|Many fucturiny - Intake 38

Y@ Fuctors affecting Cutting Conditions;

The rigi diby of machine tools, tools, cutting tools and workpieces.
Cuttiy spaed, cutting depth,cutting feed rate,
Workpiece acuucy and Sur face roughness.
-Tool life expec tancy and
and maximum productivity.
-Types of cuttiny uids and coliny methods.
-Ihe hard ness of the workpi ece material and the heat
Number of workpieces. treutment condition.
- The life of the machine tool,
Rouh Cut Finish Ut

I. Higher feed rate. |. Low feed rute.

Higher dep th of cut. a.Low depth of cut.
Q.
load on cutter. 3. Lower chip load on cutter.
3. Higher chip
t. Higher Stock removal rate. 4. -ow material removal rate.
S. Poor Surtuce finish, |S. Good Surtuce finish.

h. Poor Dimen sional accuracy. 6. High dimensional accuracy.

. Close tolerance.
t. Poor tolerance

V= lao m/min
(C) tn:o-S mm tez lm
= 4ooN

()r= to = o= tun o-S cosao

to I-0-ssinào

(D ¬= cot (a9s) + tan a9.se-a

=|.93
(i) V= Vsind = laox Sin a9-s) = S-164 = S9-99 =bom/min
Cos - ) Cos a9s4ao) 6-986a
 h
to =X siDp
O-s= hin a9-S
to

Fs = F cos - Fe Sin V= laox cos ao

cos Q9-sGr a0
= (too cos a9-S) Sox sin a?-s9
o-926a

Sheur work done= F x Ve

= (990| Wm/min
-33169 Nm/s

and guides them

igs are tools thut hold cutting tools in place tappin
Usvally in repeti bive tas ks, such as drilling or
positions.
-Fixtures are vsed to hold work pieces steady in fixed
device :
6) Basic Reayuire ments of a clam ping
work piece rigidly while machining
1. The clamps must hold the acting on the workpiece. Tae
Aguinst oll olisturbing forces enovgh to keep the workpi ice in
The clamping force should Onlyi Correct position,
workpiece while holdina them.
a. The clamping sho vld not damagecontact
always be in with the most aid aints
The campshould of the Component.
The clamping should be applied only where the workpiece has
3. helps to avoid the
fixture body. Tt
enovyh s upport of the dve to clampiny force,
bending and damaging of the workpiece
nemtia
e The clampiny shovld not inter fere the worker orthe
efricientu
of machine or tool. It must enable worker to work
and safely,
S. Time for londing and nloadiny of the workpiece Shatd be shot
ble. The clampiny device mvst be yuick acting
oS possi shovld not leesen the during machining proce sses dve to Vibration
Ciamping and distortion.
9 lool failure oceurs when the tol expuriences wear and tear unti! the
point of breaking.
Fuctors can include:Hiyh increase in to
· Proper
speed settingsthe arent vsed.
can place abnormal
tools rated is used whichStress
more Ttorce ,than on the tool.
lhe tool vsed muy be weaker than the workpiece materiul,
Ihe tool is forced to a laryer cutting depth , which can abo incronse the
stress on the tool.
These factors can be a voided by:
VS ing ppropriate Cutting fluid.
Using the appropriate toolSpindle
for the job, along with the proper
speed and feel ate,
"Instid of cutting alarge depth in one process, gralually cut throuy hthe
dLepth in various cycles.
-Ensune thut the tool is sharpened ar nepaired ,or
replacel Ls rayuired.
d) t= &tm/min tm lhoUr s 60min -T loughcuts
Rough Cuts
fish finish Cuts
C=VTh
n= / s
* loch cuts :

C= 47-486
Ta =|bb-99 min
On liaAter tinish cuts - Tool fe
Ta l67min &78 hours
 inyolves rotuting a workpiee against a single-bladed
3Alathe
SOA machine o Cutting tool.

A milling machine invalves ro tating a

mutti- bladed or pointed cuttiny
tool against a stationary workpitce.
turning , facing, threa ding
threuding ,etc.
Some operations of lathe machines are
angle milling form
face milling,
Some operations of milling machines are milling, et.

Pace ming /End millg a flat vertical, horizontal

eretessesOnerabions provide
-Both these
pgular flat surta ce. whéle end ming is vsed
Used for avh cuts,
e milling is mtly
Ln Smooth finishts.
)* Face milling : and is Used to pét create a chingn
simplest operation
nis is 0ne of the fuces of the workpiece to allow tor even ma
SürTace finish on the
in later processes.
with the axes of the milling Cutter
only used milling cutter's
-Ihe facing operation is workpiece Surface, and the
being Perpendicular tothethe Same a the breudlth otf the mil/ing suruce,
Oiame ter is usuallu
-Face imillcutters are vsual, vsed fonthis process.
* End Milling: a vertical, horiz0ntul or argular
prodvce
- lhis process is used to rovgh or Smopth finish
can be prodvceet by
a
f lat surface. Either cutting spted s.
Using different tools and
vurious s lots, grooves and Key ways,
- Can be used to cut end mil|
-flute tber
two most common are o-flute and
- lhe
* Gear Cutting: perform ed using a form cutter mounted
cutting operations can be ground to the proper promile
- Gear or an end mill
on ca horizon tul
arbor
"The cutéer profile Fits precisely with
and he ld ina verical splndlle.
ge, and the eyvally Spac edd ger teeth
the tooth space of the blank by holoing the workpiec on a
are machined on a geurand indexing it.
universuj dividing hend coerntion.
-Formed cutters are vsed for this
90 A ’ Over hunging arm with spindle and arbor.
B Table
C ’ Sudddle
D Column
D Dividing Head :
Ihis isused for indexina opertion of dividiny the periphery of a
piece of work into any number ot eqyual parts.
¿ Shows the head stock which consists of tha :
Small Index Plate
> Lurge Iadex Plate
"Crunk
Gear Housi ng.
YO Drilling. Reaminy, Boring, Counter boring, Counter sinking, Spot foci"y,
Tapping, Lapping , Grinding , Trepanning.
(b) B00 x too x So mm
Workpiece
Mole d Qmm f=|:Smmfrev Ve bSmlmin
0 Spindle Speed =- looo x6s = lo 34s rpm

) Feed Speed - l"Sx lo34-s = l$s|.76 mm/min

move 2-uxis
Vepth to egt = So +S Ssmm
.
Cutting time=9abo = oob25ma
|SSI-6
ta3serondy :O3863 min
( MR=(xao)xx1sSI-t
ISI-6 49 Soo mn?lmin
 Ve =lom/min return tine
(9C) 3oo mmx oomm K=a Stroke time
Vc= NLG-) f= &mn ldouble stroke C6omm

() tm = LB (rk)
(DooVe f loo0xo x a

N= lo00 Vo looox lo = IS38 rpm d a0lo

Li+K) Sa0(+o-a9 a

., MRR= &S Axlox

(S38x Saox +0-a9) =l9990
mmmin
(a Total time for Drilling and
Shaping = 0-0386t +y5
=4.79 min
Smins,in each machine, to center sd the workpiece
Allowing
and seh posi tion the cutters before machining:
Total time = lo +929
19-29 min n Abovt oria aomins

50 CAD/CAM refers to the inteara tion of Com puter -Aded Design CAD)
and Computer -Aided Manufac turing C),
CAD/CAM soft ware is used. to design and manvfacture prototypes,
finished produets,and prouction uns of pro ducts using a single
developnent tool.
S(6) t= lomm Safe ty clearunce Smm
Rovgh M:il:ng: Hss opis F=t000 S= 700 Tol

CC F 49so S= 670 Toa

Centre Deill : TO3 F =800 S=ho00
Dril| : To §F=+o S= 4Ro0

kbs MOb Tol G43 Hoa 25

M03 S00 MO8
Gol 2-lo F80
G3 HO 25 G4a Doa xo Yo
Mo3 S ar00 MO Gol Xbo F9000
Gol 2-lo F&0
F Go y-lo
G4a DOI XO YO GO3 X+S -as RIS
GO Xbo Fo00 X\00
Gol Y-$s
G03 X +S y-as RIS XSo
Gol xlo0 G03 X30 y-7s RaO
Gol y-SS Goi XO
Go XSo Go| YO
Go3 X 30 Y-S Kao G01 2S AAo AMos
Goo x-o YIO
Go XO
GGo ft M30
Gol YO
Go| 25 MO9 Mos
AG00 X-lo YI0
 Mob Toa
Mob TO3 G00 x- lo Ylo

G43 HO3 2S G00 X30 Y-1S

G00 Xx 30 Y-IS Mo3 S700 M08
M03 Shoo0 Mo2 Go| 2-lo Fg10
G8 GGI X30 y-6 2-lo RS F8OO
Gol zS GDoa xad-s Y-1s P o
Groa I 5 F6T00
GOO Y-3s Gol 29
G18 Gg) X3o y-35 Z-lo Rs F8ooNS
G00 X30 Y-3s
MOS M09 Gol 2-l0 F10
GOO X-l0 Ylo G4 D0a xaas y-3s
G4o G49 AAG8o M30 Góa I?S F600
Mob Tot
Goo X-lo YI0
Mos Mo9
G0o X-lo YIo
Goo X30 Y-1S
MO3 S4Ro0 M09
G98 G8 | X3o Y-1S 2-0 RS Flo

G0o Y-35
G9 Gg X30 Y-3S 2-lo RS FH0

MO5 Mo9