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d also when it comes to horizontal in the middle of the pocket may lead to insert failure or poor performance of the insert due to sudden impact. So it is suggested in the second trial to try with a reduced feed rate of 6 thousandths when the tool insert comes at an angle and at a feed of about 10 thousandths when the tool is in horizontal position. The first trials depth of cut of about 15 thousandths worked out better than the original depth of cut so it was planned to maintain the same.

4.4.1 Reasons for Taper and Solutions

At the end of the first trial analysis it was observed that the new change worked out well in the beginning and in the later stages it lead to the formation of taper during the final finish pass. This taper took a very long time to clear off to meet the tolerance, and the problem existed in almost all the production parts costing a lot of extra time and work leading to the violation of standard time.

The reasons for this taper was analyzed in detail in the shop floor with the production staff and it was decided to have a study on a part where the taper was about to start. The operator was able to judge that the part is going to have a taper in the operation, but the measures taken by the operator by reducing the speed hardly helps the process to be in control.

At one stage the author personally stopped the machine and with the help of an iron rod and a focus light, the author was able to observe that the front side of the pocket is turned well, but whereas the back side of the pocket is having a lot of problems with uneven cuts. The potential reasons for this kind of scenario may be the insert is not performing the same extent as it should do in the front and in the back side of the pocket. The material in the front side of the pocket is pushed to the back end, and this push offs and humps leads to taper formation which adds up to the extra time.

This hump and taper formation is a very common situation which takes a lot of time could be considered as a non value added activity in this operation. With the help of the iron rod when the taper was observed it was noted that the taper occurred in the middle of the part.

The total length of the pocket is about 7 inches, and with observation of a few parts it was noted that the taper starts at about 3.5 inches from the back end. The two side squaring is done in the latter stage which leads to potential hump formation near the ends and requires a lot of extra passes to remove the material. It is known for sure that the problem persists at the back end of the pocket the following two solutions were drawn to solve it.

4.4.2 Solution 1

The first modification idea is to prevent the formation of humps and taper and to make the tool insert move in both the directions. In the first pass the tool insert is made to work in the front direction and in the second pass the tool insert can be made to do the turning operation in the opposite direction. By this way there will be consistency in the process, and the inserts action can be equally felt throughout the process.

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