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Sample calculation The calculation is based on data collected during the experiment Radial forces are taken to be positive The aim of this calculation is to compute the values of the following parameters: True Back rake Angle, lt Normal Side rake Angle, an Normal Force, FN Chip Ratio, rc Shear strain, e Inclination Angle, i True Side Rake Angle, gt Friction Force, FF Coefficient of Friction, m Shear Angle, F Machinability Coefficient, l = back rake angle = 5 g = side rake angle = 5 k = SCEA (approach angle) = 0 (for this calculation) V = Cutting speed = 4467 m/s FP = Fz FQ = Fx FR = Fy The required signature for a cutting tool is 5, 5, 5, 5, 10, 0, 1/32 (08 mm) As the SCEA is zero degrees, a triangular tool (T ) is the best option for the insert Since a negative back and side rake of 5 degrees are required, an N value is needed for the insert which when tilted by 5 degrees (clearance angle) gives the necessary signature A tolerance of 80 m will involve an M nomenclature The choice of a centre hole with moulded chip breakers calls for a G An insert size 332 is selected and the required insert will have a configuration of TNMG 332 A corresponding shank size to give an SCEA of zero degrees will be MTJNRS M designates the type of clamping, which is of the strap clamp type T stands for a triangular shape insert J designates the style of the tool The clearance angle is kept as zero degrees by selecting an N type tool R designates the cutting direction from the right to the left S stands for the square cross section of the tool shank



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There are several hidden lessons in this example The rst one is that it is easier to start with existing code than to begin inventing everything from scratch It is easy to get excited by technology and run o to create everything from scratch, just so it is all yours Resist this impulse! Look around and see what other people have done, and it will save you hours, days, or even weeks of reinventing the wheel Once you ve found a good rst approximation for your solution, you can take all of that extra time and adjust the found solution to work better In the end, you ll have a better solution for the same amount of time invested Another lesson is that a good solution to the problem may not be the obvious solution.





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Referring to Figure 320, the bending moment BM = Fz L , and this is resisted by the material because of its strength Assuming the overhanging length L = 30 mm and Fz = 1160 N from experimental data, Resisting moment R = S Section modulus The bending moment of the tool shank can be expressed as Fz L = l =

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Note that the robot turns left if it is on the white background and it turns left when it sees the line, too It only turns right when it is on the edge, between bright and dark There are three states in the sensor, as programmed by the LEGO people: Bright, Dark, and somewhere in between Why does this program work What happens if you remove the If Dark 2 test and just turn right when it s not bright How does it behave if you have a fast robot A slow one This program doesn t follow the line e ciently, since it spends more time turning than it does moving forward What happens if, instead of stopping the inside wheel, it sets it to move at a slower speed Moving too fast can be a problem since you can overshoot the line and its corners.

Fig 320: Shank design [10]

l = 1735 20 mm Not only must the shank be strong but it must also be rigid enough to resist deflection ( y) that is a source of chatter The stiffness of the tool shank can be calculated as Fy = 244 N (for this calculation) E = Elastic modulus = 200000 N/mm2 I = y =

In all robotic applications, there is a middle ground where the speed of the machine, the response time of the sensors, and even the momentum of the robot come together to make a working solution It often takes a lot of experimentation to nd just the right combination This is where the scienti c method comes into play First, do some tests with an existing system to see how it behaves Then develop a theory on how to make it better Test this theory and see if it works If it does, great! Otherwise, make a note of why it didn t work and try again with a di erent theory When you are making changes in your theories and tests, take care to change just one or maybe two things at a time, so you can tell which change a ected the result.

As y is not greater than 002, the selection of the shank dimension is valid for this example The selected tool holder geometry would be MTJN 20 20 R 20 S 11 Calculation of the True Back Rake Angle, lt = i = tan 1 (tan l cos K sin K tan g ) = tan 1 (tan ( 5 ) cos (0 ) sin (0 ) tan ( 5 ) = 5 12 Calculation of the True Side Rake Angle, gt = a = tan 1 (cos K tan g + sin K tan l) = tan 1 (cos (0 ) tan (5 ) + sin (0 ) tan ( 5 )) = 5

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