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CH 15
CH 15
MACHINING
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Material Removal Processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Machining
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Why Machining is Important
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Disadvantages with Machining
Wasteful of material
Chips generated in machining are wasted
material
At least in the unit operation
Time consuming
A machining operation generally takes longer to
shape a given part than alternative shaping
processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Machining Operations
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Turning
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Drilling
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Milling
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Tool Classification
1. Single-Point Tools
One dominant cutting edge
Point is usually rounded to form a nose radius
Turning uses single point tools
2. Multiple Cutting Edge Tools
More than one cutting edge
Motion relative to work achieved by rotating
Drilling and milling use rotating multiple cutting
edge tools
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Tools
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Conditions in Machining
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Conditions in Turning
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Roughing vs. Finishing Cuts
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Machine Tools
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Chip Thickness Ratio
to
r
tc
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Determining Shear Plane Angle
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Shear Strain in Chip Formation
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Shear Strain
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Chip Formation
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Four Basic Types of Chip in
Machining
1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Discontinuous Chip
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Continuous Chip
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Continuous with BUE
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
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
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
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Forces Acting on Chip
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Resultant Forces
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Coefficient of Friction
tan
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Shear Stress
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Force and Thrust Force
F, N, Fs, and Fn
cannot be directly
measured
Forces acting on
the tool that can be
measured: Cutting
force Fc and Thrust
force Ft
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Forces in Metal Cutting
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
The Merchant Equation
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
What the Merchant Equation Tells
Us
45
2 2
To increase shear plane angle
Increase the rake angle
Reduce the friction angle (or reduce the
coefficient of friction)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Effect of Higher Shear Plane
Angle
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Power and Energy Relationships
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Power and Energy Relationships
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Power and Energy Relationships
Pc HPc
Pg or HPg
E E
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Unit Power in Machining
Pc HPc
PU = or HPu =
RMR RMR
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Specific Energy in Machining
Pc Fcv
U = Pu = =
RMR vtow
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Temperature
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Temperatures are
Important
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Cutting Temperature
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes