Politecnico di Milano

Computer Aided Manufacturing

Course project

PRESENTED BY GROUP 39

Abir Kalout 10877973

Joey Sleiman 10950190
Lea Labaki 10950777

January 11, 2024

Contents
1 Notation and Formula 6
1.1 Notation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Reaming . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Introduction of Project Product 8

2.1 Inputs and Variables . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Features and Operations . . . . . . . . . . . . . . . . . . . . . 10
2.3 Precedence Graph . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Detailed Final Solution to Realize Your Product 12

3.1 Throughput of the Product . . . . . . . . . . . . . . . . . . . . 12
3.2 Detailed Information for Your Setups . . . . . . . . . . . . . . . 12
3.2.1 Setup 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.2 Setup 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.3 Setup 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.4 Setup 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Manufacturing Resources . . . . . . . . . . . . . . . . . . . . . 18

4 Verification of operations 22
4.1 Face Milling of Bottom surface . . . . . . . . . . . . . . . . . . 22
4.2 Face Milling of Top Surface . . . . . . . . . . . . . . . . . . . 23
4.3 Pocketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5 Peripheral slab milling roughing . . . . . . . . . . . . . . . . . 25
4.6 Side Through Hole . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Side Blind Hole . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Pin Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 Thread Holes Drilling . . . . . . . . . . . . . . . . . . . . . . . 28
4.10 Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2
 4.11 Through Hole Drilling . . . . . . . . . . . . . . . . . . . . . . 29

5 Discussion on technical requirements 30

3
List of Figures
1 2D Drawing of the Product . . . . . . . . . . . . . . . . . . . . 9
2 Precedence graph . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Picture of the resulted part 1 . . . . . . . . . . . . . . . . . . . 13
4 Picture of the resulted part 2 . . . . . . . . . . . . . . . . . . . 14
5 Picture of the resulted part 3 . . . . . . . . . . . . . . . . . . . 15
6 Picture of the resulted part 4 . . . . . . . . . . . . . . . . . . . 16
7 Finished product . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Roughing milling tools . . . . . . . . . . . . . . . . . . . . . . 19
9 Finishing milling tools . . . . . . . . . . . . . . . . . . . . . . 19
10 Chamfer tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11 Side through hole tools . . . . . . . . . . . . . . . . . . . . . . 20
12 Side blind hole tools . . . . . . . . . . . . . . . . . . . . . . . 20
13 Pin hole tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
14 Threaded hole tools . . . . . . . . . . . . . . . . . . . . . . . . 21
15 Long side through hole tools . . . . . . . . . . . . . . . . . . . 21

List of Tables
1 Table of Constants . . . . . . . . . . . . . . . . . . . . . . . . 6
2 List of features and operations . . . . . . . . . . . . . . . . . . 10
3 Machining time for each setup . . . . . . . . . . . . . . . . . . 12
4 Chosen tool for each feature . . . . . . . . . . . . . . . . . . . 18
5 Tool Features-Bottom Surface Face Milling Tool . . . . . . . . 22
6 Operation Features-Bottom Surface Face Milling Tool . . . . . . 22
7 Tool Power-Bottom Surface Face Milling Tool . . . . . . . . . . 22
8 Tool Features-Top Surface Face Milling Tools . . . . . . . . . . 23
9 Operation Features-Bottom Surface Face Milling Tools . . . . . 23
10 Tool Power-Bottom Surface Face Milling Tools . . . . . . . . . 23
11 Tool Features-Pocketing . . . . . . . . . . . . . . . . . . . . . 24
12 Operation Features-Pocketing . . . . . . . . . . . . . . . . . . 24
13 Tool Power-Pocketing . . . . . . . . . . . . . . . . . . . . . . . 24

4
14 Tool Features-Slot Slab Milling Tool . . . . . . . . . . . . . . . 25
15 Operation Features-Slot Slab Milling . . . . . . . . . . . . . . . 25
16 Tool Power-Bottom Slot Slab Milling Tool . . . . . . . . . . . . 25
17 Tool Features-Corner Surface Slab Milling Tool . . . . . . . . . 25
18 Operation Features-Corner Surface Slab Milling Tool . . . . . . 25
19 Tool Power-Corner Surface Slab Milling Tool . . . . . . . . . . 26
20 Tool Features- H10 Drilling Tool . . . . . . . . . . . . . . . . . 26
21 Operation Features-H10 Drilling . . . . . . . . . . . . . . . . . 26
22 Tool Power-H10 Drilling Tool . . . . . . . . . . . . . . . . . . 26
23 Tool Features- H7 Drilling Tool . . . . . . . . . . . . . . . . . 27
24 Operation Features-H7 Drilling . . . . . . . . . . . . . . . . . . 27
25 Tool Power-H10 Reaming Tool . . . . . . . . . . . . . . . . . . 27
26 Tool Features- Pin Hole Drilling Tool . . . . . . . . . . . . . . 28
27 Operation Features-Pin Hole Drilling . . . . . . . . . . . . . . . 28
28 Tool Power-Pin Hole Drilling Tool . . . . . . . . . . . . . . . . 28
29 Tool Features- MF8x1 Drilling Tool . . . . . . . . . . . . . . . 28
30 Operation Features-MF8x1 Drilling . . . . . . . . . . . . . . . 28
31 Tool Power-MF8x1 Drilling Tool . . . . . . . . . . . . . . . . . 29
32 Tool Features-Chamfer . . . . . . . . . . . . . . . . . . . . . . 29
33 Operation Features-Chamfer . . . . . . . . . . . . . . . . . . . 29
34 Tool Power-Chamfer . . . . . . . . . . . . . . . . . . . . . . . 29
35 Tool Features- H10 Drilling Tool . . . . . . . . . . . . . . . . . 30
36 Operation Features-H10 Drilling . . . . . . . . . . . . . . . . . 30
37 Tool Power-H10 Drilling Tool . . . . . . . . . . . . . . . . . . 30
38 Requirement for roughness . . . . . . . . . . . . . . . . . . . . 30

5
1 Notation and Formula
In this section, the notations and formulas used throughout the report are
summarized in the following subsections.

1.1 Notation
Table 1 illustrates the different parameters utilized in the machining
equations along with their notations and unit.
Notation Parameter Unit
Vc Cutting Speed m/min
D Tool Diameter mm
n Spindle Speed rpm
fz Feed per tooth mm/(rev.tooth)
Z Number of Teeth
Vf Feed Velocity mm/min
γ0 Rake Angle rad
hm Cutting Thickness mm
mc Kornberg’s coefficient
kc [Mpa] Cutting Pressure MPa
ae Radial Cutting Depth mm
ap Axial Cutting Depth mm
Pc Cutting Power KW
Rmax Maximum Roughness µm
Ra Theoretical Roughness µm
Table 1: Table of Constants

1.2 Formula
1.2.1 Milling

Spindle speed [RPM]:

Vc × 1000
n= (2)
π×D
Feed velocity [mm/min]:

Vf = z × n × f z (3)

6
 Cutting Pressure [Mpa]:

1 mc γ0
kc = Kc1 × ( ) × (1 − ) (4)
hm 100
Cutting Power [W]:

ae × ap × Vf × kc
Pc = (5)
60 × 106

Maximum roughness [µm]:

(Fz × Z)2 × 103

Rmax = (6)
8×r

Average roughness [µm]:

Rmax
Ra = (7)
4

1.2.2 Drilling

Cutting Power [W]:

Vc × D × fn × kc
Pc = (8)
240 × 103

Feed per tooth [mm/rev.tooth]:

fn
fz = (9)
Z

1.2.3 Reaming

Chip Area [mm2 ]:

Dext − Dint
AD = fz ∗ (10)
2
Cutting Force [N]:
Fc = Kc ∗ AD (11)

7
 Cutting Torque [Nm]:

Dext /2+Dint/2
2
T c = Z ∗ Fc ∗ (12)
1000

Angular speed:
1000 ∗ Vc
ω= (13)
60 ∗ D/2
Cutting Power [W]:
Pc = Tc ∗ ω (14)

2 Introduction of Project Product

2.1 Inputs and Variables

Figure 1 describes the 2D drawing of the desired product; this serves as the
input and the first step in realizing the final product. Before the manufacturing
part, the design part takes place where the 3D model is realized using the design
tool in Fusion 360. According to Fig(1), the below variables are required.
Variables:

• Workpiece Material (V1): P1.4.z.AN

• Threaded holes (V2): M8x1.0

• Distance to the midline (V3): 185 mm

• Stock Size (V4): x:313 mm y:158 mm z:78 mm

The model is completed on the xy plane after sketching the different geometric
shapes; a 2D rectangle centered in the plane. The different drill holes are
sketched using 2D circles. As for the hexagon, it is drawn using the Polygon
tool The "Offset" tool is utilized to create the inner layer of the 2D sketch with
an angle of 45°. The chamfer in the body is created using the "Chamfer" tool
which creates a distance angle chamfer; a 30°chamfer is thus drawn.

8
After the drawing is done, the sketch is extruded into its 3D model to move on
to the machining part where the different operations are done to arrive at the
final desired product.

Figure 1: 2D Drawing of the Product

9
2.2 Features and Operations
Table 2 illustrates the necessary manufacturing features of the product along
with the operations needed to manufacture each. This is based on the 2D sketch
provided in figure 1.

Feature Requirement Number Operation

Bottom surface Ra=12.5 1 Face milling roughing
Side surfaces *2 Ra=12.5 2 Slab milling roughing
3 Face milling roughing
Top Surface Ra=1.6
4 Face milling finishing
Slots Ra=12.5 5 Roughing
6 Pocketing
Pocket Ra=3.2
7 Finishing
Back surface Ra=12.5 8 Slab milling roughing
Back surface Corner Ra=12.5 9 Slab milling roughing
Front surface Ra=12.5 10 Slab milling roughing
11 Drilling
Side Through Hole H10
12 Countersink
13 Drilling
Side Blind Hole H7 14 Reaming
15 Counterboring
16 Drilling
Pin Hole H7
17 Reaming
18 Drilling
Thread Holes M8x1
19 Tapping
Chamfer 20 Chamfer
21 Pilot Hole
Deep Through hole H10
22 Drilling
Table 2: List of features and operations

10
2.3 Precedence Graph

Figure 2: Precedence graph

11
3 Detailed Final Solution to Realize Your Product

3.1 Throughput of the Product

To measure the productivity and efficiency of the manufacturing process,
the throughput of the product is calculated.
The machining times of the setups are already calculated on Fusion360,
including tool changing time and rapid speed, and are shown in table 3. To
obtain the total time, the loading and unloading times must be added with each
being 60 secs.

Setups Machining Time Machining Time (s)

Setup 1 2 mins 50 secs 170
Setup 2 17 mins 15 secs 1035
Setup 3 1 min 48 secs 108
Setup 4 14 mins 19 secs 859
Total 36 mins 12 secs 2172
Table 3: Machining time for each setup

Total time = Load + S1 + unload + load + S2 + unload + load + S3

+ unload + load + S4 + unloadTotal time = 44 mins 12 secs = 0.736666 h

1
Throughput (parts/hour) = = 1.357 parts/h (15)
Total Time

3.2 Detailed Information for Your Setups

The following section presents a detailed description of the different setups
created to realize the product. In total, 4 different setups were utilized.

3.2.1 Setup 1

We chose this setup to machine the bottom of the stock as well as the sides,
hence the fixture is holding the block by its length.

12
 Figure 3: Picture of the resulted part 1

First, the bottom surface is machined by a face milling operation (OP1). Then,
the sides are machined by an end milling operation (OP2) to mimic the slab
milling that is needed.
The process parameters of each operation can be found in section 7.

3.2.2 Setup 2

The second setup is used to perform the following operations:

• Face milling roughing

• Slots

• Pocket roughing

• Back surface

• Back corner surface

• Front surface (semi-circle)

13
 Figure 4: Picture of the resulted part 2

Following the first setup’s operations, the top surface is milled using a face
milling roughing operations (OP3) leaving some stock to be finished later.
Second, the slots are done on the top surface using an end miller (OP5). Third,
the pocket roughing is performed using a pocketing operations with an end
mill (OP6). Finally, the back surface is milled using an end mill (OP8), and the
same tool is used to cut the back surface corner (OP9), as well as the
semi-circle front surface (OP10).

3.2.3 Setup 3

The third setup is used to perform the following operations:

• Side through hole

• Countersink

• Side blind hole

• Side blind hole reaming

14
 Figure 5: Picture of the resulted part 3

• Counterbore

With the third setup, the holes on the side are done. First, the three through
holes with their countersink are done to obtain a 90◦ angle (OP11 and 12).
Then, the three blind holes with a 140◦ angle at the bottom are obtained using
a drilling operation (OP13) followed by a reaming to obtain the requirement of
H7 (OP14), then the counterboring is performed for the larger diameter (OP15).
Finally, for the deep through hole, a pilot hole (OP21) is first made with a depth
of 12 mm to guide the drilling process (OP22).

15
3.2.4 Setup 4

Figure 6: Picture of the resulted part 4

For the last setup, the product is flipped back to the orientation of setup2 but
centered. The following operations are performed:

• Top surface finishing

• Pocket finishing

• Pin hole drilling

• Pin hole reaming

• Thread hole drilling

• Thread hole tapping

16
 • Chamfering

• Pilot hole for deep through hole

• Deep through hole

To finalize the product, the finishing processes as well as the top holes are made.
First, the top face finishing is performed (OP4) as well as the pocket finishing
(OP7). Then, the two pin holes are drilled (OP16) then reamed to obtain the
finish of H7 (OP17). Then, the two threaded holes are drilled (OP18) and then
tapped to get M8x1 (OP19). Then, the overall chamfer of the product is done
(OP20). Finally, for the deep through hole, a pilot hole (OP21) is first made
with a depth of 12 mm to guide the drilling process (OP22) with a change of
orientation from the z direction to the y direction.

Figure 7: Finished product

17
3.3 Manufacturing Resources
Each operation listed in section 2.2 has a corresponding tool to perform the
process. Table 2 presents the tools chosen for this project.

Nb Tool Name Tool Type Fig

1 R300-050Q22-08H Face Milling 8a
2 1K334-2000-300-XD 1730 Pocket Roughing 8b
3 2N342-1000-PD P2BM Roughing 8c
4 1K337-2500-100-XD 1730 Slab Milling roughing 8d
5 RA300-076C6-25M Face Milling finishing 9a
6 1K335-1600-300-XD 1730 pocket finishing 9b
7 316-10CM400-10045G Chamfer 10
8 860.1-0600-049A1-GM Drilling 11a
9 DLE0800S080P090 Countersink 11b
10 860.1-0790-025A1-GM Drilling 12a
11 435.B-0800-A1-XF H10F Reaming 12b
12 MFE1250X02S140 Counterboring 12c
13 860.1-0990-029A1-GM Drilling 13a
14 435.B-1000-A1-XF Reaming 13b
15 860.1-0700-057A1-GM Drilling 14a
16 T300-XM100AB-M8X100 C110 Tapping 14b
17 861.1-0800-024A1-GP GC34 Pilot Drilling 15a
18 861.1-0800-160A1-GM Drilling 15b
Table 4: Chosen tool for each feature

18
(a) Face milling roughing (b) Pocket roughing

(c) Slots tool (d) Peripheral tool

Figure 8: Roughing milling tools

(a) Face milling finishing (b) Pocket Finishing

Figure 9: Finishing milling tools

19
 Figure 10: Chamfer tool

(a) Side through hole drill (b) Side through hole chamfer

Figure 11: Side through hole tools

(a) Side blind hole drill (b) Side blind hole reamer (c) Side blind hole
counterbore

Figure 12: Side blind hole tools

20
 (a) Pin hole drill (b) Pin hole reamer

Figure 13: Pin hole tools

(a) Threaded hole drill (b) Threaded hole tapper

Figure 14: Threaded hole tools

(a) Long side through pilot hole drill (b) Long side through hole drill

Figure 15: Long side through hole tools

21
4 Verification of operations
Using the Sandvik Website and catalogue, the cutting speed Vc chosen for
each operations was interpolated using other steel due to the absence of
P1.4.Z.AN and its recommendation for Vc . Please note, unless stated otherwise
all other values are obtained from the online Sandvik tool recommendation and
formulas. In order to verify the feasibility of the operations we must see
calculate the cutting power and spindle speed needed for each operation and
check whether they comply with the power and rpm requirements.[1] [2] [3]

4.1 Face Milling of Bottom surface

To start,the bottom of the product is milled into its required shape and
roughness. A face-milling operation is done to remove the extra material and
shape the product using tool number 1 from table 4. The required roughness is
Ra = 12.5 µm
To arrive at such specifications the following tool was utilized:

Tool D [mm] Z kr[◦ ] kr’[◦ ] kc [Mpa] Tool Life [min] Nose Radius [mm]
1 42 8 90 45 1896.091 61 4
Table 5: Tool Features-Bottom Surface Face Milling Tool

Tool hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)]

1 0.15 4 33 410 3107 3728.773 0.15
Table 6: Operation Features-Bottom Surface Face Milling Tool

Tool Pc[kW] Feasible

1 15.5542 Yes
Table 7: Tool Power-Bottom Surface Face Milling Tool

The roughness of the tool is calculated as per the shwaltz equation; the
conditions for applying the equation are satisfied.

(Fz × Z)2 × 103

Ra = = 11.25µm (16)
32 × r
22
 (b) Insert used for face
(a) miller

4.2 Face Milling of Top Surface

To machine the top surface of the product, two operations were performed:
face milling roughing (tool number 1) and face milling finishing (tool number
5).
The required roughness at the end is Ra = 1.6 µm
To arrive at such specifications, the tools number 1 and 5, taken from table 4,
were used.
Tool D [mm] Z kr[◦ ] kr’[◦ ] kc [Mpa] Tool Life [min] Nose Radius [mm]
1 42 8 90 45 1896 61 4
5 50.8 4 90 45 1803 100 12.7
Table 8: Tool Features-Top Surface Face Milling Tools

Tool hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)]

1 0.15 3.5 37 410 3107 3729 0.15
5 0.176 0.5 37.5 470 2318 1854 0.2
Table 9: Operation Features-Bottom Surface Face Milling Tools

Tool Pc[kW] Feasible

1 15.2596 yes
5 1.045 yes
Table 10: Tool Power-Bottom Surface Face Milling Tools

The roughness of the tool is calculated as per the shwaltz equation; the
conditions for applying the equation are satisfied.

(Fz × Z)2 × 103

Ra = = 1.57µm (17)
32 × r
23
4.3 Pocketing
To create the pocket of the product, two operations are performed using end
mills: rough pocketing (end mill number 2) and finishing (end mill number 6).
The required roughness is Ra = 3.2 µm
To arrive at such specifications the tools number 2 and 6 from table 4 were
utilized:
Tool D [mm] Z kr[◦ ] kr’[◦ ] kc [Mpa] Tool Life [min] Nose Radius [mm]
2 20 4 90 15 234.5 40 3
6 16 5 90 45 320.389 60 3
Table 11: Tool Features-Pocketing

Tool hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)

2 0.064 24.8 14 220 3501 994.4 0.071
6 0.0184 0.4 12.6 231 4595 3446.7 0.15
Table 12: Operation Features-Pocketing

Tool Pc[kW] Feasible

2 1.349 yes
6 0.09 yes
Table 13: Tool Power-Pocketing

The roughness of the tool is calculated by using an equation from the article [4].

(Fz )2 × 103
Ra = = 0.23µm (18)
32 × r

4.4 Slots
To obtain the slots on the top surface, an end milling operation is done to
create the slots (using tool number 3). The required roughness is Ra = 12.5 µm
To arrive at such specifications the following tool was utilized:
The roughness of the tool is calculated using the equation in the article [4].

(Fz )2 × 103
Ra = = 0.136µm (19)
32 × r
24
 Tool D [mm] Z kr[◦ ] kr’[◦ ] kc [Mpa] Tool Life [min] Nose Radius [mm]
3 10 5 90 45 1965 65 0.8
Table 14: Tool Features-Slot Slab Milling Tool

Tool hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)]

3 0.13 8 10 200 6366 1878 0.059
Table 15: Operation Features-Slot Slab Milling

Tool Pc[kW] Feasible

3 4.92 yes
Table 16: Tool Power-Bottom Slot Slab Milling Tool

4.5 Peripheral slab milling roughing

To do the outer parameter of the product, there are 4 steps to perform: the
sides surfaces (OP1), the back surface (OP2), the back corner (OP3), and front
surface (OP4). All the mentioned features are done using the same tool number
4 but with different parameters.
The required roughness is Ra = 12.5 µm
To arrive at such specifications the following tool was utilized:

OP D [mm] Z kr[◦ ] kr’[◦ ] kc [Mpa] Tool Life [min] Nose Radius [mm]
1 35.5 7 90 45 2634.65 61 1
2 25 7 90 15 2478.660 68 1
3 25 7 90 15 2478.660 65 1
4 25 7 90 15 2634.65 90 1
Table 17: Tool Features-Corner Surface Slab Milling Tool

OP hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)]

1 0.0264 35.5 4 210 2674 1235 0.066
2 0.0264 25 4 210 2674 1235 0.066
3 0.0337 25 6.2 210 2674 1235 0.066
4 0.0337 25 6.5 210 2674 1235 0.066
Table 18: Operation Features-Corner Surface Slab Milling Tool
Please note that the chip thickness was obtained from the online calculator.[5]

25
 OP Pc[kW] Feasible
1 7.7 yes
2 5.42 yes
3 7.9 yes
4 8.29 yes
Table 19: Tool Power-Corner Surface Slab Milling Tool

The roughness of the tool is calculated as per the equation for a slab milling
operation.
R π 2 fz2
Ra = = 0.0237µm (20)
2 (2πR + 60Zfz )2

4.6 Side Through Hole

The operation is used to machine the 3 through-holes with counter sink of
the product. As a result, a drilling operation is done (using tool number 8)
followed by a countersink process (using tool number 9) to obtain the 90◦ angle
for the counter sink. The required specification is H10.
To arrive at such specifications the following tools were utilized:
Tool D[mm] kc [Mpa]
8 6 1180
9 8 1180
Table 20: Tool Features- H10 Drilling Tool

Tool Vc[m/min] n[rpm] fz[mm/(rev.th)]

8 125 6631 0.07
9 75 2984 0.07
Table 21: Operation Features-H10 Drilling

Tool Pc[kW] Feasible

8 0.5162 yes
9 0.232165 yes
Table 22: Tool Power-H10 Drilling Tool

Tool number 9 and its parameters were obtained from the Mistubishi catalogue.
[6]

26
4.7 Side Blind Hole
To obtain the blind holes with counterbore at the side of the product, a
drilling operation was performed (tool number 10) followed by a reaming
process (tool number 11) to achieve the desired finish, and finally a
counterboring process (tool number 12). The required specification is H7 with
an inner hole of diameter 8 mm and an outer hole of diameter 12.5 mm.
To arrive at such specifications the following tools were utilized:
Tool D[mm] kc [Mpa]
10 7.9 1180
11 8 1180
12 12.5 1180
Table 23: Tool Features- H7 Drilling Tool

Tool Vc[m/min] n[rpm] fz[mm/(rev.th)]

10 125 5036 0.07
11 30 1194 0.0333
12 74.676 1901 0.1
Table 24: Operation Features-H7 Drilling

Tool Fc[N] Tc[Nm] Pc[kW] Feasible

10 0.6797 yes
11 1.9667 0.0469 0.00586 yes
12 0.91789 yes
Table 25: Tool Power-H10 Reaming Tool

Tool number 12 and its parameters were obtained from the Mistubishi
catalogue. [6]

4.8 Pin Hole

To obtain the 2 pin holes on the top surface, a drilling operation was
performed (using tool number 13) followed by a reaming process (using tool
number 14). The required specification is H7.
The following tools were utilized:

27
 Tool D[mm] kc [Mpa]
13 9.9 1180
14 810 1180
Table 26: Tool Features- Pin Hole Drilling Tool

Tool Vc[m/min] n[rpm] fz[mm/(rev.th)]

13 125 4019 0.0875
14 30 955 0.0333
Table 27: Operation Features-Pin Hole Drilling

Tool Fc[N] Tc[Nm] Pc[kW] Feasible

13 1.0647 yes
14 1.9667 0.0469 0.0046905 yes
Table 28: Tool Power-Pin Hole Drilling Tool

4.9 Thread Holes Drilling

To obtain the threaded hole at the top surface, a drilling operation was
performed (using tool number 15) followed by a tapping operation (using tool
number 16).
The required specification is M8x1.
Due to the absence of the M8x1.0 thread in the tool catalog, a threading of
MF8x1.0 was obtained.
To arrive at such specifications the following tool was utilized:

Tool D[mm] kc [Mpa]

15 7 1180
16 8 1180
Table 29: Tool Features- MF8x1 Drilling Tool

Tool Vc[m/min] n[rpm] fz[mm/(rev.th)]

15 125 5684 0.07
16 26.7 1062 0.333
Table 30: Operation Features-MF8x1 Drilling

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 Tool Pc[kW] Feasible
15 0.60229 yes
16 0.738 yes
Table 31: Tool Power-MF8x1 Drilling Tool

4.10 Chamfer
Since the product has a chamfer all around the top surface in addition to the
corners of the back surface, tool number 7 is used.
The requirement of the chamfer is 1.5.

Tool D [mm] Z kc [Mpa]

7 10 4 1148
Table 32: Tool Features-Chamfer

Tool hd ap[mm] ae[mm] Vc[m/min] n[rpm] Vf[mm/min] fz[mm/(rev.th)]

7 0.102 1.1 2.121 230 7321 3510 0.12
Table 33: Operation Features-Chamfer

Tool Pc[kW] Feasible

7 0.156 yes
Table 34: Tool Power-Chamfer

Please note that the chip thickness was obtained from the online calculator. [7]

4.11 Through Hole Drilling

To obtain the long through hole at the side of the product, a pilot hole (using
tool number 17) is first performed with a depth of 12 mm to guide the second
drill (tool number 18), based on the recommendation using the Sandvik website
and catalogue. The required specification is H10.
To arrive at such specifications the following tools were utilized:

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 Tool D[mm] kc [Mpa]
17 8 1180
18 8 1180
Table 35: Tool Features- H10 Drilling Tool

Tool Vc[m/min] n[rpm] fz[mm/(rev.th)]

17 80 3183 0.1
18 80 3183 0.104
Table 36: Operation Features-H10 Drilling

Tool Pc[kW] Feasible

17 0.629 yes
18 0.6545 yes
Table 37: Tool Power-H10 Drilling Tool

5 Discussion on technical requirements

Feature Roughness Required Roughness Obtained Met?

Bottom surface 12.5 11.25 yes
Top surface 1.6 1.57 yes
Slot 12.5 0.136 yes
Side surface 12.5 0.0237974 yes
Front surface 12.5 0.0237974 yes
Back surface 12.5 0.0237974 yes
Back surface corner 12.5 0.0237974 yes
Pocketing 3.2 0.23 yes
Table 38: Requirement for roughness

As provided in section 4, we summarize all our roughness calculations into the

above table. Based on these results, all roughness criteria are met satisfying our
technical requirements. One most also shed light on the fact that no tool needs
to be changed throughout the entirety of the machining time. In addition, we
re-used the same tool for different operations in order to be more cost efficient.

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References
[1] Sandvik Coromant, “Workpiece materials - sandvik coromant.”
https://www.machiningdoctor.com/calculators/chip-thinning-calculator/.

[2] Sandvik Coromant, “Specific cutting force - sandvik coromant.”

https://www.sandvik.coromant.com/en-gb/knowledge/materials/specific-
cutting-force.

[3] Sandvik Coromant, “Training handbook metal cutting technology.”

https://cdn.sandvik.coromant.com/publications/a9d341b5-16cc-4f7c-8e60-
2f927ea651fa.pdf?sv=2021-08-06st=2024-01-11T18

[4] M. Alauddin, M. E. Baradie, and M. Hashmi, “Computer-aided analysis of

a surface-roughness model for end milling,” Science Direct, 1995.

[5] “Meusburger schnittdaten - average chip thickness.”

https://www.machiningdoctor.com/calculators/chip-thinning-calculator/.

[6] Mitsubishi Materials, “Cutting tools,” 2024.

https://view.publitas.com/mitsubishi-materials/catalog/page/1.

[7] “Chip thinning calculator.” https://www.machiningdoctor.com/calculators/chip-

thinning-calculator/.

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