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Week9 10 Machining
Week9 10 Machining
MACHINE TOOLS
Figure 22.1 Machined parts are classified as: (a) rotational, or (b)
nonrotational, shown here by block and flat parts.
Figure 22.2 Generating shape: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, (e) profile milling.
©2007 John Wiley & Sons, Inc. M P Groover,
Fundamentals of Modern Manufacturing 3/e
Forming to Create Shape
Figure 22.3 Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching.
Source: Kalpakjian, S, and Schmid, S, Manufacturing Engineering and Technology 4th Ed, Prentice Hall, Upper
Saddle River, 2001, pg. 595 Fig. 22.1
Various Cutting Operations (cont)
Source: Kalpakjian, S, and Schmid, S, Manufacturing Engineering and Technology 4th Ed, Prentice Hall, Upper
Saddle River, 2001, pg. 595 Fig. 22.1
Turning - Facing
• Instead of feeding
tool parallel to axis
of rotation, tool
follows a contour
that is other than
straight, thus
creating a
contoured shape
Figure 22.6 (c) contour
turning
Figure 22.6
(e) chamfering
Threading – a “V” shaped tool is used to put a thread into the stock
material
Several passes are required to get to the full depth – process is called
“chasing a thread.”
©2007 John Wiley & Sons, Inc. M P Groover,
Fundamentals of Modern Manufacturing 3/e
Drilling, Boring
Turning – Drilling on Axis
• Once a small hole is drilled, a boring tool can be used to enlarge the end
hole to the final diameter.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Turning - Tapering
– This time does not include the time required for tool approach or
retraction. •
Machinery’s Handbook, 27th ed., p996
Example – Turning Speed
MRR f d (22.6)
D 0 Df
d
2
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Example – Turning MRR
• Calculate the MRR for the last example.
Turning Guidelines
• Design Recommendations
– Minimize Material Removal
• Start with a Good Component
• Use Standard Stock
– Appropriate Tolerances
– Rigid Design
– Use of Standard Cutting Tools•
Cross slide
crank. Allows
the tool to travel
into the work
piece.
Main “saddle” or
carriage wheel. Allows
travel down the lathe
bed.
Lathe - Specifications
• Size designation
– Length of Bed
– Maximum distance between centers
– Swing - maximum diameter that can be
rotated on the lathe
• Maximum RPM
• Horsepower
• Bed
– Foundation of the
lathe
– Supports all other
major components
– Top part has two
ways •
Basic Lathe: Headstock
• Fixed
• Mounted on the ways
• Consists of:
– Hollow spindle
• has provisions for
attaching
workholders
– Bearings
– motors, pulley and
belts or transmission
gears to drive the
spindle •
Source: Kalpakjian, S, and Schmid, S, Manufacturing Engineering and Technology 4th Ed, Prentice Hall, Upper
Saddle River, 2001, pg. 610 Fig. 22.8 Source George Gorton Machine Company
Multiple Spindle Bar Machines
Four, six, or eight spindles and corresponding cross slides
Multiple parts are machined simultaneously by multiple
tool
Example: six spindle automatic bar machine works on six
parts at a time
After the necessary cuts are made at each station, the
chucks index(rotated) around to a new location.
Continues until the part has passed all the tooling stations
and is then cut off or released
High production machines
Multiple Spindle Bar Machine
Figure 22.9 (a) Part produced on a six-spindle automatic bar machine; and (b)
sequence of operations to produce the part: (1) feed stock to stop, (2) turn
main diameter, (3) form second diameter and spotface, (4) drill, (5)
chamfer, and (6) cutoff.
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 256 Fig. 6-23 (Courtesy of the National Acme Company)
Vertical Lathe
• Vertical lathes
are used for
exceptionally
large turnings.
• Easier to load
large
workpieces,
chips fall out of
the way. www.orttool.com
CNC Lathe
• Computer Numeric Control
– Computer controlled
– Wide variety of process
capability
– multiple axis
– Indexing and contouring head
– On- line and off- line
programming available www.haascnc.com
Boring
• Difference between boring and
turning:
– Boring is performed on the inside diameter of an
existing hole
– Turning is performed on the outside diameter of
an existing cylinder
• In effect, boring is internal turning
operation
• Boring machines
– Horizontal or vertical - refers to the orientation of
the axis of rotation of machine spindle
Boring
• Boring is the process of enlarging an existing
hole or internal cylindrical surface.
• This can be accomplished on a lathe or a
machine tool specifically designed for the
process; such as a horizontal boring machine. •
Vertical Boring Mill
• Boring
– Vertical
– Horizontal (like a milling machine) •
Boring Tools
www.blackbirdsf.org
www.gadgetbuilder.com
Drill Geometry
• Three main components are the:
– Shank
– Body
– Point
• Shank : the portion which is “clamped” to provide the drive.
– Straight shank for drill up to ½”. Shank is equal to body diameter.
– Above ½”, shank can be tapered or reduced. •
Drill Geometry
Body
– Flutes - Helical grooves cut around the body
• Allow coolant to flow to the cutting edge
• Allow chips to be withdrawn
• For steel 24°, plastics 35-45° •
Sizes
Numerical: No. 97 (0.0059 in.) to No. 1 (0.228 in.).
Letter: A (0.234 in.) to Z (0.413 in.).
Fractional: Straight shank from 1/64 in. to 1 1/4 in.(in 1/64 in.
increments) to 1 1/2in.(in 1/32 in. increments), and larger
drills in larger increments.
Millimeter: From 0.05 mm in increments of 0.01 mm
Drilling Forces and Torques
• Thrust force:
– In the direction of hole axis
– Depends on
• Workpiece material
• Feed
• Rotational speed
• Drill diameter and design T
• Power = Specific energy × MRR
• Torque = Power / w Fc
Drill Life Ft
Process Parameters
• Cutting speed (RPM)
D
where: N is the rotational speed (rpm)
v is the cutting speed
Feed is proportional D is the drill diameter
to drill diameter- high
feed are used with
large diameter drill fr Nf (22.8)
/www.blueridgemachinery.com
Drills - Tapping machines
• Tapping machines
synchronize the
downward
feedrate with the
tool (tap) rotation.
www.rmt.net
Drills - Multi-Spindle
• Gang Drilling Machine
– Equipped with more than one
spindle
– Multi-head arrangement
– Single table
– Used for production set-up
– Multiple operations at one
location (drill, ream, tap,
c’sink, c’borte etc.)
www.wisc-online.com
Drill Presses: Turret
• CNC Turret (Conventional)
– 2 axis motion
– Computer controlled
– Series of operations
– Turret indexes to different tools
• Individual speeds / feeds
Milling
Machining operation in which work is fed past
a rotating tool with multiple cutting edges
• Axis of tool rotation is perpendicular to
feed
• Creates a planar surface
– Other geometries possible either by cutter path or
shape
• Other factors and terms:
– Interrupted cutting operation
– Cutting tool called a milling cutter, cutting edges called
"teeth"
– Machine tool called a milling machine
Two forms of milling: (a) peripheral milling, and (b) face milling.
(b) slotting
• Straddle milling
• Gang milling•
Peripheral Milling: variations
tobkes.othellomaster.com
www.precisionmeasure.com
Horizontal Milling Machine
www.haascnc.com
Milling - Speeds and Feeds
Milling Speed: N (22.13)
D
where: N is the rotational speed (rpm)
v is the cutting speed
D is the mill diameter
Milling Feed: fr Nntf (22.14)
Feed rate
– Feed per tooth (chip load) f
– Table feed rate
• Depth of cut•
Cutting Conditions
Cutter is centered over the work Cutter is offset to one side over
piece the work
A = O = D/2 = 10 cm
t = (200 mm + 200 mm) / (0.05 mm/s) = 8000 s = 133.33 min!•
MRR = w d fr = (50 mm) (2 mm) (0.05 mm/s) = 5 mm3/s
•
Example
www.lathemaster.com
www.jjjtrain.com
Milling – Multi-axis Rotary
www.fox302.com/magclamps.jpg www.mdaprecision.com
Milling - rotary table horizontal
www.mdaprecision.com www.precisionscalereplicas.com
Milling - clock making
www.orologeria.com
Machining - difficult shapes CNC
www.allistool.com www.haas.com
Milling - 5-axis mills CNC
www.formcoplastics.com
Operation of a mill-turn center: (a) example part with turned, milled, and drilled
surfaces; and (b) sequence of operations on a mill-turn center: (1) turn second
diameter, (2) mill flat with part in programmed angular position, (3) drill hole with
part in same programmed position, and (4) cutoff.
Advantages:
• Good surface finish
• Close tolerances
• Variety of work shapes
possible
Cutting tool called a broach
• Owing to complicated and
often custom-shaped
geometry, tooling is
expensive
Broaching
• Broaching is the process of removing
metal with a tool which has “teeth”
arranged in a row.
• Each tooth is successively higher than the
previous tooth and removes more
material.
• In broaching, one stroke or cycle of the
machine produces a finished part. •
• Broaching is used to produce both
internal and external features.
• Production rates are high and
tolerances of +/- .0005” are possible. •
• Reciprocating saws
– Horizontal hacksaw and vertical
sawing machines
– Light to heavy duty
– Simple and most economical to
operate
– Manual to fully automatic feed
mechanisms
– Uses blades similar to hacksaw
blades •
SAWING