Machining operations and machine tools
J.Ramkumar Dept of Mechanical Engineering
Contents
Turning and Related Operations Drilling and Related Operations Milling Machining Centers and Turning Centers Other Machining Operations High Speed Machining
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Classification of Machined Parts
1. Rotational - cylindrical or disk-like shape 2. Nonrotational (also called prismatic) - block-like or plate-like
Machined parts are classified as: (a) rotational, or (b) nonrotational, shown here by block and flat parts
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Machining Operations and Part Geometry
Each machining operation produces a characteristic part geometry due to two factors:
1.
Relative motions between the tool and the workpart
Generating part geometry is determined by the feed trajectory of the cutting tool Forming part geometry is created by the shape of the cutting tool
2.
Shape of the cutting tool
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Generating shape: (a) straight turning, (b) taper turning, (c) contour turning, (d) plain milling, (e) profile milling
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Forming to create shape: (a) form turning, (b) drilling, and (c) broaching
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Combination of forming and generating to create shape: (a) thread cutting on a lathe, and (b) slot milling
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Lathe Toolbit Angles and Clearances
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Engine lathe
Diagram of an, showing its principal components
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Tool-work interaction
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(a) (b) (c) (d)
Methods of Holding the Work in a Lathe
Holding the work between centers Chuck Collet Face plate
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Turret Lathe
Tailstock replaced by turret that holds up to six tools Tools rapidly brought into action by indexing the turret Tool post replaced by four-sided turret to index four tools Applications: high production work that requires a sequence of cuts on the part
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Bar Machine
Similar to chucking machine except collet
replaces chuck, permitting long bar stock to be fed through headstock At the end of the machining cycle, a cutoff operation separates the new part Highly automated (the term automatic bar machine is often used) Applications: high production of rotational parts
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NEW NCs or CNCs
high speed spindle (> 40,000 rpm) high feed rate drive ( > 600 ipm) high precision ( < 0.0001" accuracy)
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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 an internal turning operation Boring machines
Horizontal or vertical - refers to the orientation of the axis of
rotation of machine spindle
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Shaping and Planing
Similar operations Both use a single point cutting tool moved linearly relative to
the workpart
A straight, flat surface is created in both operations Interrupted cutting
Subjects tool to impact loading when entering work
Low cutting speeds due to start-and-stop motion Usual tooling: single point high speed steel tools
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Type of machine tools and shapes
Components of a shaper
Open side planer
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Through Holes vs. Blind Holes
Through-holes - drill exits the opposite side of work Blind-holes drill does not exit work on opposite side
Two hole types: (a) through-hole, and (b) blind hole
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Drill Nomenclature
www.neme-s.org/2005%20May%20Meeting/drills.pdf
Machining operations related to drilling
(a) Reaming
Used to slightly enlarge a hole, provide better tolerance on diameter, and improve surface finish
(b) tapping
Used to provide internal screw threads on an existing hole Tool called a tap
(c) counterboring
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Provides a stepped hole, in which a larger diameter follows a smaller diameter partially into the hole
Work Holding for Drill Presses
Workpart can be clamped in a vise, fixture, or jig
Vise - general purpose workholder with two jaws Fixture - workholding device that is usually custom-designed for
the particular workpart Drill jig similar to fixture but also provides a means of guiding the tool during drilling
Bench Drill
Upright drill press
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Radial drill press
Milling
Machining operation in which work is fed past a rotating tool with multiple cutting edges Axis of tool rotation is perpendicular to feed direction Creates a planar surface; other geometries possible either by cutter path or shape Other factors and terms:
Milling is an interrupted cutting operation Cutting tool called a milling cutter, cutting edges called "teeth" Machine tool called a milling machine
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Two forms of milling
(a) peripheral milling, and (b) face milling
Peripheral milling
Cutter axis is parallel to surface being machined Cutting edges on outside periphery of cutter
Face milling
Cutter axis is perpendicular to surface being milled Cutting edges on both the end and outside periphery of the
cutter
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Peripheral milling cutter
The basic form of peripheral milling in which the cutter width extends beyond the workpiece on both sides
(a) slab milling (b) Slotting
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Conventional Face Milling
Cutter overhangs work on both sides
(a) conventional face milling
(c) end milling (d) profile milling (e) pocket milling (f) surface contouring
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Types of milling machine
(a) horizontal knee-and-column
(b) vertical knee-and-column
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Process planning for a component
Operation of a mill-turn center: (a) example part with turned, milled, and drilled surfaces; (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
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Two forms of milling
Up/conventional milling Cutter teeth is opposite the feed direction Chip starts from thin to thick Chip length is more Cutter engaged in the work for longer time/volume of material cut Lifting of workpart as the teeth exit the w/p
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Down/climb milling Cutter motion is the same as the feed direction Chip starts from thick to thin Chip length is less Cutter engaged for shorted time so better tool life Tends to hold the w/p against the milling m/c table
Cutting conditions in Milling
Peripheral milling
Face milling (a) cutter is centered over the workpiece (b) cutter is offset to one side
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Cutting condition in Peripheral Milling
Cutting speed : D cutter diameter
Feed(f) is usually feed/cutter tooth chip load MRR
: w = width and d= depth of cut Approach distance(A)
Milling time (Tm)
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Cutting condition in Face Milling
Cutter in centre
Cutter offset
Machining time
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Moves a multiple tooth cutting tool linearly relative to work
Broaching
in direction of tool axis. tooling is expensive
Advantages: broach Good surface finish Close tolerances Variety of work shapes possible A starting hole must be present in the part to insert broach at beginning of stroke Cutting tool called a broach Owing to complicated and often (a) Typical parts that can be made by internal custom-shaped geometry,
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broaching. (b) Parts made by surface broaching. Heavy lines indicate broached surfaces.
Sawing
Cuts narrow slit in work by a tool consisting of a series of
narrowly spaced teeth Tool called a saw blade Typical functions:
Separate a workpart into two pieces Cut off unwanted portions of part
(a)power hacksaw
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(c) circular saw (b) bandsaw
Sawing operations
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High Speed Machining
Cutting at speeds significantly higher than those used in conventional machining operations. faster production rates, shorter lead times, and reduced costs
Comparison of conventional vs. high speed machining
Indexable tools (face mills) Work material Conventional speed m/min Aluminum Cast iron, soft Cast iron, ductile Steel, alloy Source: Kennametal Inc.
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High speed m/min 3600+ 1200 900 360
600+ 360 250 210
High Speed Machining Applications
Aircraft industry, machining of large airframe components
from large aluminum blocks
Much metal removal, mostly by milling
Multiple machining operations on aluminum to produce
automotive, computer, and medical components
Quick tool changes and tool path control important
Die and mold industry
Fabricating complex geometries from hard materials
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