Machining And Operating Rate If Cost Of Changing Tool Is Also Considered Calculator

Formula Used:

\[ \text{Machining Rate For Cost Changing Tool} = \left( \frac{\text{Cost of A Tool} + \text{Cost of Changing Each Tool}}{\text{Time to Change One Tool}} \right) \times \left( \frac{1 - \text{Taylor's Tool Life Exponent}}{2 \times \text{Taylor's Tool Life Exponent} - 1} \right) \]

Cost of A Tool:

Cost of Changing Each Tool:

Time to Change One Tool:

Taylor's Tool Life Exponent:

Machining Rate For Cost Changing Tool:

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1. What is Machining Rate For Cost Changing Tool?

Machining Rate For Cost Changing Tool is the money charged for processing on and operating machines per unit time, including overheads for minimum production cost when tool changing costs are considered.

2. How Does the Calculator Work?

The calculator uses the formula:

Where:

Cost of A Tool — Cost of one tool being used for machining ($)
Cost of Changing Each Tool — Cost that arises due to the time taken by the operator to change one tool ($)
Time to Change One Tool — Time it takes to change one tool during machining (s)
Taylor's Tool Life Exponent — Experimental exponent that helps in quantifying the rate of Tool Wear

Explanation: The formula calculates the optimal machining rate that minimizes production costs by considering both tool costs and tool changing costs.

3. Importance of Machining Rate Calculation

Details: Accurate machining rate calculation is crucial for determining optimal production costs, scheduling manufacturing operations, and maximizing profitability in machining processes.

4. Using the Calculator

Tips: Enter all cost values in dollars, time in seconds, and Taylor's exponent as a decimal between 0 and 1. All values must be valid (time > 0, exponent between 0-1).

5. Frequently Asked Questions (FAQ)

Q1: Why include tool changing costs in machining rate calculation?
A: Tool changing costs significantly impact overall production costs, especially in high-volume manufacturing where tools need frequent replacement.

Q2: What is a typical range for Taylor's Tool Life Exponent?
A: Taylor's exponent typically ranges from 0.1 to 0.5 for most tool materials, with higher values indicating slower tool wear rates.

Q3: How does tool changing time affect the machining rate?
A: Longer tool changing times increase the non-productive time, which increases the overall machining rate needed to maintain profitability.

Q4: Can this formula be used for different types of machining operations?
A: Yes, the formula is applicable to various machining operations including turning, milling, and drilling where tool wear is a significant factor.

Q5: How often should machining rates be recalculated?
A: Machining rates should be recalculated whenever there are changes in tool costs, labor rates, or tool life characteristics.