Course Contents: Machine Tools Work Holding Devices Machining Parameters Non-Traditional Machining Processes Metrology Surface Texture and Measurement Standardization CLO/ PLO: es SE Osos teste ce excel oad nl a serra according to particular manufacturing requirements. ‘Analyze manufacturing tasks, identify relevant machining processes and perform 3 pertinent calculations. ‘Classify and characterize various measurement and tolerance techniques. z Books: + Fundamentals of Modern Manufacturing Materials, Processes & Systems By Mikell P. Groover (2! & 4"* Edition). + Materials & Processes in Manufacturing By J T. Black & Ronald A, Kohser (Degarmo) (11" Edition).+ Production Engineering: It is a combination of manufacturing technology, engineering sciences with management science. A production engineer typically has a wide knowledge of engineering practices and is aware of the management challenges related to production. + Purpose: Production engineers will have design duties related to materials, processes and work flows. They perform these duties using drafting tools and design software such as CAD. Production engineers must develop efficient design and manufacturing methods to find the right balance between cost, safety and quality. + Factors: The factors of production are: * Land + Labor * Capital + Entrepreneurship+ Manufacturing Processes: A manufacturing process converts unfinished materials to finished products, often using machines or machine tools. For example, injection molding, die casting, progressive stamping, milling, arc welding, painting and assembling. are commonly called processes or manufacturing processes. rir = 4 ay pees hss os oo se |-=s = -Sss -=s a = —- 1o=~ “ emma 1.1 Tore ways tn ste manner fo} en tection pecan, ad i) an econ precmem + Basic Manufacturing Process Its the manufacturing processes that create or add value to product. The manufacturing processes can be classified as: + Casting, foundry, or molding processes. + Forming or metalworking processes. + Machining (material removal) processes. + Joining and assembly. + Surface treatments (finishing) + Rapid prototyping. + Heat treating. + Other.Classification Of Material Removal Processes: rane cone Camere | are Sse [ccesses | 7|_pocance eon Manufacturing Support [Otis steaaive System: Mechanical ener Peaster sen Tomato |_| [Searoctercs Tonena nonnny 7 poceses Chemical macnnTo operate its facilities efficiently, a company must organize itself to design the processes and equipment, plan and control the production orders, and satisfy product quality requirements. These functions are accomplished by manufacturing support systems— people and procedures by which a company manages its production operations. Most of these support systems do not directly contact the product, but they plan and control its progress through the factory. Manufacturing support functions are often carried out in the firm by people organized into departments such as the following: + Manufacturing engineering. The manufacturing engineering department is responsible for planning the manufacturing processes—deciding what processes should be used to make the parts and assemble the products. This department is also involved in designing and ordering the machine tools and other equipment used by the operating departments to accomplish processing and assembly. + Production planning and control. This department is responsible for solving the logistics problem in manufacturing—ordering materials and purchased parts, scheduling production, and making sure that the operating departments have the necessary capacity to meet the production schedules. + Quality control. Producing high-quality products should be a top priority of any manufacturing firm in today’s competitive environment. It means designing and building products that conform to specifications and satisfy or exceed customer expectations. Much of this effort is the responsibility of the QC department.Cutting tools Introduction to metal cutting processBy using various types of process, the metals are removed from work piece to obtain require shape and size. That are classified as below (i) non cutting process (ii) cutting process. For generally, the metals are shaped in require form under the action of force and heating. That is no any cutting of metal, chip formation removal. So, this method of no cutting process. The process such as forging, drawing, spinning, rolling, extrusion are non cutting process. The metal of removed and become with required shape and size to be obtained. So the unwanted metal removing from the work piece is called the form of chip. The various cutting process obtained such as turning, drilling, boring, shaping, milling and etc. For generally edge of cutting tools having harder than the work piece metal. The various metal cutting process done by the relative motion between work piece and cutting tools. The relative motion may be occurred during metal cutting process as follows: + The rotation of work against the cutting tools. Example — turning + The rotation of tools against the work piece. Ex: milling and drilling + The linear motion of work against the cutting tool. Ex: planning * The linear motion of tools obtain against the work. Ex: shaping. Cutting Tool Technology ‘Two principal aspects: + Tool geometry + Tool materialCLASSIFICATION According to the number of major cutting edges (points) involved as follows: + Single point: e.g., turning tools, shaping, planning and slotting tools and boring tools + Double (two) point: e.g., drills * Multipoint (more than two): e.g., milling cutters, broaching tools, ==] Marcin ewiew (srieroec) hobs, gear shaping cutters etc. =Single Point Multipoint y \ .Classification of cutting tools New sutce fr Speed meten (wo) nx t Li) Ke ‘Cin ooh Wer cy o ating exter % eee New satce wont Feed moto (wor) wen © 23.2 The dhe mnt common types of machining proce: tein. ling ant mo Fling perp riled wb ace ringSingle Point Cutting Tool The single point cutting tool is mainly used to metal remove from work piece become with require shape and size of product. It remove large amount of metal in quickly again rotating the work piece. Boring, turning are performed by using single point cutting tool in lathe machine. Major Cutting edge Shank {side cuttin: Cutting part Minor cutting edge(end cutting edge) Minor Flank Major Flank ComerParts of Tool: Shank: It is main body of tool. Flank: surface/ surfaces below & adjacent to cutting edge is flank of tool. Face: Surface on which chip slides is called face of tool. Nose: It is formed at junction of side & end cutting edges. This junction/ nose has a curve of small radius, know as nose radius. Cutting Edge: It is the edge on the face of the tool which removes the material from the work piece. The cutting edge consists of the side cutting edge(major cutting edge) and cutting edge(minor cutting edge) and the nose.Single point cutting tool Sold too! shank brazed to tool shank (8) Soli toot (©) Brazed inset (6) Mechanically clamped insert Three ways of holding and presenting the cutting edge for a single-point tool: (a) solid tool, typical of HSS; (b) brazed insert, one way of holding a cemented carbide insert; and (c) mechanically clamped insert, used for cemented carbides, ceramics,Common insert shapes: Cm B22 206 (a) round, (b) square, (c) rhombus with two 80. point angles, (d) hexagon with three 80! point angles, (e) triangle (equilateral), (f) rhombus with two 55 point angles, (g) rhombus with two 35. point angles. Also shown are typical features of the geometry.Cutting edges at the lathe tool: 1 tool point, 2 shank, 3 main cutting edge 4 secondary cutting edge rake surface principal cutting Auxiliary cutting edge edge Tool nose Auxiliary flank (clearance) surface Basic features of single point tool (turning) (clearance) surfaceEnd cutting- side edgeangle rake angle, + ce oo _ Face, ‘utting edge $+ Back rake angle, + =. (BR) Flank Side relief angle Side cutting-edge angle (SCEA) Axis clearance or end relief angleEnd cutting edge angle (ECEA) Nose radius (NR) Side cutting edge angle —}— (SCEA) (a) Side rake angle (co Back rake angle («,) Side relief End relief angle (SRA) angle (ERA) (b) Tool signature: op, a5, ERA, SRA, ECEA, SCEA, NRBack Rake Angie [ean ‘Base1.Side Cutting Edge Angle: The angle between side cutting edge and the side of the tool shank is called side cutting edge angle. 2.End Cutting Edge Angle: The angle between the end cutting edge and a line perpendicular to the shank of the tool shank is called end cutting edge angle. 3. Side Relief Angle: The angle between the portion of the side flank immediately below the side cutting edge and a line perpendicular to the base of the tool. 4.End Relief Angle: The angle between the end flank and the line perpendicular to the base of the tool is called end relief angle. 5.Back Rake Angle: The angle between the face of the tool and line perpendicular to the base of the tool measures on perpendicular plane through the side cutting edge. 6.Side Rake Angle: The angle between the face of the tool and a line parallel to the base of the tool measured on plane perpendicular to the base and the side edge.(i) Concept of rake and clearance angles of cutting tools. The word tool geometry is basically referred to some specific angles or slope of the salient faces and edges of the tools at their cutting point. Rake angle and clearance angle are the most significant for all the cutting tools. The concept of rake angle and clearance angle will be clear from some simple operations shown in Fig. 3.1 Velocity rake angle, Reference plane (rx) >} vector Vo rake surface 2 YA ef. Plane (ra) Cutting ‘ Velocity YF Felearance Flank surface Flank surface 0 Fig. 3.1 Rake and clearance angles of cutting tools.Definition - ¢ Rake angle (y): Angle of inclination of rake surface from reference plane « clearance angle («): Angle of inclination of clearance or flank surface from the finished surface Rake angle is provided for ease of chip flow and overall machining. Rake angle may be positive, or negative or even zero as shown in Fig. 3.2. (a) positive rake (b) zero rake (c) negative rake Fig. 3.2 Three possible types of rake angles