proyecto de mecanizacion(ingles)
TRANSCRIPT
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ESCUELA SUPERIOR POLITCNICA DEL LITORAL
FINAL PROJECT OF MACHINIG PROCESS
CNC-FABRICATION CYCLES
NAME (ID number):
JOSU GAVILANES TRIVIO (200726388)
M.Sc. Gabriel Helguero
PROJECT DELIVERY DATE: 28/01/2011
II TERM YEAR 2010-2011
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Contents1) Objectives .................................................................................................................................... 4
2) Introduction ................................................................................................................................. 4
3) Principles ..................................................................................................................................... 4
3.1) Machining centers and turning centers .............................................................................. 4
3.2) Cutting conditions ............................................................................................................... 5
4) Process ......................................................................................................................................... 6
5) Machining guide .......................................................................................................................... 7
Piece 1 ............................................................................................................................................. 7
Piece 2 ............................................................................................................................................. 9
Piece 3 ........................................................................................................................................... 11
Piece 4 ........................................................................................................................................... 13
Piece 5 ........................................................................................................................................... 14
Piece 6 ........................................................................................................................................... 16
Piece 7 ........................................................................................................................................... 19
Piece 8 ........................................................................................................................................... 22
6) Results ....................................................................................................................................... 24
7) Conclusion ................................................................................................................................. 27
8) Recommendations ..................................................................................................................... 28
9) Bibliography .............................................................................................................................. 28
10) Apendix ................................................................................................................................. 29
10.1) Material ......................................................................................................................... 29
10.2) Tool selections ............................................................................................................... 29
Turning process ......................................................................................................................... 29
Milling process .......................................................................................................................... 33
10.3) Selection of parameters ................................................................................................. 34
10.4) Piece 1 ........................................................................................................................... 36
10.1.1) Material selection and initial dimension ................................................................... 36
10.1.2) Machining time calculation ....................................................................................... 37
10.5) Piece 2 ........................................................................................................................... 40
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10.2.1) Material selection and initial dimension ....................................................................... 40
10.2.2) Machining time and other parameters calculation....................................................... 40
10.6) Piece 3 ........................................................................................................................... 43
10.3.1) Material selection and initial dimension ...................................................................... 43
10.3.2) Machining time and other parameters calculation........................................................ 43
10.7) Piece 4 ........................................................................................................................... 46
10.4.1) Material selection and initial dimension ...................................................................... 46
10.4.2) Machining time and other parameters calculation....................................................... 46
10.8) Piece 5 ........................................................................................................................... 49
10.5.1) Material selection and initial dimension ...................................................................... 49
10.5.2) Machining time and other parameters calculation....................................................... 49
10.9) Piece 6 ........................................................................................................................... 5810.6.1) Material selection and initial dimension ...................................................................... 58
10.6.2) Machining time and other parameters calculation ..................................................... 58
10.10) Piece 7 ........................................................................................................................... 68
10.7.1) Material selection and initial dimension ...................................................................... 68
10.7.2) Machining time and other parameters calculation....................................................... 68
10.11) Piece 8 ........................................................................................................................... 76
10.8.1) Material selection and initial dimension ...................................................................... 76
10.8.2) Machining time and other parameters calculation....................................................... 77
10.12) Calculation Unit Time .................................................................................................... 86
10.13) Budget ........................................................................................................................... 88
10.14) CNC Code ....................................................................................................................... 91
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1)
Objectives
1. To elaborate a fabrication cycle for each one of the die tool pieces. This means to choosethe machine tool and cutting tools for each process. Your cutting tool selection should
contemplate tool materials and geometries. Although it is recommended that you use on-line Sandviks catalog, you can use whichever catalog as long as you include the selectionsheets on your work.
2.
To generate a CNC Fabrication code for each piece of the die tool. This must be done usingINVENTORCAM Software. You should indicate which machine tool you are going to
use for each piece.3.
To prepare a budget for the whole process.4.
To return a written report of all process.
2)
Introduction
In this project we will detail step by step how a mechanical element is made, piece by piece. Forthat we start to draw the parts using the program Inventor. Then we choose the right material foreach of the parts, because depending on the property we need, more tenacity, endurance or highercompression, we choose the kind of steel or bronze. Once ready we will prepare parts step by stepmachining process for each, some only work on a CNC turn, other some work only in a CNC
milling, and another piece need be work in both. But to achieve all that we need to select tools workproperly, for each process, as there are for example to make a longitudinal turning different tools
used to make a profile turning That's why we use the Sandviks catalog. In the case of making aturning process, we must choose the proper plate holder and plates as well as choose appropriatemill to work on the milling machine. The next step is go to Ivan Bohman, where we quote both the
materials and tools you'll use, if there is no tool that initially had planned to use, we should chooseone with similar characteristics. From here we turn to the selection of the parameters of cutting
speed and feed on the lathe, where we have to be careful because choosing a bad combination ofthese parameters we will have a poor surface finish, I even make both the lathe and the cutterworking on a RPM which were not designed. Once we have properly chosen parameters, is just
simply use the formulas found the book to calculate the machining time. Finally we use the programInventorCAM to generate CNC code manufacture of each piece, where we have to indicate that we
will use parameters for each machining process of each piece. All this must be clearly detailed intables that include all processes.
3)
Principles
3.1) Machining centers and turning centers
A machining center is a highly automated machine tool capable of performing multiple machiningoperations under CNC control in one setup with minimal human attention. Typical operations arethose that use a rotating cutting tool, such as milling and drilling. The features that make a
machining center such a productive machine includes:
Automatic tool changing. To change from one machining operation to the next, the cutting
tool must be changed. This is done on machining center under NC program control by an
automatic tool-changer designed to exchange cutters between the machine tool spindle anda tool storage drum. Capacities of these drums commonly range from 16 to 18 cutting tools.
Pallets shuttles. Some machining centers are equipped with two or more pallet shuttleswhich can be automatically transferred to the spindle to machine the workpart. With two
shuttles, the operator can be unloading the previous part and loading the next part while ehmachine tool is engaged in machining the current part. This reduces nonproductive time on
the machine.
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Automatic workpart positioning. Many machining centers have more than three axes. One
of the additional axes is often designed as a rotary table to position the part at same
specified angle relative to the spindle. The rotary table permits the cutter to performmachining on four sides of the part in a single setup.
3.2)
Cutting conditions Turning
Turning
Rotational speed(N) Final diameter() Lineal travel rate( Machining time(Tm)
Milling (Face milling)
Milling
Rotational speed(N) Lineal travel rate( Approach distance(A) a) b)
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Machining time(Tm)
Drilling and related operation
Drilling and related operation
Rotational speed(N)
Lineal travel rate( Machining time(Tm), in a thought hole
Machining time(Tm), in a blind hole
4) Process
i) Draw each of the pieces in the program Inventor.ii) With the help of Ivan Bohmans guide, we choose the material and the initial dimensions of
each piece of work. For that we must considerer the properties that we require for each
piece, in some cases we will need a higher toughness, or a higher ductility. Once chosen thematerial, let the tables to see the dimensions that are in stock, always trying to get thedimensions are slightly larger than the final piece, so we reduced material waste andreduced machining time.
iii) The next step is to select the procedure to reach the final form of a single piece for examplewill be worked around, one in router, and one will be worked around in two and one on a
wire cutter.iv) Select the tools to make operation of the lathe. For that we use Sandvik, as specified in this
type of combination of insert and insert holder required for each operation. For example fora longitudinal turning operation require a slide insert with a position angle of 75 and asquare insert. It is recommended that each insert it chooses not to finish, and for roughing,
but medium, to give a better versatility to our tool.
v)
Also we will repeat the above procedure for choosing strawberries to help us in milling. Inthis case we will choose strawberries universal.
vi)
We chose not to use the drilling on the mill going to perform all operations related to
drilling, so just choose a strawberry to make the holes.vii) From here we will ask for a quote with all materials and tools we used in the machining
process. In the case that no one tool or the size of the material we had originally planned,
we will exchange them for others of similar characteristics.
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viii) Once you have all the tools we select all the cutting parameters for each of the processes.
For that too in the same guide Sandvik going to select the parameters depending on the toolthat we have chosen, the type of material we are working, and resistance quality of each
insert. All these values were found in the tables at the end of the guide. It is recommendedthat the turning process is chosen small advances high speeds to give a better finish and inturn we are removing material.
ix)
With the parameters chosen, we began the machining process, calculating the machiningtime of each piece, taking into account the different processes that will be submitted each
piece to reach its final form. The calculations are very important to take into account is thatthe maximum value of N for is around 2500RPM, and 3500RPM strawberry. If thecalculations we show a higher value than this, then we will have to repeat step 7, only this
time we choose parameters that we fulfill this condition.x) Since we have all the values, the next step is to guide, where practically all of the above
detail.xi) From here we will use the program InventorCAM, where we simulate the different
processes of turning, milling and that we will execute to reach the final shape. For that wehave to put the necessary tools for each process, and the parameters for it. The program willgive us InventorCAM CNC code for machining each piece.
5)
Machining guide
Piece 1
A-B
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/rev) d(mm)
Facing turning
Side A
DDJNL 2020K 15Calibrator 255
1803.75 0.11
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Center point
Side A
-------------------- -------------------- 60 -------- ------- -----
Facing turning
Side B
DDJNL 2020K 15 Calibrator 255 1803.75 0.1 1
4 Center point
Side B
----------------
----------------- 60 --------- -------- ------
5Longitudinal
turning
A-B; L=188mm
DDJNL 2020K 15Calibrator 255 1804.67 0.1 1.5
6 Longitudinalturning
A-B; L=167mm
DDJNL 2020K 15 Calibrator 255 1932.6 0.1 2
7Longitudinal
turning
A-B; L=135mm
DDJNL 2020K 15 Calibrator255 2136.02 0.1 2
8Longitudinal
turning
A-B; L=135mm
DDJNL 2020K 15Calibrator
255 2387 0.1 2
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9Turning: Curve
chamfering
A-B, R=2mm
DDJNL 2020K 15 ---------180 1909.86 0.1 -------
10Longitudinal
turning
B-A, L=11 mm
DDJNL 2020K 15
-------- 255 1932 0.1 2
Piece 2
A-B
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/rev) d(mm)
Facing turning
Side A
DDJNL 2020K 15Calibrator 255
1159.55 0.11
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Center point
Side A
-------------------- -------------------- 60 -------- ------- -----
Facing turning
Side B
DDJNL 2020K 15 Calibrator 255 1159.55 0.1 1
4 Center point
Side B
----------------
----------------- 60 --------- -------- ------
5Longitudinal
turning
A-B; L=35mm
DDJNL 2020K 15Calibrator 255 1159.55 0.1 1
6 Longitudinalturning
A-B; L=25mm
DDJNL 2020K 15 Calibrator 255 1193.66 0.1 3
Milling: End
Milling
ap=15mm
R216.33-15030-AC26P
Dc=15mm
Calibrator100 2122.06
0.054
mm/tee1
Milling: End
Milling
ap=20mm
R216.33-06030-Ak22P
Dc=6mm
Calibrator50 2652.58
0.014
mm/tee1
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Wire-EDM
ap=20mm
------Calibrator
365(Job/s) ------ ----- -----
Piece 3
A-B
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/rev) d(mm
Facing turning
Side A
DDJNL 2020K 15
Calibrator 180 2046.27 0.1 1
Center point
Side A
-------------------- -------------------- ------- -------- ------- -----
Facing turningSide B
DDJNL 2020K 15 Calibrator 180 2046.27 0.1 1
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4 Center point
Side B
--------------------------------- ------ --------- -------- ------
5Longitudinal
turning
A-B; L=85mm
DDJNL 2020K 15Calibrator 180 2046.28 0.1 1.5
6Longitudinal
turning
A-B; L=79mm
DDJNL 2020K 15Calibrator
180 2291.83 0.1 2.5
7 Contour turning
A-B; L=40.23mm
DDJNL 2020K 15 Calibrator180 2228.16 0.1 1
8 Contour turning
A-B; L=48.96mm
DDJNL 2020K 15Calibrator
180 2228.16 0.1 1
9 Contour turning
A-B; L=48.96mm
DDJNL 2020K 15 Calibrator180 2228.16 0.1 2
10Peripheral
Milling: Slab
milling
ap=35mm
R216.34-20050-AK38P
Calibrator
100 1591.55 0.078 1
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Piece 4
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/rev) d(mm
Facing turning
Side A
SDJCL 2020K 11Calibrator 120
830.37 0.151
Facing turning
Side B
SDJCL 2020K 11Calibrator 120 830.37 0.15 1
3Longitudinal
turning
A-B; L=44mm
SDJCL 2020K 11Calibrator 120 830.37 0.15 1
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4Longitudinal
turning
A-B; L=22mm
SDJCL 2020K 11 Calibrator120 868.12 0.15 2
Longitudinal
turning
B-A; L=12mm
SDJCL 2020K 11 Calibrator120 868.12 0.15 2
Longitudinal
turning
(internal)
B-A; L=44mm
SDJCL 2020K 11Calibrator
120 1123.45 0.1 2
Piece 5
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/tee) d(mm
Partial and
End milling
Side A(Up)
Side B(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1.5
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2Partial and
End milling
Side B(Up)
Side A(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1.5
Partial and
End milling
Side C(up)
Side D(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side D(up)
Side C(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
5Partial and
End milling
Side F(Up)
Side G(Down)
R216.24-20050IAK38P
Dc=20mm
L=84mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=7m
6Partial and
End milling
Side G(Up)
Side F(Down)
R216.24-20050IAK38P
Dc=20mm
L=84mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=7m
7Pocket
milling
Side A(Up), =8mm
R216.33-08030-AK28P
Dc=8mmCalibrator
80 3183.09 0.02
Ap1=8m
Ap2=8m
Ap3=6m
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8Pocket
milling
Side A(Up), =20mm
R216.24-20050IAK38P
Dc=20mmCalibrator
100 2652.58 0.036
Ap1=8m
Ap2=8m
Ap3=6m
9Pocket
milling
Side A(Up), =40mm
R216.24-20050IAK38P
Dc=20mmCalibrator 100
1591.54 0.078
Ap1=8m
Ap2=8m
Ap3=6m
0 Tapping
Side A(up), =8mm
T110M8 -------------- 60 ----- ------ 22
Piece 6
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# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/tee) d(mm
Partial and
End milling
Side A(Up)
Side B(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1.5
2Partial and
End milling
Side B(Up)
Side A(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1.5
Partial and
End milling
Side C(up)
Side D(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side D(up)
Side C(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
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5Partial and
End milling
Side F(Up)
Side G(Down)
R216.24-20050IAK38P
Dc=20mm
L=84mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=7m
6Partial and
End milling
Side G(Up)
Side F(Down)
R216.24-20050IAK38P
Dc=20mm
L=84mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=7m
7Pocket
milling
6 hole: =8mm
Side A(Up)
R216.33-08030-AK28P
Dc=8mmCalibrator
80 3183.09 0.02Ap1=5m
Ap2=5m
8Pocket
milling
6 hole: =11mm
Side B(Up)
R216.33-11030-AC22P
Dc=11mmCalibrator 100
2893.3 0.036
Ap1=5m
Ap2=5m
Ap3=2m
Pocket
milling
1 hole: =12mm
Side A(Up)
R216.24-08050EAK19P
Dc=12mmCalibrator 100
2652.58 0.036
Ap1=8m
Ap2=8m
Ap3=6m
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10Pocket
milling
1 hole: =40
Side A(Up)
R216.24-20050IAK38P
Dc=20mmCalibrator 100
1591.54 0.078
Ap1=5m
Ap2=5m
Ap3=2m
11Pocket
milling
1 hole: =44
Side B(Up)
R216.24-20050IAK38P
Dc=20mmCalibrator 100
1591.54 0.078Ap1=5m
Ap2=5m
2 Tapping
Side A(up): =12
T110M12 -------- 60 ---- ---- 22
Piece 7
# Process Description Tool holderCutter conditions
Measurer v(mm/s) N(RPM) f(mm/tee) d(mm
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Partial and
End milling
Side A(Up)
Side B(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
2Partial and
End milling
Side B(Up)
Side A(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side C(up)
Side D(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side D(up)
Side C(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
5Partial and
End milling
Side F(Up)
Side G(Down)
R216.24-20050IAK38P
Dc=20mm
L=130mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=5m
6Partial and
End milling
Side G(Up)
Side F(Down)
R216.24-20050IAK38P
Dc=20mm
L=130mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=5m
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7 Pocket milling
6 hole
Side A(Up), =12mm
R216.24-12050-GAK26P
Dc=12mmCalibrator
100 2652.58 0.036
Ap1=8m
Ap2=8m
Ap3=7m
8 Pocket milling
Side A(Up), =38mm
R216.24-20050IAK38P
Dc=20mmCalibrator
100 1591.54 0.078
Ap1=8m
Ap2=8m
Ap3=7m
9 Pocket milling
Side A(Up), =62mm
R216.24-20050IAK38P
Dc=20mm
Calibrator 1001591.54 0.078
Ap1=8m
Ap2=8m
Ap3=7m
0 Tapping
Side A(up), =12mm
T110M12 -------------- 60 ----- ------ 22
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Piece 8
# Process Description Tool holder Cutter conditions
Measurer v(mm/s) N(RPM) f(mm/tee) d(mm
Partial and
End milling
Side A(Up)
Side B(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side B(Up)
Side A(Down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
Partial and
End milling
Side C(up)
Side D(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
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4Partial and
End milling
Side D(up)
Side C(down)
R216.24-20050IAK38P
Dc=20mm
L=250mm
Calibrator 1001591.54 0.078
1
5Partial and
End milling
Side F(Up)
Side G(Down)
R216.24-20050IAK38P
Dc=20mm
L=130mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=5m
6Partial and
End milling
Side G(Up)
Side F(Down)
R216.24-20050IAK38P
Dc=20mm
L=130mm
Calibrator 1001591.54 0.078
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=5m
7
Pocket
milling
6 hole
Side A(Up), =12mm
R216.24-12050-GAK26P
Dc=12mm
Calibrator
80 3183.09 0.02
Ap1=6m
Ap2=6m
Ap3=6m
Ap4=5m
8Pocket
milling
2 hole: =38mm
Side A(Up)
R216.24-20050IAK38P
Dc=20mmCalibrator 100
1591.54 0.078
Ap1=5m
Ap2=5m
Ap3=3m
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Pocket
milling
2 hole: =42mm
Side B(Up)
R216.24-20050IAK38P
Dc=20mm
Calibrator 1001591.54 0.078
Ap1=5m
Ap2=5m
10Pocket
milling
1 hole: =15mm
Side A(Up)
R216.33-15030-AC26P
Dc=15mmCalibrator
100 2122.060.054
Ap1=5m
Ap2=5m
Ap3=3m
1Pocket
milling
1 hole: =68mm
Side B(Up)
R216.24-20050IAK38P
Dc=20mm
Calibrator 1001591.54 0.078
Ap1=5m
Ap2=5m
6)
ResultsPiece 1
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 0,125 0,01875 0,03125 6 6,175
3 0,125 0,01875 0,03125 6 6,175
5 1,04 0,156 0,26 6 7,456
6 0,865 0,12975 0,21625 0 1,211
7 0,635 0,09525 0,15875 0 0,889
8 0,55 0,0825 0,1375 0 0,77
9 0,0164 0,00246 0,0041 0 0,02296
10 0,055 0,00825 0,01375 6 6,077Tu total 28,77596
Piece 2
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 0,301 0,04515 0,07525 6 6,4214
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3 0,301 0,04515 0,07525 6 6,4214
5 0,301 0,04515 0,07525 6 6,4214
6 0,209 0,03135 0,05225 0 0,2926
7 0,0436 0,00654 0,0109 6 6,06104
8 0,179 0,02685 0,04475 6 6,2506
Tu total 31,86844
Piece 3
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 0,068 0,0102 0,017 6 6,0952
3 0,068 0,0102 0,017 6 6,0952
5 0,41 0,0615 0,1025 6 6,574
6 0,34 0,051 0,085 0 0,476
7 0,18 0,027 0,045 0 0,252
8 0,219 0,03285 0,05475 0 0,30669 0,22 0,033 0,055 0 0,308
10 0,0208 0,00312 0,0052 6 6,02912
Tu total 26,13612
Piece4
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 0,048 0,0072 0,012 6 6,0672
3 0,048 0,0072 0,012 6 6,0672
5 0,353 0,05295 0,08825 6 6,49426 0,169 0,02535 0,04225 0 0,2366
7 0,0291 0,004365 0,007275 6 6,04074
8 0,261 0,03915 0,06525 0 0,3654
Tu total 25,27134
Piece 5
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 1,078 0,1617 0,2695 6 7,5092
2 1,078 0,1617 0,2695 6 7,5092
3 1,078 0,1617 0,2695 6 7,5092
4 1,078 0,1617 0,2695 6 7,5092
5 1,596 0,2394 0,399 6 8,2344
6 1,596 0,2394 0,399 6 8,2344
7 0,516 0,0774 0,129 6 6,7224
8 0,057 0,00855 0,01425 0 0,0798
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9 2,038 0,3057 0,5095 0 2,8532
Tu total 56,161
Piece 6
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 1,078 0,1617 0,2695 6 7,5092
2 1,078 0,1617 0,2695 6 7,5092
3 1,078 0,1617 0,2695 6 7,5092
4 1,078 0,1617 0,2695 6 7,5092
5 1,596 0,2394 0,399 6 8,2344
6 1,596 0,2394 0,399 6 8,2344
7 0,236 0,0354 0,059 6 6,3304
8 0,18 0,027 0,045 6 6,2529 0,057 0,00855 0,01425 6 6,0798
10 1,504 0,2256 0,376 0 2,1056
11 1,65 0,2475 0,4125 6 8,31
Tu total 75,5834
Piece 7
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 1,078 0,1617 0,2695 6 7,5092
2 1,078 0,1617 0,2695 6 7,5092
3 1,078 0,1617 0,2695 6 7,5092
4 1,078 0,1617 0,2695 6 7,5092
5 2,4 0,36 0,6 6 9,36
6 2,4 0,36 0,6 6 9,36
7 0,36 0,054 0,09 6 6,504
8 1,36 0,204 0,34 0 1,904
9 1,12 0,168 0,28 0 1,568
Tu Total 58,7328
Piece 8
Process Tf(min) Taux(min) Trl(min) Ts/n(min) Tu c/p(min)
1 1,078 0,1617 0,2695 6 7,5092
2 1,078 0,1617 0,2695 6 7,5092
3 1,078 0,1617 0,2695 6 7,5092
4 1,078 0,1617 0,2695 6 7,5092
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5 2,4 0,36 0,6 6 9,36
6 2,4 0,36 0,6 6 9,36
7 0,36 0,054 0,09 6 6,504
8 1,32 0,198 0,33 6 7,848
9 0,935 0,14025 0,23375 6 7,309
10 0,037 0,00555 0,00925 6 6,0518
11 1,07 0,1605 0,2675 6 7,498
Tu total 83,9676
7) Conclusion
The manufacture of a simple plate of steel or other material is a simple process that is
simple dresses, but as we demonstrated in this project is the result of a complex process that
starts from the choice of material of the piece, after by the size of it. Later is one of the most
important parts of the process, choosing the tools that help to give me the way I want.
Because if I choose a tool not suitable for that material or geometry of the workpiece at
work I can create the piece is not head out on surface finish or desire to directly influence
the machining time, making it take longer than expected and causing economic losses.
This value of time that leaves us to manufacture all the parts is worth more than if you had
made on a lathe and milling machine manual. But the difference is that for a massproduction process CNC lathe and CNC milling machine is the best solution, because Ioffered almost equal parts with each other, so we are ensuring a quality product to our
buyers.
It is very important to take steps to develop the process of turning and milling in an
appropriate way to better efficiency for the transformation of the piece.
By using the program InventorCAM we realize that times that comes with running the
program with the times that we come to calculate the formulas are different, one could say
that up to 50% error. That's because of two reasons, first is that the program calculates the
time InventorCAM both when working on the board, and the time that the tool is moved to
another job. In contrast to the formulas to calculate and add all those days we only take into
account the time working on the piece. And the second is because in some calculations as in
the holes, to calculate the perimeter of the spiral only use approximations, which lead to
errors in calculations.
The proper selection of parts is a fundamental relationship with the machining time, but thisis hardly reflected in the economic part. This is because we can make a tool confronted with
a diameter 15 and compared with the time it takes to make it confronted a 20 in diameter.
No doubt the diameter 20 is going to take longer, and simple inspection would be the best
tool for the job, seeing it from the standpoint of expediency, but now is about the
economics and to buy a cutter 20 is much more expensive than buying a 15, and if the job
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does not require much use of that Strawberry would have to choose the bit that takes longer
but will eventually be economically viable for us.
8)
Recommendations
When choosing the inserts to work on the lathe, it is preferable to choose carries negative
inserts for machining a slide outside and positive inserts to work internally. When choosing cutting tools for turning process, it is preferable to choose a tool that allows
me to rough while giving a surface finish to the workpiece.
By choosing an appropriate combination of port inserts and inserts in the process of turning,
always choose to give us a better versatility, some processes to work with our tool.
For the milling, it is preferable to choose a universal cutter; with this we are giving you
more versatility to various types of milling work.
It is very important to read the guide machining of each part follow the instructions on the
slides to be turning and milling in an appropriate way the relevant part.
By choosing the parameters of speed and progress in the case of the lathe to give a better
finish and also remove material, it is necessary to choose a high speed and a small advance. While we are the milling process is important that although the ap is high, not giving more
ago to 8 mm and that would decrease the lifetime of the tool.
When choosing the parameters of cutting speed, it is important to note whether the value of
N exceeds the case around the 2500 RPM and in the case of the router 3500 RPM, if this
happens it is necessary to choose a lower speed value.
To choose appropriate setting time, Ts, it is necessary to ask several operators as the
estimated time of placing a piece for each operation, for our calculations we choose a value
of 6 minutes.
To select the appropriate number of tools to buy, we need to look at the time of using it,
since the catalog is based on a life of 15 min. To spend this time this tool no longer works,
so we would have to use another.
When we make a hole in the plates with the dams is necessary to go down in a few passes
to get to the depth of cut.
When choose the mill to work in the milling machine is better to choose those that have
four teeth because it can ensure a quicker and better work surface finish.
9)
Bibliography
http://www.unibague.edu.co/sitios/imecanica/index.php?option=com_content&view=article&id=72:f
abricacion-de-piezas-i&catid=6:semestre-vi&Itemid=17
https://www.serina.es/empresas/cede_muestra/301/TEMA%20MUESTRA.pdf
http://www2.coromant.sandvik.com/coromant/downloads/catalogue/ENG/MC_2009_Klick_ENG_A
.pdf
http://centraltrust.net/ivanbohman/productopdf/acero%20al%20carbono%20para%20maquinarioa.pd
f
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10)
Apendix
10.1)Material
AISI 4340
We chose this material in this piece because we need to have a great resistance to fatigue.In turn, this material combines high strength with good toughness. This material is use in
the piece 1.
AISI 4140
We chose this material in this piece because it has a high resistance for parts that are small,
in turn also has good resistance to fatigue, abrasion and impact. This material is use in the
piece 2,3.
SAE 40
Bronze was chosen because this is going to be a part of the sacrifice of our array, whichwill wear and it is best to wear the most expensive. Although it has good mechanical
strength and is used for parts that are subjected to high loads. This material is use in thepiece 4.
AISI 1045
Carbon steel unalloyed careful manufacturing, with good toughness. Feature is its highuniformity performance. Can supply used condition or treatment thermal quenching and
tempering. This material is used in the piece 5, 6, 7 and 8.
10.2)Tool selections
Turning process
In the piece that required longitudinal turning exterior we use the next port insert and insert
recommendation, this is following the instructions of the Sandviks Guide.
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I nserts
We go to the part of the catalog where the inserts are. We choose a negative insert, with a
rhombic 55. And choose an insert that will help us to finish and rough, so we chose a
middle ground, Medium. The size must be the same that the sizes in the port insert. In this
case is 15.
Now, when we do a longitudinal turning internal, we need change the tool:In this case we must
choose a port insert that can be utilized in a longitudinal turning external and internal. The
kind of tool CoroTurn 107 may work in both.
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In both cases the best combination between port insert and insert is a holder with a rhombic
55 insert and a 93 entering angle.
Port i nsert
I nsert
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Milling process
In the case of milling, select the correct mill; first go to the Sandviks catalog, to choose anappropriate mill for this process.
Like we need more kind of method for work with our mill, the best cutter is the first, with a helix
angle 50, in the case that there is not any mill whit 50 we can chose another whit a helix angle
different. For the process of milling, we will use mill of 6, 8,11,12, ,15 and 20 mm of diameter.
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The process for select another mill whit different helix angle is the same.
10.3)
Selection of parameters
Turning process
For choose the correct parameters, is necessary use the following table (this table is in function of
the resistance of the insert). These are in the final of the Sandviks guide. The cutting speed and
feed rate are in function of the grade for general turning and the depth of cut that we chose must be
between the value that are specified in the table.
This table change with work with another kind of material:
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Exist other table, this table tell us the maximum and minimum ap that we can work in each
process.
Milling process
In the last part of the Sandviks guide we can find the correct parameters necessary for the milling
process. By general the product between the ap and ae always is more than the diameter of the mill.The following parameters are in function of the diameter of the mill (Dc), the hardness of the work
material, ap and ae.
Tapping process
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10.4) Piece 1
10.1.1)
Material selection and initial dimension
Piece 1Material Weight
AISI 4340(705) 2.812 Kg
We chose this material in this piece because we need to have a great resistance to fatigue. In turn,this material combines high strength with good toughness.
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10.1.2)
Machining time calculation
Process #1: Facing (face A)
Process #3: Facing (face B)
Process #5: Longitudinal turning
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Process #6: Longitudinal turning
Process #7: Longitudinal turning (first pass)
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Process #8: Longitudinal turning (second pass)
Process #9: Turning: Curve chamfering
Process #10: Longitudinal turning
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10.5) Piece 2
10.2.1) Material selection and initial dimension
Piece 2Material Weight
Steel AISI 4140(709) 1.1174 Kg
We chose this material in this piece because it has a high resistance for parts that are small, in turn
also has good resistance to fatigue, abrasion and impact.
10.2.2) Machining time and other parameters calculation
Process #1: Facing (face A)
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Process #3: Facing (face B)
Process #5: Longitudinal turning
Process #6: Longitudinal turning
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Process #7: Pocket milling
Process #8: Pocket milling
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10.6)
Piece 3
10.3.1) Material selection and initial dimension
Piece 3Material Weight
Steel AISI 4140(709) 0.4176 Kg
10.3.2) Machining time and other parameters calculation
Process #1: Facing (face A)
Process #3: Facing (face B)
Process #5: Longitudinal turning
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Process #6: Longitudinal turning
Process #7: Contour turning (first pass)
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( )
Process #8: Contour turning (second pass)
( )
Process #9: Contour turning (third pass)
( )
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Process #10: Slab Milling
10.7) Piece 4
10.4.1) Material selection and initial dimensionPiece 4 Material Weight
Bronze SAE 40 0.51 Kg
10.4.2) Machining time and other parameters calculation
Process #1: Facing (face A)
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Process #3: Facing (face B)
Process #5: Longitudinal turning
Process #6: Longitudinal turning
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Process #7: Longitudinal turning
Process #8: Longitudinal turning (internal)
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10.8)Piece 5
10.5.1) Material selection and initial dimension
Piece 4 Material Weight
AISI 1045 4.22 Kg
10.5.2) Machining time and other parameters calculation
Process #1: Partial and end milling
Side A (Up)
Side B (Down)
End milling:
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Partial milling, w=4mm
Process #2: End and partial milling
Side B (Up)
Side A (Down)
End milling:
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Partial milling, w=4mm
Process #3: Partial and end milling
Side C (up)
Side D (down)
End milling:
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Partial milling, w=5mm
Process #4: Partial and end milling
Side D (up)
Side C (down)
End milling:
Partial milling, w=5mm
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Process #5: Partial and end milling
Side F(Up)
Side G(Down)
End milling:
Partial milling, w=2mm
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Process #6: Partial and end milling
Side G(Up)
Side H(Down)
End milling:
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Partial milling, w=2mm
Process #7: Pocket milling
6 hole: =8mm
Side A(Up)
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Process #8: Pocket milling
1 hole: =20mmSide A(Up)
Process #9: Pocket milling
1 hole: =40
Side A(Up)
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10.9)
Piece 6
10.6.1) Material selection and initial dimension
Piece 4 Material Weight
AISI 1045 4.22 Kg
10.6.2) Machining time and other parameters calculation
Process #1: Partial and end milling
Side A (Up)
Side B (Down)
End milling:
Partial milling, w=4mm
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Process #2: End and partial milling
Side B (Up)
Side A (Down)
End milling:
Partial milling, w=4mm
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Process #3: Partial and end milling
Side C (up)
Side D (down)
End milling:
Partial milling, w=5mm
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Process #4: Partial and end milling
Side D (up)
Side C (down)
End milling:
Partial milling, w=5mm
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Process #5: Partial and end milling
Side F(Up)
Side G(Down)
End milling:
Partial milling, w=2mm
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Process #6: Partial and end milling
Side G(Up)
Side H(Down)
End milling:
Partial milling, w=2mm
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Process #7: Pocket milling
Side A(Up)
6 hole: =8mm
Process #8: Pocket milling
Side B(Up)
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6 hole: =11mm
Process #9: Pocket milling
Side A(Up)
1 hole: =12mm
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Process #10: Pocket milling
Side A(Up)
1 hole: =40
Process #11: Pocket milling
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Side B(Up)
1 hole: =44
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10.10)
Piece 7
10.7.1) Material selection and initial dimension
Piece 4 Material WeightAISI 1045 6.38 Kg
10.7.2) Machining time and other parameters calculation
Process #1: Partial and end milling
Side A (Up)
Side B (Down)
End milling:
Partial milling, w=4mm
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Process #2: End and partial milling
Side B (Up)
Side A (Down)
End milling:
Partial milling, w=4mm
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Process #3: Partial and end milling
Side C (up)
Side D (down)
End milling:
Partial milling, w=5mm
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Process #4: Partial and end milling
Side D (up)
Side C (down)
End milling:
Partial milling, w=5mm
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Process #5: Partial and end milling
Side F(Up)
Side G(Down)
End milling:
Partial milling, w=2mm
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Process #6: Partial and end milling
Side G(Up)
Side H(Down)
End milling:
Partial milling, w=2mm
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Process #7: Pocket milling
6 hole: =12mm
Side A(Up)
Process #8: Pocket milling
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1 hole: =38
Side A(Up)
Process #9: Pocket milling
1 hole: =62mm
Side A(Up)
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10.11) Piece 8
10.8.1) Material selection and initial dimension
Piece 4 Material Weight
AISI 1045 6.38 Kg
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10.8.2) Machining time and other parameters calculation
Process #1: Partial and end milling
Side A (Up)
Side B (Down)
End milling:
Partial milling, w=4mm
Process #2: End and partial milling
Side B (Up)
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Side A (Down)
End milling:
Partial milling, w=4mm
Process #3: Partial and end milling
Side C (up)
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Side D (down)
End milling:
Partial milling, w=5mm
Process #4: Partial and end milling
Side D (up)
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Side C (down)
End milling:
Partial milling, w=5mm
Process #5: Partial and end milling
Side F(Up)
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Side G(Down)
End milling:
Partial milling, w=2mm
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Process #6: Partial and end milling
Side G(Up)
Side H(Down)
End milling:
Partial milling, w=2mm
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Process #7: Pocket milling
6 hole: =12mm
Side A(Up)
Process #8: Pocket milling
1 hole: =38
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Side A(Up)
Process #9: Pocket milling
1 hole: =42
Side B (Up)
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Process #10: Pocket milling
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Process #11: Pocket milling
1 hole: =68
Side B (Up)
10.12) Calculation Unit Time
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After we have to calculate the , this time is a average, we chose 6 minute, that is the time in putthe piece in the correct position for do the each process. For example if in the process 2 I need to
change the position of the workpiece the is:
But in the process 3, I dont move the workpiece the
is:
Process Ts(min)
1 6
3 6
5 6
6 0
7 6
8 6
After we add the Ts, Taux, Tm and Ts for each process:
Process Ts(min)
1 6,4214
3 6,4214
5 6,4214
6 0,29267 6,06104
8 6,2506
Finally add all the unit time for obtain the unit time what we use for give the final shape of each
piece:
Piece 1: Tu=31, 87 min
10.13)
Budget
Tool
Quantity Code Description Unit price Total price
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1 DDJNL 2020K 15 $100 $100
1 SDJCL 2020k 11 $110 $110
1 DNMG 150412-PM $13 $18
1 DCET 11T304-UM $18 $18
5
R216.24-
20050IAK38P $620 $3100
1
R216.33-15030-
AC26P $275 $275
1
R216.24-
12050GAK26P $247 $247
1
R216.33-11030-
AC22P $170 $170
1
R216.33-06030-
Ak22P $82 $82
1T110M8
$352 $352
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1T110M12
$638 $638
Total $5110
Amoun
t
Material Kind Unit
Price
Total
Price
1 Acero AISI 4340(705) Redondo(=46mm) 14,06 14,06
1 Acero AISI 4140(709) Redondo(=70mm) 3.91 3.91
1 Acero AISI 4140(709) Redondo(=28mm) 1.65 1.65
1 Bronce SAE 40 (Calidad BS 1400 LG-
2)
Barra perforada (46 x
34)mm
6,21 6,21
2 Acero AISI 1045(760) Platina (25 x 250) mm 27.76 55.52
2 Acero AISI 1045(760) Platina (25 x 250) mm 18.36 36,72
Total $117.97
Cost of labor
Total Hour Cost per hour Cost
6.44 $3.75/h $24.15
Rental machine
Total Hour Cost per hour Cost6.44 $30/h* $193.2
*This price contains the rental of turning machine and milling machine.
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10.14)
CNC Code