Machining

ver. 1

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Old Machine
Shop
Edisons lab

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Machining
g = Chip
p formation by
y a tool

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Big lathe with big chips

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Discontinuous chips

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Continuous chips

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Machine Tools and Processes

Turning
g
Boring
Milling
Planing
Shaping
Broaching
g
Drilling

Filing
Sawing
Grinding
Reaming
H i
Honing
Tapping

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Lathe (for turning)

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Lathe Parts

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

Typical Insert Cutting Tool

insert

holder

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

10

Old Lathe

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

11

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

12

Boring

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

13

Old Boring Machine

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

14

Old Planer

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

15

Shaper

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

16

Trepanning

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

17

Drilling
(a)

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

18

Milling

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

19

Face Milling

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

20

Horizontal Mill

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

21

Old Horizontal Mill

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

22

Vertical Mill

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

23

Milling
g Types
yp

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

24

Broach

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

25

Reamers

bridge reamer
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

26

Honing

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

27

Thread Tap and Die

internal

external

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

28

Idealized Chip-formation Process

Orthogonal Cutting
chip
shear zone

cutting tool

workpiece

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

29

Chip-formation
p
Geometryy

chip

primary shear zone

B
to

tc

tool
V (cutting velocity)

workpiece
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

30

Turning vs
vs. Orthogonal Cutting

Terminology used in a turning

operation on a lathe, where f is
the feed rate (in./rev or mm/rev)
and d is the depth of cut.
In turning,
turning the orthogonality
orthogonality is
to the left in the drawing, hence
a change of coordinate system
is needed. If you were doing a
diametral cut-off (p
(plunge
g cut))
operation, no change would be
needed.
Note that feed in turning is
equivalent to the depth of cut in
orthogonal
th
l cutting,
tti
and
d th
the
depth of cut in turning is
equivalent to the width of cut in
orthogonal cutting.

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

31

Cutting Force Diagram

Fc
R

Ft
Fs

Ns

F
V

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

32

Merchants
Merchant
s Force Circle
Fs

Fc
Ns
Ft

F
N

M Eugene Merchant
M.
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

33

3D Cutting (Oblique)
Z
n

Vc

X, V
O

i
Y

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

34

Typical Insert Cutting Tool

insert

holder

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

35

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

36

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

37

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

38

Tool Coatings

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

39

Chip Types
Basic types of chips
and their
photomicrographs
produced in metal
cutting: (a) continuous
chip with narrow,
straight primary shear
zone; (b) secondary
shear zone at the
chip-tool interface; (c)
continuous chip with
built-up edge; (d)
continuous chip with
large primary shear
zone; (e) segmented
or nonhomogeneous
chip and (f)
discontinuous chip.
Source: After M. C.
Shaw, P. K. Wright,
and S. Kalpakjian.

(a)

(d)

(b)

(c)

(e)

(f)

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

40

Chip Types
(a) Continuous chip with narrow primary
shear zone
ductile materials at high speed
bad
b d ffor automation
t
ti (use
(
chip
hi b
breakers)
k )

(b) Secondary shear zone at chip-tool

interface
increased energy dissipation

(c) Continuous chip with built up edge (BUE)

hi
high
h plastic
l ti working
ki
bad for automation

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

41

Chip Types
(d) Continuous chip with large primary shear
zone
soft metals at low speeds and low rake angles
poor surface finish
residual stresses

(e) Segmented chip

low thermal conductivity materials

(f) Discontinuous chip

low ductility materials and/or negative rake angles
good for automation
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

42

Segmented chips

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

43

Chip Breaker
chip breaker

chip
hi
shear zone

cutting tool

workpiece

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

44

Integral Chip Breakers

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

45

Tool Marks

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

46

Roughness
Roughness AA

18 3 r

f = feed
f d
r = nose radius
AA = arithmetic
ith ti average
t = peak-to-valley

f
Roughnesst
8r
f

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

47

Surface Marks
(a)

(b)

Surfaces produced on steel by cutting, as observed with a scanning electron microscope: (a) turned
surface and (b) surface produced by shaping. Source: J. T. Black and S. Ramalingam.

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

48

Formation of Built
Built-up
up Edge (BUE)
BUE
deposit

chip

cutting tool

BUE

BUE
deposit
workpiece
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

49

Chatter
Results from vibration
Tool
T lb
bounces iin and
d outt off th
the
workpiece

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

50

Glacial Chatter

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

51

Chip / Tool Interface

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

52

Tool Wear
(b)

(a)

(c)

Rake

Flank

(d)

( )
(e)

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

53

Taylors
y
Equation
q
VTn = C
V = cutting speed
T = tool life
n, C = Taylor constants (empirical)
C

Frederick W. Taylor
1856-1915

n
log V
log T
1

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

54

F W Taylor
F.W.
Taylors
s Contributions
Metal cutting
Time / motion studies
Led to Congressional
inquiry and banning of
stop
p watch use by
y civil
servants (1912-1949)

Design of shovels
Scientific management
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

55

Cost components
Total
Tool changing

CO
OST

Min

Tool
Machining
Raw material
Material handling

CUTTING VELOCITY
ME 4210: Manufacturing Processes and Engineering
Prof. J.S. Colton GIT 2009

56

Cutting cost example

HSS
Vcm
N (rpm)
183
T (min)
43 5
43.5
Cm
3.1831
Cc
0.1463
Cg
0.2117
Ci
0.699
Cs
0.05
Cr
0.85
Total ($)
5 14
5.14

Vtm
200
18 1
18.1
2.9125
0.3218
0.4655
0.699
0.05
0.85
5 30
5.30

Carbide
Vcm
432
5 64
5.64
1.3484
0.1793
0.1603
0.699
0.05
0.85
3 29
3.29

Vtm
490
3
1.1888
0.2972
0.2657
0.699
0.05
0.85
3 35
3.35

Carbide
Vcm
432
5 64
5.64
1.3484
0.3495
0.3125
0.699
0.05
0.85
3 61
3.61

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

all
Vtm
490
3
1.1888
0.3495
0.3125
0.699
0.05
0.85
3 45
3.45
57

ME 4210: Manufacturing Processes and Engineering

Prof. J.S. Colton GIT 2009

58