Minimise the Costs of Cutting Tool Trials and Maximise Applicability to Industry

ABSTRACT

In general, it might be difficult to estimating all the cost components that are assumed to be caused by a machined part. The result of improvement model can be used for estimating the cost and analysis, part scheduling, design of manufacturing cell and other manufacturing decision processes which is involve the economics consideration. Even though the scope of this attempt is limited to small-scale manufacturing cell, the concepts of costing have general applicability to all levels in manufacturing operations. By creating a software that can calculated the costing and others parameter is one of the solution. This software give the user some recommendation of the suitable cost, the cutting material and workpiece material can be used in manufacturing process for improvements. The result from the software shows that the cost can be minimised and the production rate can be maximised by using the expensive tool rather than cheap cutting tool such as insert (carbide).

Keywords: Cost, Tool life, Parameters, Cutting tool, Software.

TABLE OF CONTENTS

ABSTRACT………………………………………………..

ACKNOWLEDGEMENTS……………………………………….

TABLE OF CONTENTS………………………………………..

LIST OF FIGURES……………………………………………

LIST OF TABLES…………………………………………….

NOMENCLATURE……………………………………………

1 INTRODUCTION…………………………………………..

1.1 Background and Context……………………………………

1.2 Aim and Objectives……………………………………….

1.3 Overview of Dissertation……………………………………

1.4 Summary……………………………………………..

2 LITERATURE REVIEW………………………………………

2.1 Cutting tool Materials……………………………………..

2.1.1 Types of Cutting Tool Material……………………………..

2.1.2 Insert Materials……………………………………….

2.1.3 Carbide Insert Technology………………………………..

2.2 Tool Wear and Tool life……………………………………

2.2.1 Mechanisms of wear…………………………………….

2.2.2 Types of wear………………………………………..

2.2.3 Parameters influence in Tool wear and Tool life…………………..

2.2.4 Journal related to Tool Wear and Tool Life……………………..

2.3 Machining Parameters……………………………………..

2.3.1 Cutting Speed………………………………………..

2.3.2 Feed Rate…………………………………………..

2.3.3 Depth of Cut…………………………………………

2.3.4 Machining Formula…………………………………….

2.3.5 Journal related to the machining parameters……………………..

2.4 Cutting Fluids…………………………………………..

2.4.1 Types of cutting fluid……………………………………

2.4.1.1 Cutting oils……………………………………….

2.4.1.2 Emulsifiable (Soluble) oils……………………………..

2.4.1.3 Chemical cutting Fluids……………………………….

2.5 Cost…………………………………………………

2.5.1 Fixed Cost…………………………………………..

2.5.2 Variable Cost…………………………………………

2.5.3 Economics of Metal Cutting Operations………………………..

2.5.3.1 Feed Selection…………………………………….

2.5.3.2 Cutting Speed Selection……………………………….

2.5.4 Journal related to the costs………………………………..

2.6 Software………………………………………………

2.6.1 CAD/CAM………………………………………….

2.6.2 CIMCO…………………………………………….

3 METHODOLOGY

3.1 The developed system model…………………………………

3.2 Formulae used in Machining Cost program………………………..

3.2.1 Cost Factors………………………………………….

3.2.2 Cutting Speed for Minimum Cost……………………………

3.2.3 Maximum production rate…………………………………

3.3 Cost Model for Cutting tools…………………………………

3.4 Creating Database for Cutting Tools

3.5 Integrating Database into Program……………………………..

3.5.1 Design Modelling………………………………………

3.5.2 Program Data…………………………………………

3.5.3 CIMCO Testing……………………………………….

3.5.4 Introduce software……………………………………..

4 RESULT AND DISCUSSION…………………………………..

5 CONCLUSION…………………………………………….

5.1 Summary……………………………………………..

5.2 Future Work……………………………………………

5.2.1 Limitations………………………………………….

5.2.2 Recommendations……………………………………..

REFERENCES……………………………………………….

APPENDIX 1 – Tool Table……………………………………….

APPENDIX 2 – Operation Summary…………………………………

APPENDIX 3 – Calculation for Cost Model…………………………….

APPENDIX 4  – Installation guide for CIMCO Edit V7…………………….

LIST OF FIGURES

Figure 1‑1: The production costs division.

Figure 2‑1: Kennametal insert identification system.

Figure 2‑2: Examples of wear in cutting tools. (a) Flank wear; (b) crater wear; (c) chipped cutting edge; (d) thermal cracking on rake face; (e) flank wear and built-up edge; (f) catastrophic failure (fracture).

Figure 2‑3: Plot of experimental data on log-log graph paper.

Figure 2‑4: (a) Tool-life curves for a variety of cutting-tool materials. (b) Relationship between measured temperature during cutting and tool life which is flank wear.

Figure 2‑5: Factors which affect the cost of machining a part.

Figure 2‑6: Effect of cutting speed on total cost of product.

Figure 2‑7: Cost component in a machining operation plotted as a function of cutting speed.

Figure 2‑8: Production time in a machining operation plotted as a function of cutting speed.

Figure 3‑1: Turning process in SolidWorks Software.

Figure 3‑2: SolidCAM operation

Figure 3‑3: Tool Sheet Extra Parameters

Figure 3‑4: WEEK_35_TURN_1_KBP_TURNING.NC data.

Figure 3‑5: CIMCO Edit Software.

Figure 3‑6: Opening Software.

Figure 3‑7: Selecting database

Figure 3‑8: Selecting cutting tool material and workpiece material.

Figure 3‑9: Selecting the NC part-program.

Figure 3‑10: The NC part-program appear in CIMCO.

Figure 3‑11: The list of the machine time produce by toolpath statistics for turning process.

Figure 3‑12: Machine Time.

Figure 3‑13: The machine time appeared in right side of the program.

Figure 3‑14: The Excel Database.

Figure 4‑1: Tool Cost against Cutting Tools

Figure 4‑2: Cutting Speed, meter per minutes.

Figure 4‑3: Tool life, minutes per edges.

Figure 4‑4: Machine Time, minutes per part.

Figure 4‑5: Cost per Part.

 

 

LIST OF TABLES

Table 2‑1: Insert material and their characteristics.

Table 2‑2: Carbide insert grades and machining applications.

Table 2‑3: Allowable average wear lands for cutting tools in various operations.

Table 2‑4: Various of cutting tool materials with typical range of n values.

Table 2‑5: Shop Formula for Turning, Milling and Drilling – English Units

Table 2‑6: Cutting Fluid for Various Materials and Operations.

Table 3‑1: Results of machinability test – example

Table 3‑2: Time and cost data – example

Table 3‑3: Labour rate data – example

Table 4‑1: The result of calculation for HSS and Carbide.

 

NOMENCLATURE

3.3         Cost Model for Cutting tools Sample of situation for machinability tests of a turning operation to find the minimum cost and maximum rate of cutting speeds and the cost per part for each condition (Drozda and Wick, 1983). There are two material of cutting tool was used in the operation which is HSS and Carbide tool. The following parameter that needed to be calculated was given below: A depth of cut = 5.0 mm Feed = 0.15 mm/rev Length of cut on the part to be machined = 330 mm Diameter of the part = 178 mm Setup time per part (load/unload and tool advance time = 10 min Table 3‑1: Results of machinability test – example Tool Type Cutting Speed (m/min) Tool Life (min) HSS 41.4