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f
2
4
Mechanistic Nose
Radius Model
(cont.)
Peak-to-Valley
- 350 -
Planing and
Shaping Modeling
(Use orthogonal Model)
p In Planing the workpiece is mounted on a table that
reciprocates along a straight path. The tool is fixed to a head
that indexes a small distance (feed), normal to the direction of
travel, after each stroke.
p In Shaping the tool reciprocates whilst the workpiece
indexes normal to the direction of travel after each stroke
In both cases cutting is usually in only one direction with the
tool tilted out of the way during the return stroke.
Workpiece
Tool
- 350 -
Shaping and Planing
Typical Parameters
Planing:
Cutting Speeds: up to 2 m/s
Power capacities: 110 Kw (150 hp)
Feeds: 0.5 - 3 mm/stroke
Strokes: as large as 25m
Shaping:
Cutting speeds: 0.3 m/s (typical but some up to 2 m/s)
Return speeds: usually twice as fast
Power capacities: less than 15 Kw (20 hp) typically
Feeds: same as planing
Strokes : up to 1.2 m
Ram reciprocations: up to 150 per min. typically
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Shaping & Planing Terminology
L
d
f
Tool
Workpiece
b
Chip
f = Incremental feed
(distance/pass)
d = depth of cut
b = part width
L = Part length
L' = L + % overstroke
V = Cutting Velocity
(distance/time)
Vr = Speed of return
stroke (dist./time)
Vf = Speed if indexing
stroke (dist./time)
L' = L + % overstroke
Return Stroke
Cutting Stroke
Indexing Stroke
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Shaping and Planing
CycleTimes
Cutting Time per pass = L'/V
Non-cutting Time per pass = L'/Vr + f/Vf
Time per pass = L'/V + L'/Vr + f/Vf
time
MRR
0
Cutting Period
Non-cutting
Period
Time/Pass
- 350 -
Shaping and Planing
Machining Time and MRR
Machining Time: tm = Np ( L'/V + L'/Vr + f/Vf)
Tool engagement time: te = Np (L/V)
Volume of material removed per pass = f x d x L
Number of passes per part: Np = b/f (round up)
Machining Time: tm = Np ( L'/V + L'/Vr + f/Vf)
Tool engagement time: te = Np (L/V)
Average MRR (overall productivity of the operation):
MRR
ave
=
Vol ume of Materi al Removed
Ti me to compl ete the operati on
=
b L d
t
m
- 350 -
Shaping and Planing
MRR and Total Power
MRR
max
= Cutting Velocity x feed x depth
MRR
max
= V f d
Power in Cutting = U
t
x MRR
max .
Total Motor Power =
MRR
max
U
t
E
Where E = Efficiency