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Machining Process Used To Produce Various Shapes
Machining Process Used To Produce Various Shapes
Machining Process Used To Produce Various Shapes
Various Shapes
CHAPTER 23
Introduction
Addition to producing various external or internal round
profiles,cutting operations can produce many other parts with more
complex shapes
Milling Operation
Highly versatile machining operation
Multitooth tool that produces a number of chips in one revolution
Fig : A typical part that can be produced on a milling machine equipped with computer controls.Such
parts can be made efficiently and respectively on computer numerical control (CNC) machines,
without the need for refixturing or reclamping the part
Slab Milling
Slab milling also called as peripheral milling
Cutters have straight or helical teeth resulting in
orthogonal or oblique cutting action
Fig : (a) Conventional milling and climb milling (b) Slab milling operation, showing depth of
cut , d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v. (c) cutter travel
distance lc to reach full depth of cut.
Milling parameters
Face Milling
The cutter is mounted on a spindle having an axis of rotation perpendicular
to the workpiece surface.
Fig:The effect of insert shape on feed marks on a face-milled surface (a) small corner radius, (b) corner
flat on insert, and (c) wiper consisting of a small radius followed by a large radius which leaves
smoother feed marks (d) feed marks due to various insert shapes
Fig : The effect of Lead angle on the undeformed chip thickness in face milling. Note that as the lead
angle increases, the chip thickness decreases, but the length of contact (i.e. chip width) increases.
The insert in (a) must be sufficiently large to accommodate the contact length increases
Fig : (a) Relative position of the cutter and insert as it first engages the workpiece in face milling, (b)
insert positions towards the end of cut, and (c) examples of exit angles of insert, showing
desirable (positive or negative angle) and undesirable (zero angle) positions. In all figures, the
cutter spindle is perpendicular to the page.
Fig : Cutters for (a) Straddle Milling, (b) form milling, (c) slotting, and (d) slitting with a milling cutter.
Arbors
Fig : Mounting a milling cutter on an arbor for use on a horizontal milling machine.
Fig : Schematic illustration of a bed-type milling machine. Note the single vertical-spindle cutter
and two horizontal-spindle cutters.
Broaches
Fig : (a) Cutting action of a broach, showing various features. (b) Terminology for a
branch.
Fig : Chipbreaker features on (a) a flat broach and (b) a round broach. (c) Vertical broaching machine.
Sawing Operations
Fig : (a) Terminology for saw teeth. (b) Types of tooth set on saw teeth, staggered to
provide clearance for the saw blade to prevent binding during sawing.
Spur Gear
Gear Generating
Fig : (a) Producing gear teeth on a blank by form cutting. (b) Schematic illustration of gear generating with a
pinion-shaped gear cutter. (c) Schematic illustration of gear generating in a gear shaper using a pinionshaped cutter. Note that the cutter reciprocates vertically. (d) Gear generating with rack-shaped cutter.
Fig : (a) Cutting a straight bevel-gear blank with two cutters. (b) Cutting a spiral bevel gear
with a single cutter.
Gear Grinding
Fig : Finishing gears by grinding: (a) form grinding with shaped grinding wheels; (b) grinding by
generating with two wheels.
THE END