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Manufacturing Technology-1
Manufacturing Technology-1
Manufacturing Technology-1
J.Ramkumar
Topics covered
Topicscovered
Generalintroduction
General
introduction
Classificationofmachiningprocess
Machiningwithsingleedgetools
hi i
ih i l d
l
Typesofcutting
Typesofchip
Introduction
Manufacturingprocesstoproduce
Specifiedshape
Materialproperties
Process
Changeinconfigurationandphysicalproperties
Change in configuration and physical properties
Followingtypeofoperations
Constantmassoperations
p
Casting,rolling,extrusion,wiredrawing,forging,etc
Materialadditionoperations Bottomupapproach
Bolting,rivetting
Bolting rivetting ,keying,welding,rapidprototyping,etc
keying welding rapid prototyping etc
Materialremovaloperations(surplusmaterials
removed) Topdownapproach
Machining,finishing,etc
M hi i fi i hi
t
Otherexamples
Milling Surfaceandendmilling
drilling
BasicsofMachiningprocess
gp
Ge
Generatix
e at
Linesgeneratedbycuttingmotion
Directrix
Linesfromfeedmotion
Howisatapermade?
Methodsofgeneratingsurfaces
Tracingmethod directtracingofthegeneratrices Eg:
shaping,planing
Generation surfaceproducedistheenvelopofthe
generatrices milling,etc
milling etc
Directrix perpendiculartotheplaneofgeneratrix
Directrix intheplaneofgeneratix
p
g
Surplusmaterialremovedintheformofchip
Differencebetweentoolandmachinetool?
Machinetoolrelativemotion
Machine tool relative motion
Primary Power
Secondary feed
3:
4:
Turningg Operation
p
5:
6:
7:
8:
Importantanglesinawedgeshapetool
Rakeangle toolfacewithaplanenormalto
cuttingvelocityvectorandthemachinedsurface
Flankangle
Fl k
l flankfaceandmachinedsurface
fl k f
d
hi d f
Chipthicknessratior=t1/t2?
Types of cutting
Typesofcutting
Differencebetween
Orthogonalcutting
Cuttingedgeofthetoolisperpendiculartothedirectioncutting
velocity
l it
Cuttingedgeiswiderthantheworkpiecewidth plainstraincondition
flowisconfinedtothex,z plane
Chipflowsontherakefacewithvelocityperpendiculartothecutting
edge
CuttingforcesactalongXandZdirectionsonly
Obliquecutting
CuttingedgeofthetoolisinclinedatanangleIwiththenormaltothe
cuttingvelocity
ChipflowsontherakefaceatanangleequaltoI
Cuttingedgeextendsbeyondthewidthofworkpiece
Cuttingforcesactalongalldirections
Cutting forces act along all directions
Typesofchips
Dependingupontheworkmaterial,cutting
conditions,threebasictypes
Relativemotionbetweentoolandworkpiece
compressionatcuttingedge plasticstate.
Plastic
Plasticflowonrakesurface
flow on rake surface
Shearingactionoftheworkmaterial
Continuouschip
Continuous chip
Continuouschipwithbuiltupedge
Discontinuouschip
Discontinuous chip
Types of chips
Typesofchips
ContinuouschipwithBuiltupedge
U
Undercertainconditionstemperatureandpressureattool
d
t i
diti
t
t
d
tt l
chipinterfaceishigh
sliding rupture(strainhardeningandthermalsoftening)
from the chip takes place
fromthechiptakesplace
Highresistanceattoolchipinterface protectinglayer
removed
Affinityforwelding
Affi it f
ldi
Startinggrowing build upedge
Growthishigh unstable
Movealongthechip
Movewiththemachinedsurface
Formsonlyatcriticalspeed
Forms only at critical speed
Types of chips
Typesofchips
Continuouschip,
Continuouschipwithbuiltupedge
Discontinuouschip
Type of chips
Typeofchips
speed recrystalization temperature
Aboverecrystal temp strainhardening
i
isneglected
l
d
Lowrecrystal temp strainhardeningis
high
Same BUEisformed
Influenceofcuttingspeedand
Roughness
h
Region
Region1
1 Raispoor,discontinuouschip,as
Ra is poor discontinuous chip as
speedincreasesRaimprovesfrom
discontinuous to semi discontinuous
discontinuoustosemidiscontinuous
Region2 BUEisformedandcontinuoustill
recrystalization temperature
Region3 ContinuouschipswithoutBUEso
goodRa
dR
ToolGeometry
Cutting
Cuttingprocessisinfluencedbytheinclinationofthecuttingedge
process is influenced by the inclination of the cutting edge
andorientationofrakeandflankface.
Orientationdefineweneedreferenceplaneandaxes.
Important
I
rakefaceinclination
k f
i li i
Rakeanglecanbemeasuredin
A plane normal to the cutting edge and perpendicular to the plane
Aplanenormaltothecuttingedgeandperpendiculartotheplane
containingcuttingedge OABC
Aplaneparalleltothecuttingvelocityvectorandperpendicularto
the plane containing the cutting edge ODEF
theplanecontainingthecuttingedge
Aplanecontainingthecuttingvelocityandchipvelocity ODGHas
showninfig
ASA/Coordinatesystem
Continental/Orthogonalsystem German
Maximumrakesystem/British
Normal rake system/International
Normalrakesystem/International
Referenceplanes
Referenceplanesincoordinate system
Referenceplanesinorthogonalsystem
((1)Longitudinal(2)transfer
)
g
( )
feeddirections
Thirdplaneisinthedirectionofthe
Third
plane is in the direction of the
Maxslopeoftherakeface
Referenceplanesinnormalrakesystems
(1)Longitudinal(2)Transversefeeddirections
Third
Thirdplaneisperpendicular
plane is perpendicular
tothecuttingedgeofthe
tool
System of axes
Systemofaxes
Thesearenotthecartesian
coordinateaxesbuttracesofthe
referenceplane.
The
Theauxiliarycuttingedgeand
auxiliary cutting edge and
auxiliaryflankanglesarealso
shown
ASA/Coordinatesystem
Singlegdnttodspecificationin
Continentalsystem(ORS)
SinglepointtoolspecificationinBritishsystem
(MRS)
SinglepointtoolspecificationinInternational
system(NRS)
SinglepointtoolspecificationinAmericancontinental
system(MRS)
t
(MRS)
Geometryofhelicalmillingcutter
Geometryoftwistdrill
12:
=r
(4.1)
r=CuttingRatio
(4.2)
(4.3)
13:
ExpressFc inFsandFn
FtinFnandFs
FinFc andFt
NinFc andFt
Fs in Fc andFt
FsinFc
and Ft
FninFc andFt
RinFandangles
Fc inRandfrictionandrakeangles
Ft i R d f i ti
FtinRandfrictionandrakeangles
d k
l
(4.4)
(4 5)
(4.5)
(4.6a)
(4.6b)
(4.7a)
(4.7b)
(4.8a)
(4.8b)
( )
(4.9)
(
(4.10a)
)
(4.10b)
(4.11)
(4.12)
(4.13)
(4.14)
(4.15)
can be expressed as
(4.17)
During machining,
is given by
Where =normalstressactingonthe
shear plane
shearplane
can be expressed as
and writing
in terms of
, we get
Using equation (4.9) and (4.10 a) along with the foregoing equation, we obtain
(4.18)
Where
and is constant for the work material.
called the machining constant.
Itisclear increases increasesand increases decreases
Asthecuttingspeedincreases, decerases andsoFc too
is sometimes
15:
Duringanorthogonalmachiningoperationonmildsteel,theresultsobtainedare
uncutthickness=0.25mm,chipthickness=0.75mm,w=2.5mm,rakeangleiszeroand
C i f
Cuttingforce=950Nandthrustforce=475N.
950 N d h
f
475 N
Determinethecoefficientoffriction
Determinetheultimateshearstressoftheworkmaterial
Determinationofcoefficientoffriction
Thedistributionofshearandnormal
The
distribution of shear and normal
stressontherakefaceisnotuniform.
TiptoC,normalstressishighso
stickingfrictionishigh
CtoD,curling slidingfriction
Whennormalforceissmall,Fis
proportionaltonormalload.
Independent of apparent area Elastic
Independentofapparentarea.Elastic
plasticregion.
Whennormalforceishigh,plastic
deformationatslidinginterfaceso
fi i f
frictionforceisindependentofnormal
i i d
d
f
l
load
Strainratecalculation:
Strainrate=((deltaS)/(deltay))*(1/(deltat))
Strainratecanbeexpressedinshearvelocity
Strain rate can be expressed in shear velocity
Needforvelocitydiagram
MeasurementofShearangle
DirectMethod
IndirectMethod
Step1:determiner;ltb =(ltb)ofchipwecalculatetc
Step 2 : AB = t/sin () = tc/cos ()weget
Step2:AB=t/sin()=tc/cos
() we get
Alternativemethod
Weightofthechip=lctcbc=ltb
Machining Constant
:2
:2
Power Consumption
Specific Energy
(4.20)
(4.21a)
(4.21b)
:4
(4.22)
=Uncutthickness,mm
Q=Volumerateofmaterial
removal
Mechanicsofobliquecutting
WhencuttingedgeinclinedbyI,thenfollowingrakeanglecomesintoexistence
1. Normalrakeangle
2. Velocityrakeangle
3. Effectiverakeangle
Becauseofthistwoshearangle
1.Normalshearangle anglefromshearplanetoplanecontainingthenewlyformedwork
surfacemeasuredinaplanenormaltocuttingedge
2 Eff ti
2.Effectiveshearangle
h
l angleismeasuredintheplanecontainingthecuttingvelocityand
l i
d i th l
t i i th
tti
l it
d
chipvelocityvector
Relationshipbetweendifferentrakeanglesandinclination
:16
16
(4 23)
(4.23)
(4.24)
When a material particle moves across the primary deformation zone, the temperature
rise is given by
(4.26)
Where
= Fraction of primary heat which goes to the workpiece
= Density of the material
= Specific heat of the material
thickness width of cut respectively
= Uncut thickness,
and a nondimensional
(4.27)
The maximum temperature rise when the material particle passes through the
secondary deformation zone along the rake face of the tool can be approximately
expressed as
(4.29a)
Where is the length of contact between the tool and the chip
The corresponding average temperature rise
(4.29b)
V i i off Temperature
Variation
T
with
i h Cutting
C i Speed
S d
(4.30)
= Specific energy
Theoverallinterfacetemperatureriseis
Proportionaltothesquarerootofthe
Cuttingspeed
:17
:18
:19
ToolWearvariousmechanism
AdhesionWear:Surfacemating weldingoftoolandworkpiecematerial
Smallwearparticles attritious wear
Largewearparticles galling
Abrasionwear:surfaceasperitiesploughaseriesofgrooves
Basiccondition particlesmustbeharderthanthesurface.
Thiswearratethroughthisisprocessdependsonhardness,elasticproperties
Andthegeometryofthematingsurfaces.
Diffusion:Twosurfacesinclosecontact,atomfromonetransfertootherbydiffusion
Diffusion
: Two surfaces in close contact, atom from one transfer to other by diffusion
Changesthephysicalpropertieslikehardness,toughness,etc.
Diffusionrateistemperaturedependentsodependsonslidingrate
Amountofmaterialtransferistimeofcontactandinverseofslidingspeed
:20
Variablesaffectingtoollife
Cuttingconditions
toolgeometry
toolmaterial
workmaterial
cuttingfluid
cutting fluid
Propertiesoftoolmaterial
Properties
of tool material
1. Hothardness
2. Toughness
3. Thermalconductivityandspecificheatshouldbehigh
4. Coefficientoffrictionbetweentheworkpieceandtool
Toollist
1. Carbontoolsteel
2. HighSpeedsteel
3. Cementedcarbide WCCowithotheringradients likeTaC,TiC,etc
4. Ceramicoxide
5 CeramicNonoxide
5.
Ceramic Non oxide
6. Coatings Singleandmultilayer
7. Diamond
:24
Cuttingfluids
Ways in which cutting fluid affects machining
Cooling
C li down
d
off chip-tool-work
hi t l
k zone be
b
carrying away generated heat
Reducing the coefficient of friction a chip-tool
interface
Reducing thermal distortion caused by
temperature gradient
Washing of chip
Protecting from corrosion
Cutting Fluids
: 29
:29
:30
: 31
:31