41.5
0.31
0.2
207
0.5
5
SemiFinishing
Milling
345R1305MPM 4340
530000
0.25 500
27.67
0.31 0.12
230
0.5
6
Rough
Turing
CNMG
12 04 12MR 4335
371000
0.25 500 120.22 0.39 0.36
333
0.15
7
SemiFinishing
Turning
CNMG
12 04 12WF 1515
411000
0.25 500
575
0.15
8
Rough
Turning
CNMG
12 04 12MR 4335
371000
0.25 500 120.22 0.39 0.06 2003 0.15
9
SemiFinishing
Turning
CNMG
12 04 12WF 1515
411000
0.25 500
74.83
0.39 0.03 2494 0.15
10
Rough
Turning
CNMG
12 04 12MR 4335
371000
0.25 500
84.32
0.39 0.18
3
5
1
2
74.83
0.39 0.13
4
10
84
468
0.15
Manufacturing Engineering Project
11
12
PhD. Ton Thien Phuong
SemiFinishing
Turning
CNMG
12 04 12WF 1515
411000
0.25 500
53.36
0.39 0.06
889
0.15
Drilling
460.10550017A0XM
GC34
1494000
0.1
20
35.4
0.55 0.08
442
0.15
346000
0.25 500
26.68
0.55 0.28
95
0.5
346000
0.25 500
20.15
0.55 0.43
46
0.5
1494000
0.1
20
63.76
0.55 0.09
708
0.15
20
13
Rough
Milling
14
SemiFinishing
Milling
11, 13, 15,
17
N331.1A11 50
08M12, 14, 16, PM4040
18
N331.1A11 50
08MPM4040
15
Drilling
6, 7, 8, 9
460.10420013A0XM GC
16
Tapping
6, 7, 8, 9
E046M5
1064000
0.1
165.38 0.55 0.24
689
0.15
17
Finishing
Boring
3
CCMT
09 T3 08PF 1515
289000
0.25 500 123.46 0.39 0.28
440
0.15
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Manufacturing Engineering Project
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No.
Task
Machined
surface
𝑪𝒉
𝑪𝒎
𝑪𝒄
𝑪𝒕
1
Rough Boring
3
3705
3135
1
214
2
Rough Turning
3705
760
1
370
3
Semi-Finishing Turning
3705
1900
5
1478
4
Rough Milling
3596
2320
28
2560
5
Semi-Finishing Milling
3596
1392
25
2304
6
Rough Turning
3705
3420
4
1114
7
Semi-Finishing Turning
3705
1235
2
715
8
Rough Turning
3705
570
1
185
5
1
2
4
9
Semi-Finishing Turning
3705
285
1
165
10
Rough Turning
3705
1710
3
793
3705
570
2
462
2090
304
1
3380
6380
3248
61
3642
6380
4988
126
7522
11
10, 14, 17,
20
Semi-Finishing Turning
11, 13, 16,
19
12
Drilling
13
Rough Milling
14
Semi-Finishing Milling
12, 15, 18,
21
15
Drilling
6, 7, 8, 9
2090
342
1
2110
16
Tapping
6, 7, 8, 9
2090
912
1
1544
17
Finishing boring
3
3705
2660
3
657
63272
29751
266
29215
SUM
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Manufacturing Engineering Project
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5.2.2 Tool holder cost
No.
1
Tool holder
Price
Tool Life
(min)
E12Q-SCLCR 06-R bar
9,707,000
1,051,200
131-2512-B rectangular shank
4,877,000
2,628,000
Task
Rough boring
2
Turning
DCLNR 2020K 12 tool shank
2,612,000
1,051,200
3
Face milling
345-063Q22-13M cutter
16,309,000
1,051,200
4
Disc milling
L331.52-100S32KM cutter
33,623,000
1,051,200
A16R-PCLNR09 bar
9,191,000
1,051,200
131-2516-B rectangular shank
4,877,000
2,628,000
5
Finishing boring
No.
Type
Price
T
1
SK40-FMB22-50 taper
9,740,000
3,153,600
2
F-Arbor SK50
13,408,000
3,153,600
𝑍𝒕 = ∑
𝑇𝑚 × 𝑃𝑟𝑖𝑐𝑒
× 1000 = 𝟑𝟒𝟎𝟎𝟎 (𝑽𝑵𝑫)
𝑇
A2 = (𝐶ℎ + 𝐶𝑚 + 𝐶𝑐 + 𝐶𝑡 ) × 1000 + 𝑍𝑡
= (63272 + 29751 + 266 + 29215) × 1000 + 34000
= 122,504,000 VND
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Manufacturing Engineering Project
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5.3 Direct and Indirect Costs
5.3.1 Direct cost
𝐴3 =
𝑤𝑖 × 𝑡
60
With: 𝑤𝑖 : hourly salary of worker, 𝑤𝑖 = 25,000 VND/hour
𝑡: processing time 1000 part
𝑡 = (∑ 𝑇ℎ + ∑ 𝑇𝑚 + ∑ 𝑇𝑡 ) × 1000
= (7.27 + 3.15 + 3.95) × 1000 = 14370 min
Salary payable to main production worker
𝐴3 = 25000 ×
14370
60
= 5,987,500 VND
5.3.2 Indirect cost
- Hourly salary of secretary: 22000 VND/hour
- Hourly salary of engineer: 40000 VND/hour
- Hourly salary of security: 20000 VND/hour
- Salary of indirect worker according to processing time
𝑍1 =
(22000+40000+20000)×14370
60
= 19,639,000 VND
- Cost of renting manufacturing workshop: 46000 VND/m2/month
- Area of manufacturing workshop: 300m2
- Total time to manufacture 1000 piece:
14.37 × 1000 = 14370 𝑚𝑖𝑛𝑠 = 30 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑎𝑦𝑠 (8 ℎ𝑜𝑢𝑟 𝑝𝑒𝑟 𝑑𝑎𝑦)
- Total cost of renting: 𝑍𝑟𝑒𝑛𝑡 =
46000×300
30
× 30 = 13,800,000 VND
𝐴4 = 𝑍1 + 𝑍𝑟𝑒𝑛𝑡 = 19639000 + 13800000 = 33,439,000 VND
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Manufacturing Engineering Project
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5.3.3 Energy cost
𝐴5 = 𝑄 × 𝐶 × 𝑡
With: Q: average power consumed by the machined (kW)
t: running time of the machine (mins)
C: cost of 1 unit of energy (VND/kW)
𝐴5 = 4.5 × 1650 ×
3.15×1000
60
= 389,813 VND
TOTAL COST:
𝐴 = 𝐴1 + 𝐴2 + 𝐴3 + 𝐴4 + 𝐴5
= 37,500,000 + 122,504,000 + 5,987,500 + 33,439,000 + 389,813
= 199,464,478 VND
Then, Cost per part =
𝐴
1000
=
199464478
1000
≈ 200,000 VND/part
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Manufacturing Engineering Project
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REFERRENCES
[1] ASTM A-600 92a: Standard Specification for Tool Steel High Speed, 2016
[2] Boring | Milling MAPAL Competence Tools with ISO element
[3] Geoffrey Boothroyd, Product Design for Manufacture and Assembly, New
York:
CRC Press.
[4] Guide to Strap Clamps, website: https://www.carrlane.com/engineeringresources/technical-information/manual-workholding/strap-clamps
[5] ISO 8062: Castings - System of dimensional tolerances and machining
allowances, 2007.
[6] Machining Operations & Fixture Layout, website:
https://www.carrlane.com/engineering-resources/technical
information/power-workholding/design-information/machining-operationsfixture-layout
[7] Mikell P. Groover (2010), Fundamentals of Modern Manufacturing
Materials, Processes and Systems, Fourth Edition, Lehigh University
[8] Milling Operation, website: faculty.ksu.edu.sa/sites/default/files/lecture-05milling_-_dr_saqib_2018_final.pdf
[9] SANDVIK Coromart, website: https://www.sandvik.coromant.com/engb/pages/default.aspx
[10] Serope Kalpakjian & Steven R. Schmid (2010), Manufacturing, Engineering
and Technology, 6th Edition, Pearson
[11] Spring Calculations, website: us.misumiec.com/pdf/tech/mech/US2010_fa_p3501_3502.pdf
[12] Surface Finish – 4: Predicting Surface Finishes, website:
http://thevms.net/3engineering/9eng_surface/eng_surface_04.html
[13] Tran Van Dich (2000), so tay va atlat do ga, NXB Khoa hoc va Ky Thuat,
Ha Noi
90