Machining Chapter 5

MANUFACTURING 1
WEEK 5
Machining
 No calculations!

 Machining is removing material in small

pieces, also called Chips
Chips can be recycled
 Aircraft parts: 90-95 % material will be
removed
 Forged and Cast products: less than 5%
is removed
Machining
 Berekeningen in H6 geen examenstof

 Materiaal wordt afgenomen in vorm van

spanen, die worden afgevoerd.
Spanen kunnen gerecycled worden
 Vliegtuigonderdelen: 90-95 % verwijderd
 Smeed-gietstukken: minder dan 5%
Machinability (to machine or
not)
 Shape (almost no limitations, apart from
size)
 Tolerances (can be very accurate)
 Material properties (limitations)
 Costs (energy / labour), also compared
to other methods

 In general: Large series of products:

Do not machine
Machinability
Machinability
 Turning on a Lathe
Machinability
Cutting Tool(s)
Principles / Cutting Tool angles
Chip formation
 Pressure stress -> shear stress

 Continuous soft material

 Continuous with build-up edge
 Discontinuous hard materiaal
Heat development
Tool life / Tool wear
 Tool failure
1. Crater wear
2. Flank wear
3. Nose wear
Choice of cutting material
 Material
 Type of process
 Type and shape of tool
 Price
 Hardness of cutting materials
SOFT

 Unalloyed and alloyed tool steel

 High-Speed Steel (HSS)
 Cemented Carbide (Hardmetal - WIDIA)
 Cermets (TiN, TiC, DLC)
 Ceramics (Al2O3)
 Polycristalline CBN
 Diamond
HARD
See figure 5.13
Cutting material
 Hardened
0,9-1,2 % C
0,1-0,2 m/s
+- 200 degrees Celsius

 HSS
18-4-1 alloy (18%Tu, 4%Cr, 1%V)
0,3-0,5 m/s
500 – 550 degrees Celsius
Best for complex tool geometry
○ Other alloys possible 0,5-1 m/s
Cutting material
 Hardmetal (WIDIA); (Coated Carbides)
Composites of metalcarbides in Cobalt
(sintered) (W, Ta, Mo, Ti, Nb, Co (binder)

 Coating (CVD or PVD)

Thin layer of 2 – 20 µm coating
(TiC, TiN, Al2O3)
1200 °C
1-10 m/s
Cutting material
 Cermets
CERamic METals (TiN, Nickel, Cobalt and
Tantalum nitrides)

 Ceramic cutting material (Al2O3)

1500 degrees Celsius
20 m/s
Cast iron and hard alloys
Cutting material
 PCBN (polycrystalline cubic boron nitride)
Man made tool material
Used for hardened steels and superalloys
1800 degrees Celsius

 Diamond
Hardest material known
600-700 degrees Celsius
Finishing of non-ferro metals (Alu, brass, copper)
Expensive
Tools
 Forged tool
Grinding
 Inserts
One time use
Guess the landing gear!
Machining processes
 Turning
 Hole-making processes
 Broaching
 Milling
 Grinding
 Finishing
Turning (using a lathe)
 Rotating main movement
 Tool, feed movement
Axial with long. turning
Radial with lateral turning
Chipcontrol
 Chips can spin around the workpiece / tool
 Chips are sharp and hot

 Behavior of the chip can be controlled by:

Geometry of the tool
Chipbreaker
Turning tools
Hole-making processes
 Drilling
 Boring (kotteren (NL))
 Reamers
 Tapping
Hole-making processes
 Drilling
 Boring
 Reamers
 Tapping
Drilling
 Conventional Drilling
All the material will be removed
 Core Drilling
There will be a core left after drilling
 Re-bore
To make the diameter of an existing hole
larger
Drill
Special drills
Drilling machines
 Bench drilling machine
 Column drilling machine
 Radial drill press
 CNC drilling
Other hole-making operations
 Finish boring
Three-cutting face and four-cutting face
drills
 Reaming
Tolerance fits
 Boring (longitudinal)
Milling
 Sidemilling
Horizontal spindle machine
 Facemilling
Vertical spindle machine

 Sidemilling
Downmilling
Upmilling
Up- or down milling
Axial Turbine milling
 Milling tools

a. Peripheral (or slab) milling cutter d. T-groove milling cutter

b. side-and-face milling cutter e. Slotting end milling cutter

c. Disc cutter f. End milling cutter

Milling tools
CNC Milling (radial turbine)
Grinding
 Grinding, wherein the abrasive are
bonded together into a wheel

 Cylindrical grinding and surface grinding

Accurate
Surface quality
Hardness of product
Grindstone
 Abrasive grain
Aluminium oxide
Silicon carbide
CBN or diamant
 Binder
Ceramic binder

 70% of the energy used will be

transformed in heat
Finishing operations
 Technology is almost same as grinding

1. Honing – inside of cylindrical shape

Honing stones
2. Superfinishing – outside cylindrical shape
Stone is shaped in contour
3. Lapping (or flat honing)
Flat or cylindrical Surface
Finishing operations
1. Honing – inside of cylindrical shape
Honing stones
Finishing operations
2. Superfinishing – outside cylindrical shape
Stone is shaped in contour
Finishing operations
3. Lapping (or flat honing)
Flat or cylindrical Surface
Honing (movie)
Honen en Leppen
 Honen Leppen
Lapping (leppen)
Finishing - Superfiinishing
 Technologie is the same as grinding but
with smaller “stones”

 Honing
Finishing inside diameter of a hole
 Superfijnen
Polishing outside diameter superfinishing
 Leppen
Polishing flat surfaces (lap discs)
Some movies of Machining processes

 Machine an Engine Block

 Triumph Cylinder Honing
 How it's Made; Aircraft Landing Gear