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This study was primarily done for consistency i.e. No extra passes for the same depth of cut and the turning operation should follow as per the program. At the end of this trial it was also observed that the inserts lasted longer than the conventional depth of cut which mean that the insert failure in the middle of the cut was reduced. By this way it helped to reduce the time by 3 hrs.

In the earlier conventional way when an insert failed in the middle of a cut, the inserts are changed at the end of the cycle and is made to rerun for the same depth of cut. Thus extending the time and wasting resources. This scenario was reduced in the new trail which indicates that the process optimization is going on the right direction.

At the end of the cutting operation there were some notable taper formations which lead to more number of repass in the finish stage. This is not a new addition due to the change; rather this is happens in most parts during this operation. Further Investigation is done in this area to prevent it in the future trials.

The above diagram illustrates the current cutting path method. The insert starts to cut from one end, and the turning operation is done to the entire length of about 7 to 10 inches depends on the size of the product. After the initial sizing is done there is a 30o angle to the side of the part where there are the two side drilled holes.

The feed is maintained the same when the tool moves from the side and to the middle of the pocket. In the later steps after completing the shaping process of the pocket the tool insert is again repositioned to remove the front and the back squares. In the final stage after the squaring operation is completed the final finish pass is done to complete the process as per the tolerance.

4.4 Reasons for Change

With the first trial study which partially worked out with the help of the reduced depth of cut in the beginning, but had trouble when it entered into the mid section of the interrupted cut. At the end of the trial 1 pocket analysis it was noted that the front 30o angle is not of much help to the process, as the material in this area is removed again in subsequent steps, and it can be concluded that the operation is repeated which adds more time to the operation, which can be eliminated by combining it with the first step.

This extra squaring not only adds time but also eats a few more inserts. The tool holder was analyzed and it was confirmed that the tool can go straight and could perform the combined operation. With the current working tool head it was observed that the back squaring operation cannot be done in the same process as it involves the tool head direction to be changed in the middle of the process, so back squaring operation is maintained as a separate step. The above ideas were brain stormed with the operators to get their views and opinions for any potential problems.

The process was given a positive feedback and it was supported for time reduction. It was noted that when the feed rate was kept the same when the tool insert moves at an angle during the initial pocket sizing, an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。