As new products are taken on by the manufacturing team operational planning is needed, which involves finding solutions for certain process variables such as tooling geometry, cutting speeds, feed rates and tool life expectancy.

Task 1

During the course of the practical workshop activities, you would have encountered a range of cutting tools, from generating tools (for cutting flat/parallel profiles) to forming tools (for cutting particular profiles).

With reference to the attached drawing (Appendix A), select the cutting tools that you plan to use for performing its required function. Included for each tool selected, identify the material it is made from and cutting angles (as appropriate).

This provides evidence for P3.1

From the previous practical exercises you have performed, you would have turned a mild steel bar from Ø1” to Ø20mm by 80mm long. If the surface/cutting speed for mild steel is 28m/mm and feed/tooth on average is 0.05mm/rev determine what the cutting force will be for this process (use the formula sheet provide). Specific energy = 2 W.s/mm³. Refer to Appendix B for formula sheet.

NB: all workings for calculations to be submitted with report

This provides evidence for P3.2

Calculate the speeds and feed rates for the following (referring to Appendix C):

a)    Spindle speed for turning a mild steel bar of Ø20mm with carbide tipped cutting tool.

b)    Spindle speed for milling a high carbon steel material, using an Ø125mm high-speed steel HSS cutter.

c)    Feed rate using a 4-tooth Ø25mm HSS end mill for cutting brass.

d)    Feed rate using an HSS slot drill for cutting a 12mm wide slot in aluminium.

NB: all workings for calculations to be submitted with report

This provides evidence for P3.3

Task 4

Produce a written report that describes the possible causes of tool wear and catastrophic failure that you could encounter during a manufacturing activity.

NB: If you happen to experience any issues, relating to tool wear or catastrophic failure during your practical activity you can refer to them for this task.

This provides evidence for P3.4

Given that Vtⁿ = C, calculate the tool life expectancy of a High Speed Steel lathe tool operating for 4 hours at a cutting speed of 80 m/min. Once you have determined this, estimate the new cutting speed that will give a tool life of 10 hours (n = 0.125).

NB: all workings for calculations to be submitted with report

This provides evidence for P3.5

Practical Activity – the following assessment criteria is to be assessed by means of tutor observation of your performance throughout the manufacturing task.

Perform manufacturing operations to produce the given product (refer to Appendix A) and record your experience in the form of a logbook.

You are going to be assessed against the following:

–       Demonstrating health and safety awareness whilst carrying out practical activities, noting any issues related the manufacture of the product within your logbook.

I, D. Fairbairn (observing teacher), certify that the student (named on front page of this Assignment Brief) demonstrated awareness of health and safety during the manufacturing activity.

Observer sign & date: ……………………………/…………………….

Student sign & date: ……………………………/…………………….

This provides evidence for P4.1

–       Correct selection and setup of equipment (machine and cutting tools) required for manufacturing the product.

I, D. Fairbairn (observing teacher), certify that the student (named on front page of this Assignment Brief) selected, set up and used appropriate equipment for manufacturing the product.

Observer sign & date: ……………………………/…………………….

Student sign & date: ……………………………/…………………….

This provides evidence for P4.2

–       Produce the given product to specification whilst following your plan, including the completion of the attached Specification Check Sheet (see Appendix D).

I, D. Fairbairn (observing teacher), certify that the student (named on front page of this Assignment Brief) produce the product using secondary machining techniques.

Observer sign & date: ……………………………/…………………….

Student sign & date: ……………………………/…………………….

This provides evidence for P4.3

–       To achieve the M3 criteria you will need to include in your logbook the use of images, sketches and/or photographic evidence of the product’s progression. These must be supported by the written detail within the logbook, using appropriate technical language that details the operations performed.

This provides evidence for M3 

Brass

Bronze

Mild Steel

Cast Iron

High Carbon Steel

Hard Alloy Steel

45

30

28

25

18

10

144

96

90

80

58

32

(feed/min)

(feed/tooth)        (No. of teeth)                 (rev/min)

for end mills

for slot drills

3

6

12

25

50

0.013 – 0.025

0.025 – 0.037

0.037 – 0.050

0.050 – 0.064

0.064 – 0.075

0.018

0.025

0.050

0.090

0.130