Face Milling 절삭동력 계산
- Work material : FC30
- Material of tip : Insert tip
- $D$ (mm) : Cutting diameter (= 100)
- $L$ (mm) : Cutting length (= 200)
- $B$ (mm) : Cutting width (= 60)
- $H$ (mm) : Cutter center distance (= 40)
- $d$ (mm) : Clearance (절삭 깊이) (= 4.0)
- $K_r$ (deg) : Entering angle (= 75)
- $T_r$ (deg) : Top rake angle (= 5)
- $Z$ (EA) : Count of tip (날 수) (= 8)
- $K_{Fs}$ ($\text{kg/mm}^3$) : Material factor
- $V$ (m/min) : Cutting speed (= 100)
- $f_z$ (mm/날) : Feed rate for 1 tooth (= 0.2)
R.P.M (rev/min)
$$RPM = \frac{V \times 1000}{\pi \times D} = \frac{100 \times 1000}{\pi \times 100} = 318.31$$
Feed rate $f$ (mm/rev)
$$f = Z_{eff} \times f_z = 8 \times 0.2 = 1.6$$
Effective number of teeth $Z_{eff} = Z$
Feed rate $F_1$ (mm/min)
$$F_1 = Z_{eff} \times f_z \times RPM = 8 \times 0.2 \times 318.310 = 509.296$$
Cutting Time $T$ (sec)
$$T = \frac{(L + 3.0) \times 60}{F_1} = \frac{(200 + 3.0) \times 60}{509.296} = 23.915$$
Chip량 (Rate of metal removal) $Q$ ($\text{cm}^3\text{/min}$)
$$Q = \frac{B \times d \times F_1}{1000} = \frac{60 \times 4.0 \times 509.296}{1000} = 122.231$$
Average chip thickness $h_m$ (mm)
$$\rho_1 = \sin^{-1}\left(\frac{2H}{D}\right) = \sin^{-1}\left(\frac{2 \times 40}{100}\right) = 53.130^\circ$$
$$\rho_2 = \sin^{-1}\left(\frac{B-H}{0.5 \times D}\right) = \sin^{-1}\left(\frac{60-40}{0.5 \times 100}\right) = 23.578^\circ$$
$$\rho = \rho_1 + \rho_2 = 53.130 + 23.578 = 76.708^\circ$$
$$\rho_r = \rho \times \frac{\pi}{180} = 76.708 \times \frac{\pi}{180} = 1.339\text{ rad}$$
$$L_e = 0.5 \times D \times \rho_r = 0.5 \times 100 \times 1.339 = 66.941\text{ mm}$$
$$h_m = f_z \times \left(\frac{B}{L_e}\right) \times \sin(K_r) = 0.2 \times \left(\frac{60}{66.941}\right) \times \sin(75^\circ) = 0.173\text{ mm}$$
$$h_{m1} = \frac{h_m}{0.913} = \frac{0.173}{0.913} = 0.189\text{ mm}$$
Material factor $K_{Fs}$ ($\text{kg/mm}^3$)
절삭계수표에서 MILLING의 $h_{m1}$ 및 재질로 선택 $K_{Fs} = 202.5$
Top rake angle의 계수 $K_t$
$$K_t = 1 - T_r \times 0.013 = 1 - 5.0 \times 0.013 = 0.935$$
순수절삭동력 $N_o$ (Kw)
$$N_o = \frac{d \times B \times F_1 \times K_{Fs} \times K_t}{60 \times 102 \times 1000} = \frac{4.0 \times 60 \times 509.296 \times 202.5 \times 0.935}{60 \times 102 \times 1000} = 3.782$$
절삭 토크 $M_d$ ($\text{N}\cdot\text{m}$)
$$M_d = \frac{9550 \times N_o}{RPM} = \frac{9550 \times 3.782}{318.310} = 113.445$$
Motor의 선정 = 5.5 kW
계산된 순수절삭동력 $N_o = 3.782\text{ kW}$를 기준으로 한 단계 높은 사양을 채택합니다.
No
(kW) | 초과 | - | 0.8 | 1.3 | 2.6 | 4.1 | 5.9 | 9.2 | 13.1 | 16.5 | 19.1 |
|---|
| 이하 | 0.8 | 1.3 | 2.6 | 4.1 | 5.9 | 9.2 | 13.1 | 16.5 | 19.1 | 26.0 |
|---|
| 효율(η) | 1.88 | 1.7 | 1.4 | 1.34 | 1.27 | 1.2 | 1.15 | 1.15 | 1.15 | 1.15 |
|---|
| 사용 Motor | 1.5 | 2.2 | 3.7 | 5.5 | 7.5 | 11.0 | 15.0 | 19.0 | 22.0 | 30.0 |
|---|
Side Milling 절삭동력 계산
- Work material : SCM318
- Material of tip : Coating tip
- $D$ (mm) : Cutting diameter (= 80)
- $L$ (mm) : Cutting length (= 150)
- $B$ (mm) : Cutting width (= 20)
- $d$ (mm) : Clearance (절삭 깊이) (= 5.0)
- $T_r$ (deg) : Top rake angle (= 3)
- $Z$ (EA) : Count of tip (날 수) (= 6)
- $K_{Fs}$ ($\text{kg/mm}^3$) : Material factor
- $V$ (m/min) : Cutting speed (= 100)
- $f_z$ (mm/날) : Feed rate for 1 tooth (= 0.15)
R.P.M (rev/min)
$$RPM = \frac{V \times 1000}{\pi \times D} = \frac{100 \times 1000}{\pi \times 80} = 397.887$$
Feed rate $f$ (mm/rev)
$$f = Z_{eff} \times f_z = 6 \times 0.15 = 0.9$$
Effective number of teeth $Z_{eff} = Z$
Feed rate $F_1$ (mm/min)
$$F_1 = Z_{eff} \times f_z \times RPM = 6 \times 0.15 \times 397.887 = 358.099$$
Cutting Time $T$ (sec)
$$T = \frac{(L + 3.0) \times 60}{F_1} = \frac{(150 + 3.0) \times 60}{358.099} = 25.635$$
Chip량 (Rate of metal removal) $Q$ ($\text{cm}^3\text{/min}$)
$$Q = \frac{B \times d \times F_1}{1000} = \frac{20 \times 5.0 \times 358.099}{1000} = 35.81$$
Average chip thickness $h_m$ (mm)
$$R = \frac{D}{2.0} = \frac{80}{2.0} = 40$$
$$\rho = \cos^{-1}\left(\frac{R-d}{R}\right) = \cos^{-1}\left(\frac{40 - 5.0}{40}\right)$$
$$\rho_r = \rho \times \frac{\pi}{180} = 0.505\text{ rad}$$
$$L_e = R \times \rho_r = 40 \times 0.505 = 20.214\text{ mm}$$
$$h_m = \frac{f_z \times d}{L_e} = \frac{0.15 \times 5.0}{20.214} = 0.0371\text{ mm}$$
$$h_{m1} = \frac{h_m}{0.913} = \frac{0.0371}{0.913} = 0.0406\text{ mm}$$
Material factor $K_{Fs}$ ($\text{kg/mm}^3$)
절삭계수표에서 MILLING의 $h_{m1}$ 및 재질로 선택 $K_{Fs} = 250.9$
Top rake angle의 계수 $K_t$
$$K_t = 1 - T_r \times 0.013 = 1 - 3.0 \times 0.013 = 0.961$$
순수절삭동력 $N_o$ (Kw)
$$N_o = \frac{d \times B \times F_1 \times K_{Fs} \times K_t}{60 \times 102 \times 1000} = \frac{5.0 \times 20 \times 358.099 \times 250.9 \times 0.961}{60 \times 102 \times 1000} = 1.414$$
절삭 토크 $M_d$ ($\text{N}\cdot\text{m}$)
$$M_d = \frac{9550 \times N_o}{RPM} = \frac{9550 \times 1.414}{397.887} = 33.862$$
Motor의 선정 = 3.7 kW
계산된 순수절삭동력 $N_o = 1.414\text{ kW}$를 기준으로 한 단계 높은 사양을 채택합니다.
No
(kW) | 초과 | - | 0.8 | 1.3 | 2.6 | 4.1 | 5.9 | 9.2 | 13.1 | 16.5 | 19.1 |
|---|
| 이하 | 0.8 | 1.3 | 2.6 | 4.1 | 5.9 | 9.2 | 13.1 | 16.5 | 19.1 | 26.0 |
|---|
| 효율(η) | 1.88 | 1.7 | 1.4 | 1.34 | 1.27 | 1.2 | 1.15 | 1.15 | 1.15 | 1.15 |
|---|
| 사용 Motor | 1.5 | 2.2 | 3.7 | 5.5 | 7.5 | 11.0 | 15.0 | 19.0 | 22.0 | 30.0 |
|---|