Topic: Manufacturing Processes
Fifty flat pieces of 1 mm thick and initial dimensions as shown in the figure (a) to be milled in a single cut to the final dimensions shown in figure (b) using end milling. The cutter of diameter 25 mm has 10 teeth and rotates at 100 rpm. Horizontal feed of the table is 10 mm/min. Assuming single tooth in contact, the material removal rate will be
- A. 35.7 mm³/s
- B. 37.7 mm³/s
- C. 41.7 mm³/s
- D. 47.7 mm³/s
Answer: C. 41.7 mm³/s
Explanation: The width of the material removed from each piece is 30 mm - 25 mm = 5 mm. With a thickness of 1 mm, the volume removed per piece along the 205 mm length is 5 * 1 * 205 = 1025 mm³. Given the table feed is 10 mm/min, it takes 205 / 10 = 20.5 minutes to travel the entire length. The Material Removal Rate (MRR) per piece is 1025 / (20.5 * 60) = 0.833 mm³/s. For 50 pieces, the total MRR is 50 * 0.833 = 41.67 mm³/s, which rounds to 41.7 mm³/s.