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CH2-MACHINING Mac 2021
CH2-MACHINING Mac 2021
Material Removal
Process
BDA 30502
MANUFACTURING TECHNOLOGY
Manufacturing - Technology
2
Classification of manufacturing processes
3
Products in Various Stages of Life Cycle
Material Removal Process
(Metal Machining Process)
Wasteful of material
Chips generated in machining are wasted material,
at least in the unit operation
Time consuming
A machining operation generally takes more time
to shape a given part than alternative shaping
processes, such as casting, powder metallurgy, or
forming
l s sin sin
r
l s cos( ) cos( )
BDA 30502 Manufacturing
Technology
Chip Thickness Ratio
to
r
tc
Shear strain during chip formation: (a) chip formation depicted as a series of
parallel plates sliding relative to each other, (b) one of the plates isolated to
show shear strain, and (c) shear strain triangle used to derive strain equation.
= tan( - ) + cot
Answer : = 25.4
= 2.386
More realistic view of chip formation, showing shear zone rather than
shear plane. Also shown is the secondary shear zone resulting from
tool-chip friction.
BDA 30502 Manufacturing
Technology
Four Basic Types of Chip in Machining
1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip
Brittle work
materials
Low cutting
speeds
Large feed and
depth of cut
High tool-chip
friction
Ductile work
materials
High cutting speeds
Small feeds and
depths
Sharp cutting edge
Low tool-chip
friction
Ductile materials
Low-to-medium
cutting speeds
Tool-chip friction
causes portions of
chip to adhere to
rake face
BUE forms, then
breaks off, cyclically
BDA 30502 Manufacturing
Technology
Serrated Chip
Semicontinuous -
saw-tooth appearance
Cyclical chip forms
with alternating high
shear strain then low
shear strain
Associated with
difficult-to-machine
metals at high cutting
speeds Figure 21.9 (d) serrated.
Effect of shear plane angle : (a) higher with a resulting lower shear
plane area; (b) smaller with a corresponding larger shear plane
area. Note that the rake angle is larger in (a), which tends to increase
shear angle according to the Merchant equation
BDA 30502 Manufacturing
Technology
Forces Acting on Chip
tan -(2)
t ow
As -(4)
sin
Shear stress = shear strength of work material during cutting
Forces in metal
cutting: (b) forces
acting on the tool that
can be measured
Fc cos Ft sin
(to / sin )
45
2 2
Derived by Eugene Merchant
Based on orthogonal cutting, but validity extends to
3-D machining
45
2 2
To increase shear plane angle
Increase the rake angle
Pc = Fc
HPc = Fc/33,000
Pc HPc
Pg or HPg
E E
Pc HPc
PU or HPu
MRR MRR
Pc Fc v Fc
U Pu
MRR vto w to w
Figure 22.2 Generating shape: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, (e) profile milling.
Forming to Create Shape
Forming to create shape: (a) form turning, (b) drilling, and (c) broaching.
Forming and Generating
Facing
Contour turning
Chamfering
Cutoff
Threading
Turning
Turning operation.
Turning Operation
Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert (photo
courtesy of Kennametal
Inc.)
Facing
Tool is fed
radially inward
Contour Turning
Do – Df = 2d
fr = Nf
Tm = L/fr
MRR = vfd
Where v=π·Davg·N
and Davg=(Do-Df)/2
Calculate:
1. Cutting velocity,
2. Time taken to machine to the length of 55 mm,
3. Total Material removal rate to get 51 mm diameter.
Milling
Machining operation in which work is fed past a
rotating tool with multiple cutting edges
Axis of tool rotation is perpendicular to feed
Peripheral milling
Cutter axis parallel to surface being machined
Face milling
Cutter axis perpendicular to surface being milled
Another form
of end milling
used to mill
shallow
pockets into
flat parts
Surface Contouring
Ball-nose cutter
fed back and forth
across work along
a curvilinear path
at close intervals
to create a three
dimensional
surface form
End Milling
Cutter diameter is
less than work
width, so a slot is
cut into part
Machining Centers
Highly automated machine tool can perform
multiple machining operations under CNC
control in one setup with minimal human
attention
Typical operations are milling and drilling
Other features:
Automatic tool-changing
Pallet shuttles
N
D
N = rotational speed, rev/min; = cutting speed,
m/min,
And Do = outside diameter of a milling cutter,mm.
Cutting Conditions in Milling - 2
fr = Nnt f
fr = Nnt f
MRR = wdfr
A d (D d )
L A
Tm
fr
Face Milling – cutter is centered
Cutting Conditions in Milling - 6
A = O = D/2
D= cutter diameter, mm
Face Milling – cutter is offset
Cutting Conditions in Milling - 7
A O w( D w)
w= width of the cut, mm
Cutting Conditions in Milling - 8
L 2A
Tm
fr
Cutting Conditions in Milling
Problem 1
A peripheral milling operation is performed
on the top surface of a rectangular
workpart which is 400 mm long by 60 mm
wide. The milling cutter, which is 80 mm in
diameter and has five teeth, overhangs the
width of the part on both sides. The cutting
speed is 70 m/min, the chip load is 0.25
mm/tooth, and the depth of cut is 5.0 mm.
Determine (a) the time to make one pass
across the surface, and (b) the maximum
material removal rate during the cut.
Cutting Conditions in Milling
Problem 2
A face milling operation is performed to finish
the top surface of a steel rectangular work
piece 350 mm long by 55 mm wide. The milling
cutter has four teeth (cemented carbide inserts)
and a 85 mm diameter. Cutting conditions are:
v = 600 m/min, f = 0.35 mm / tooth, and d =
3.5 mm.
Determine:
a) the time to make one pass across the surface.
b) the metal removal rate during the cut.
Drilling
Creates a round
hole in a workpart
Compare to boring
which can only
enlarge an existing
hole
Cutting tool called a
drill or drill bit
Machine tool: drill
press
Through Holes vs. Blind Holes
Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish
Tapping
Used to provide
internal screw
threads on an
existing hole
Tool called a tap
Counterboring
Provides a stepped
hole, in which a
larger diameter
follows smaller
diameter partially
into the hole
Cutting Conditions in Drilling - 1
N
D
= cutting speed, m/min; D = the drill
diameter,mm.
Cutting Conditions in Drilling - 2
fr = Nf
tA
Tm
fr
A 0.5D tan 90
2
d
Tm
fr
1. Tool Life
2. Tool Materials
3. Tool Geometry
4. Cutting Fluids
Cutting Tool Technology
2. Tool geometry
Three Modes of Tool Failure
1. Fracture failure
Cutting force becomes excessive and/or
dynamic, leading to brittle fracture
2. Temperature failure
Cutting temperature is too high for the tool
material
3. Gradual wear
Gradual wearing of the cutting tool
Preferred Mode: Gradual Wear
vT n C
to Fs
r S = tan( - ) + cot
tc As
r cos
tan 45
1 r sin As
t ow 2 2
sin