Basic of Machining PDF

Machining
ver. 1
ME 338: Manufacturing Processes II 1

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Old Machine
Shop –
Edison’s lab

Machining = Chip formation by a tool

Big lathe with big chips

Giant Lathe

Discontinuous chips

Continuous chips

Machine Tools and Processes
• Turning • Filing
• Boring • Sawing
• Milling • Grinding
• Planing • Reaming
• Shaping • Honing
• Broaching • Tapping
• Drilling

Classification of Conventional Machining
• Cutting processes
– Single point: e.g. shaping, planing, turning, boring, etc.
– Multiple point: e.g. milling, drilling, etc.
• Abrasive processes
– Grinding, honing, etc.

Lathe (for turning)

Lathe Parts

Typical Insert Cutting Tool
insert
holder

Pillars made on Lathe

Old Lathe

Boring

Old Boring Machine

Old Planer

Shaper
This image cannot currently be display ed.

Trepanning

Drilling
(a)

Milling

Face Milling

Horizontal Mill

Old Horizontal Mill

Vertical Mill

Milling Types

Ultra-High Speed Micromilling Machine in
the Machine Tools Lab at IITB

Broach

Reamers
bridge reamer
Honing

Thread Tap and Die
internal external

Shaping

Planing

Shaping & Planing
• Material removal rate, MRR = Vwt0
• Cutting power, Pc = ucMRR
• Machining time, tm = L/V

– L is the length of cut

u is composed of:
• us, the shear energy per unit volume

• uf, frictional energy per unit volume
• chip curl energy
• chip acceleration kinetic energy
• surface energy of new surfaces

Where does cutting energy go?
• 90% to chip
• 5% to tool
• 5% to workpiece

u can be obtained in two ways
• Tabulated
• Estimated
– u ~ HB

Cutting Energy (u)
As a first approximation:
u ≈ us + uf
us ≈ 0.75 - 0.8 u
hence
u ≈ 1.5 us

Estimation of u
• Assume a simple, rigid-perfectly
plastic material:
σ
σ0
∫
u s = σ ⋅ dε = σ o ⋅ ε = τ fm ⋅ γ
ε
HB
σo ≈ for heavily cold-worked metals
3
ε ≈1− 2 ⇒ γ ≈ 2 − 4

Estimation of u
σo 1
τ fm ≈ ≈ HB
2 6
1 2
us ≈ HB → HB
3 3

What number to use?
From above
u ≈ 1.5 us
us ≈ (1/3 to 2/3) HB
u ≈ (1/2 to 1) HB
so, if no data, u ≈ HB

Comparison of Tensile and Cutting (Ex. 1-1)
• 304 stainless steel rod

• do = 0.5 in, df = 0.48 in, lo = 6 in
• What is the energy required using tension?

• What is the energy required using cutting?

Tension: Ex. 1-2
K ⋅ ε1n +1
∫ σ ⋅ dε1 = u =
n +1
ε1 ε
u × volume = Energy
K = 185,000 psi; n = 0.45

Tension - Ex. 1-3
 0.5 
ε1 = 2 ln  = 0.0816
K ⋅ ε1n +1  0.48 
Energy = Aolo
n +1
(185,000 ) ⋅ (0.0816)1.45 2
= π (0.25) (6)
1.45
= 3,970 in − lbf = 449 J

Cutting - Ex. 1-4
Energy = (specific cutting energy) *

(volume removed)
π 2
E = u × (Di − D 2f ) ⋅ l
4
uss ≈ 1.5 hp min/in3 x 550 x 60 x 12
= 594,000 in-lbf/in3
π
E = 594,000 ×
4
(0.5 2
− 0.482 ) ⋅ 6
= 54,650 in-lbf (6,176 J)

Relation between u and t0
• As the depth of cut decreases, the surface

area to volume ratio increases, hence friction
(energy) increases
• Since
u ≈ us + u f
• Hence
1
u∝
t0
Turning -MRR

Turning
• Average cutting speed, Vavg = πDavgN

– Davg is the average diameter of workpiece
– N is the spindle speed in rpm
• Material removal rate, MRR = Vavgdf
– d is the depth of cut
– f is the feed (units: mm/rev or in/rev)
• Cutting power, Pc = ucMRR=FcV
– Fc=Cutting force
– V = Cutting speed
• Machining time, tm = L/(fN) = L/F
– F is the feed rate (units: mm/min or in/min)

Turning Power and Force- Ex. 2-1
Turning Titanium:
• speed = 1 m/s = 200 sfpm
• feed rate = 0.1 mm/rev = 0.0004” / rev
• depth of cut = 3 mm = 0.1”
What is cutting power and cutting force?

Power - Ex. 2-2
u ≈ 0.06 kW/cm3/min = 3.6 W/mm3/sec
MRR =Q = Vfd = 1,000 x 0.1 x 3

= 300 mm3/sec
P = u x MRR = 3.6 x 300 = 1,080 W

= 1.45 hp

Force - Ex. 2-3
F = P/V = 1,080 W ÷ 1 m/s

= 1,080 N (243 lbf)

Milling
fr
cutter
N
dr
feed
workpiece
da

Milling Modes
dr
Up Milling Down Milling

Milling
• Cutting speed, V = πDN
– D is the cutter diameter
• Material removal rate, MRR = fNdadr = Fdadr

– da is the axial depth of cut
– dr is the radial depth of cut
– f is the feed per revolution (= ftNt ; ft is the feed per cutting edge/tooth
and Nt is the number of teeth)
– F is the feed rate (in/min or mm/min)
• Cutting power, Pc = ucMRR
• Machining time, tm = (L + lc)/F

– lc is the length of the cutter’s first contact with the workpiece
Example
• A slab-milling operation is being carried out

on a 25-in. long, 4-in. wide metal block (u =
4.3 hp-min/in3) at a feed of 0.02 in./tooth and
a depth of cut of 0.125 in. The cutter has a
diameter of 4 in., has eight straight cutting
teeth, is 2 inches wide and rotates at 200
rpm. Calculate the material removal rate, the
cutting time, and the power required.

• d a=
• d r=
• u=

Summary
• General Machining Process

• Shaping & planing
• Turning
• Milling


Basic of Machining PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Basic of Machining PDF

Uploaded by

Copyright:

Available Formats

Machining

ME 338: Manufacturing Processes II 1

ME 338: Manufacturing Processes II 2

ME 338: Manufacturing Processes II 3

ME 338: Manufacturing Processes II 4

ME 338: Manufacturing Processes II 5

ME 338: Manufacturing Processes II 6

ME 338: Manufacturing Processes II 7

ME 338: Manufacturing Processes II 8

ME 338: Manufacturing Processes II 9

ME 338: Manufacturing Processes II 10

ME 338: Manufacturing Processes II 11

ME 338: Manufacturing Processes II 12

ME 338: Manufacturing Processes II 13

ME 338: Manufacturing Processes II 14

ME 338: Manufacturing Processes II 16

ME 338: Manufacturing Processes II 17

ME 338: Manufacturing Processes II 18

ME 338: Manufacturing Processes II 19

ME 338: Manufacturing Processes II 20

ME 338: Manufacturing Processes II 21

ME 338: Manufacturing Processes II 22

ME 338: Manufacturing Processes II 23

ME 338: Manufacturing Processes II 24

ME 338: Manufacturing Processes II 25

ME 338: Manufacturing Processes II 26

ME 338: Manufacturing Processes II 27

ME 338: Manufacturing Processes II 28

ME 338: Manufacturing Processes II 29

ME 338: Manufacturing Processes II 31

ME 338: Manufacturing Processes II 32

ME 338: Manufacturing Processes II 33

ME 338: Manufacturing Processes II 34

• Material removal rate, MRR = Vwt0

• Cutting power, Pc = ucMRR

• Machining time, tm = L/V

ME 338: Manufacturing Processes II 35

• us, the shear energy per unit volume

ME 338: Manufacturing Processes II 36

ME 338: Manufacturing Processes II 37

ME 338: Manufacturing Processes II 38

ME 338: Manufacturing Processes II 39

ME 338: Manufacturing Processes II 40

ME 338: Manufacturing Processes II 41

ME 338: Manufacturing Processes II 42

• 304 stainless steel rod

• What is the energy required using tension?

ME 338: Manufacturing Processes II 43

K = 185,000 psi; n = 0.45

ME 338: Manufacturing Processes II 44

ME 338: Manufacturing Processes II 45

Energy = (specific cutting energy) *

= 54,650 in-lbf (6,176 J)

• As the depth of cut decreases, the surface

ME 338: Manufacturing Processes II 48

• Average cutting speed, Vavg = πDavgN

ME 338: Manufacturing Processes II 49

ME 338: Manufacturing Processes II 50

u ≈ 0.06 kW/cm3/min = 3.6 W/mm3/sec

MRR =Q = Vfd = 1,000 x 0.1 x 3

P = u x MRR = 3.6 x 300 = 1,080 W

ME 338: Manufacturing Processes II 51

F = P/V = 1,080 W ÷ 1 m/s