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This trail was again made for consistency i.e. how far can we go safely with the same insert without any trouble, and this trial proved successful. The pocket operation was reprogrammed according to the new cutting parameters and a simulation was done using edge cam software and the time to complete this operation was observed to be 6 hours of working time. The time taken to check the insert was not taken into consideration in this simulation. The actual operating time to complete the pocket was 10 hours in the actual machine. The change proved to be successful and it almost matched the results, when the insert change time and some common delay are added to the simulation time.

At each pass the insert conditions were studied and it was observed that there was no insert breakage in the middle of the pass, and it was observed to be normal insert wear. This good performance of the insert helped to reduce the taper thus saving time in the final pass. In this trial a lot number of re pass which was a usual scenario earlier was avoided and the turning operation followed the original program.

Some noticeable points in this operation was that during the final finishing stage there was some push offs and some hump formation in the back squaring area. The increased speed helped to reduce the taper formation in a quick way thus saving a considerable amount of time. This proved to be a good trial ground for removing taper. At the end of this trial it could be said that the pocket operation can be made in this new way at a rough average of 3 times the simulation time done in edge cam software. This is due to the extra time required to check the inserts and other usual delays in the shop floor. This new cutting path helped to reach the standard times for this operation.

4.6 Trial 3

The second trial was successful with the help of the lessons learned from the first trial. The second trial was made on a less tough material, and so the third trial was planned on a bigger size part and also on the toughest material of the product range i.e. on inconel. This trial is also a check for consistency for the new process.

New cutting parameters were tried in this trial, the depth of cut of 33 thousandths used in the previous trial before it touched the interrupted cut performed better, so in this trial the depth of cut is increased to 55 thousandths per side to save some more time. The depth of cut of 15 thousandths in the interrupted cut process worked good in the previous trials and it is maintained the same in this trial as it is a critical factor for insert failure in this operation.

The final finish pass in the process is divided into 4 passes of 10 thousandths each. There is also a check pass at the end of the 4 passes just to make sure to complete the piece with the right tolerance limit. The cutting speed of 100 SFM in the interrupted cut process worked out well and the speed of 120 SFM before the interrupted cut process also worked本论文由英语论文网提供整理，提供论文代写，英语论文代写，代写论文，代写英语论文，代写留学生论文，代写英文论文，留学生论文代写相关核心关键词搜索。