TECHNOLOGY II

Industrial Engineering
oscar.caldas@unimilitar.edu.co

@oicaldas

Oscar I. Caldas

Eng. Oscar I. Caldas

SHAPING / PLANNING

Single-point cutting tool COMMON OPERATIONS:

• Creating straight, flat surfaces
Limited to low speeds (horizontal, vertical, or inclined)
• Creating specific shapes
Impact loading upon
• Performing knurling on flat surfaces
entry into the workpart

SHAPING PLANNING
 SHAPING / PLANNING

SHAPER PLANER

Types of shapes cut by

shapers and planers:
SHAPING / PLANNING
SHAPING / PLANNING

Cutting conditions:
(Energy expenditure, tool wear, part’s surface finish)

𝑽𝑪 𝑽𝑹 𝑽𝒎
𝑳 𝑳 𝑽𝒎 = 𝟐 𝒏=
𝑽𝑪 = 𝑽𝑹 = 𝑽𝑪 + 𝑽 𝑹 𝟐𝑳
𝒕𝑨 𝒕𝑹
𝑛= Number of double strokes per minute (1/min)
𝑽𝑹 ≅ 𝟐𝑽𝑪
𝑳 = 𝒍𝒖 + 𝒍𝒂 + 𝒍

𝑉𝐶 = Cutting speed (m/min)

𝑉𝑅 = Returning speed (m/min)
L = Length of stroke (m)
𝑡𝐶 = Cutting time (min)
𝑡𝑅 = Returning time (min)
𝑙𝑎 = Approach length (m) -> ≈ 0.1 m
𝑙𝑜 = Overtravel length (m) -> ≈ 0.05 m Speed for shaping and planing by using a High Speed Steel (HSS) tool
BROACHING

Multiple-teeth cutting tool

• Good surface finish

• Close tolerances
• A variety of work shapes
BROACHING

External broaching

Internal broaching
DRILLING

Rotating cylindrical tool that has two COMMON OPERATIONS:

cutting edges (twist drill) • Creating round holes in a
workpart
Good access for fluids and exit for chip

OPERATIONS RELATED TO DRILLING

• Reaming
• Tapping
• Centering
• Countersinking
• Counterboring
Through hole Blind hole
 DRILLING

Cutting conditions: Cutting Feed rate

(Energy expenditure, tool speed
wear, part’s surface finish)
𝒗
𝑵= 𝒇𝒓 = 𝑵𝒇
𝝅 ∗ 𝑫𝑫

𝒕+𝑨 𝜽
𝑻𝒎 = 𝑨 = 𝟎. 𝟓𝑫𝑫 𝒕𝒂𝒏 𝟗𝟎 −
𝒇𝒓 2

• Lower feeds: Longer chip, better Surface

finish, and more energy expenditure.
Drills – Cutting speed for HSS machining tools
• Higher feeds: Less tool wear, less energy
expenditure and les risk of fracture.
DRILLING
MILLING

Machining of a workpart by Multiple-edges

feeding past a rotating cutting tool
cylindrical tool

• Spindle rotational speed

• Tool feed rate
• Depth of cut

Axis of rotation
Perpendicular
Feed direction
Interrupted
cutting operation
MILLING

PERIPHERAL (PLAIN) FACE

Axis of the tool Axis of the tool

parallel perpendicular
Work surface Work surface
TYPES OF PERIPHERAL MILLING

Slab milling Slotting Side milling Straddle milling

Up milling Down milling

TYPES OF FACE MILLING

Conventional Partial fase milling End milling

face milling

Profile milling Pocket milling Surface contouring

MILLING
MILLING – CUTTING CONDITIONS

CUTTING SPEED ROTATIONAL SPEED

𝑣 N: Spindle rotation [rpm]
𝑁= v: Cutting speed [m/min]
𝜋𝐷 D: Tool diameter [m]

FEED RATE
fr: Feed rate [mm/min]
𝑓𝑟 = 𝑁𝑍𝑓 f: Feed (chip load) [mm/tooth]
Z: Number of teeth on cutter

MACHINING TIME

𝐿+𝐴 L: Length of workpart [mm]

𝑇𝑚 = A: Aproach distance [mm]
𝑓𝑟
MILLING – CUTTING CONDITIONS

Slab (peripheral) milling Face milling

APPROACH APPROACH
DISTANCE DISTANCE

𝐴= 𝑑(𝐷 − 𝑑) 𝐴 = 2 𝑤(𝐷 − 𝑤)
d: depth of cut (mm) w: width of the cut (mm)
THANKS