Manufacturing Formula Sheet

Cutting Forces 𝑡 𝑟= 𝑡 𝑟 cos 𝛼 tan 𝜙 = 1 − 𝑟 sin 𝛼 Milling 𝑣 𝑁= 𝜋𝐷 𝜏= 𝐴 = × 𝑀𝑅𝑅 = 𝑤𝑑𝑓 𝐿+𝐴 𝑓 𝑃 + (Peripheral) 𝑣= 𝑇 = 𝐹 𝜇 = = tan 𝛽 𝑁 (𝐹 + 𝐹 tan 𝛼) = (𝐹 − 𝐹 tan 𝛼) 𝐹 = 𝐹 sin 𝛼 + 𝐹 cos 𝛼 𝑁 = 𝐹 cos 𝛼 − 𝐹 sin 𝛼 𝐹 = 𝐹 cos 𝜙 − 𝐹 sin 𝜙 𝐴= 𝑑(𝐷 − 𝑑) (Face milling) 𝐴= 𝜌𝑣 𝜌𝑣 + 𝜌𝑔ℎ = 𝑃 + + 𝜌𝑔ℎ + 𝑓 2 2 𝐾= 𝑁𝑦 = 𝐺/√𝐶𝑅 S = CR x.SR [(oC0.5/mm] [oC m/s 2] 𝑅 = =𝑡 𝐹= 𝐾 (𝑇𝑆)𝑤𝑡 𝐷 V-bending, 𝐾 =1.33 Edge bending, 𝐾 =0.33 𝛼 (𝑅 + 𝐾 𝑡) 360 If 𝑅 < 2𝑡, 𝐾 = 0.33 𝐴 = 2𝜋 𝑀𝑅𝑅 = 𝑣 𝑤𝑑 𝑤 𝑟 = 𝑡 𝑛 = 𝑣𝑤𝐶 𝐹𝑣 𝑈= 𝑣 𝑤𝑑 𝑟𝑣 . 𝑑 . 𝐹 =𝐾( ) ( ) 𝑣𝐶 𝐷 𝑇 = 𝑟 𝐶𝑣 . 𝐾𝑑 . ( ) (𝐷) . 𝑣 Forming 𝐷𝑅 = 𝐷 /𝐷 ≤ 2 𝐷 𝐹 = 𝜋𝐷 𝑡(𝑇𝑆)( − 0.7) 𝐷 𝑌 = 𝜀 = 𝑑𝑙/𝑙 𝜀 = ln 𝜎 = 𝐸𝜀 Elastic 𝜎 = 𝐾𝜀 Plastic Economics 𝑇 𝑛 = 𝑇 𝑇 𝐶 𝐶 = 𝐶 𝑇 +𝐶 𝑇 +𝐶 + 𝑛 𝑛 𝐶 𝑣 = 1 −1 𝑇 𝑛 𝑛 𝐶 𝑣 =𝐶 1−𝑛 𝐶 𝑇 +𝐶 1 𝑇 = −1 𝑇 𝑛 1 𝐶 𝑇 +𝐶 𝑇 = −1 𝑛 𝐶 =𝜇 𝑅 𝑓 = 𝑁 × 𝑡𝑎𝑝 _ 𝑝𝑖𝑡𝑐ℎ 𝑡+𝐴 𝑇 = 𝑓 𝐴 𝑣 =𝐴 𝑣 𝐾𝜀 𝑌 = 1+𝑛 𝑡 𝜀 = ln 𝑡 0.4𝜇𝐷 ℎ 𝜀̇ = Extrusion 𝐴 𝑟 = 𝐴 𝜀 = 𝑎 + 𝑏 ln 𝑟 𝑝=𝑌 𝜀 2𝐿 𝐷 𝑃 = 𝑇𝜔 ∙𝜙∙𝜀∙𝑌 𝑟= 𝐴 −𝐴 𝐴 𝑇= 2𝜋𝑅 𝜏 3 𝑌 = 𝐾𝜀 𝑌 = Conversions 𝐾𝜀 1+𝑛 𝜙 = 0.88 + 0.12 𝜀 = ln 𝑟 =𝑓𝑓 𝑅 = =𝑈 𝐴 𝑣 = (1 + 𝜇 cot 𝛼) 𝐷 +𝐷 2 𝐷 −𝐷 𝐿 = 2 sin 𝛼 𝐷= 𝑃 = 2𝜋𝑁𝐹𝐿 𝑝=𝑌 𝜀 + 𝑇 = 0.5𝐹𝐿 𝑃 = 𝐹𝑣 𝐹=𝜎 𝐹 = 𝑝𝐴 𝑃 = 𝐹𝑣 𝑅 𝑡 −𝑡 𝑅 𝑄 𝐴 ℎ =𝐴 ℎ 𝐹 = 𝑌 𝑤𝐿 𝐿= 𝐻 =𝑓𝑓 𝐻 𝐴 1 𝜀 = ln = ln 𝐴 1−𝑟 𝐾 =1+ 𝑑 𝐻 =𝑈 𝑉 Bar/Wire Drawing =𝑄 Kelvin 𝐽/𝑚𝑚 ℎ 𝜀 = ln ℎ 𝐹=𝑌𝐴 𝐾𝜀 1+𝑛 𝑌 = 𝐶𝜀̇ 𝑁= 𝑈 = 3.33 × 10 (𝑇 ) 𝜎 𝐹=𝐾𝑌𝐴 Rolling 𝑃 𝑃𝐷 = 𝐴 𝑌 = 𝐾𝜀 𝑌 = 𝐾𝜀 Drilling Welding 𝑇 𝑇 =𝑇 +𝑇 + 𝑛 Forging = 0.55 --------------------------------------------------------- 𝑅 =𝑟 𝑅 Grinding 𝑣 = 𝜋𝐷𝑁 𝑀𝑅𝑅 = 𝑣 × 𝑓 × 𝑑 𝑓 𝜋𝐷 𝑀𝑅𝑅 = 4 [2] = [um] [CR] = [ C/s] Tool Wear 𝑣𝑇 = 𝐶 𝜎 = 𝐹 /𝐴 𝜃 2 𝐶𝑅 = 14,500 𝜆 𝑅 If 𝑅 ≥ 2𝑡, 𝐾 Turning 𝐴 = 0.5 𝐷 tan 90 − . Surface Finish 𝑣 𝑁= 𝜋𝐷 𝐷 −𝐷 𝑑= 2 𝑓 =𝑁×𝑓 𝐿 𝜋𝐷 𝐿 𝑇 = = 𝑓 𝑓𝑣 𝑣 𝜋𝐷 𝑓 =𝑁×𝑓 . o 𝐹 = 0.4𝑈 𝑣𝑡 . ∆𝑇 = ( ) 𝜌𝐶 𝐾 1 −1 2𝑞 𝑞 = (𝐴 − 𝐴 )/𝐴 𝜆 = 𝑎(𝑇̇ ) SDAS=2 aluminum 𝜆 = 46 𝐶𝑅 𝐴 = 0.5 𝐷 − 𝐷 − 𝑤 --------------------------------------------------------- = 2𝑔ℎ 𝑤(𝐷 − 𝑤) 𝐹 = 𝐹 sin 𝜙 + 𝐹 cos 𝜙 𝐹 cos(𝛽 − 𝛼) cos(𝜙 + 𝛽 − 𝛼) 𝐹 sin(𝛽 − 𝛼) 𝐹 = cos(𝜙 + 𝛽 − 𝛼) 𝐹 cos 𝜙 − 𝐹 sin 𝜙 𝜏= (𝑡 𝑤/ sin 𝜙) 𝛼 𝛽 𝜙 = 45° + − 2 2 𝑃 = 𝐹 𝑣 𝑃 = 𝑃 /𝐸 𝐹𝑣 𝐻𝑃 = 33,000 𝑃 𝐹 𝑈=𝑃 = = 𝑀𝑅𝑅 𝑡 𝑤 Sheet Metal 𝐾𝜀 𝑌 = 1+𝑛 𝐹 = 0.7 ∙ 𝑡 ∙ 𝐿 ∙ 𝑇𝑆 𝑡 𝐿= tan 𝛼 𝐻 = 𝜌𝑉 𝐶 (𝑇 − 𝑇 ) + 𝐻 + 𝐶 𝑇 − 𝑇 𝑉 𝑇 =𝐶 ( ) 𝐴 𝑣 𝐴 =𝑣 𝐴 𝑓 = 𝑁𝑛 𝑓 𝛾 = tan(𝜙 − 𝛼) + 𝑐𝑜𝑡 𝜙 Casting 𝐴 𝐷 𝐿 1 inch = 25.4 mm 1 ft = 12” = 305 mm 1 mm = 0.040” 1 kg = 2.2 lb ¼” ; 1/8”; ½” ; 3/8” ; 5/8” 6+ 3+ 12.7 9.5 16 mm 1 psi = 6.9 kPa 1 k.s.i. = 6.9 MPa 15 p.s.i. = 1 atm = 0.1 MPa 10 Nm = 1 kgf m = 7.4 lbf ft 135 Nm = 100 ft-lb 1 gallon = 3.78 liters (US)

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