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MACHINING OPERATIONS AND MACHINE TOOLS 1. Turning and Related Operations 2. Drilling and Related Operations 3. Milling 4. Machining & Turning Centers 5. Other Machining Operations 6. Shape, Tolerance and Surface Finish 7. Machinability 8. Selection of Cutting Conditions 9. Product Design Consideration 1
1. Turning & Related Operations • Turning – a machining v Rotational Speed: N = process in which a πDo single-point tool remove Do − D f = 2d material from the Feed rate: f r = Nf surface of a rotating L work piece. (Lathe) Time of machining: Tm = Material Removal Rate: Do
v
Df
fr
MRR = vfd
d L
f 2
Operations related to Turning Contour turning
Facing
Taper turning
Cutoff
Threading
Chamfering
Form turning
Boring
Drilling
Knurling 3
Work Holding • Mounting between two centers (Dog & Live center) • Chuck • Collet • Face plate
4
Engine Lathe Headstock
Tailstock
Tool post
Carriage
Bed
Threaded Lead Screw 5
Other Lathes & Turning Machine • Toolroom Lathe and Speed Lathe • Turret Lathe – The tailstock is replaced with a turret
• Chucking Machines – No tailstock • Automatic Bar Machine – Similar to chuck machine but with a collet – A single- and multiple-spindle bar machines
• NC Lathe 6
Boring Machining • Boring – Cutting is done inside diameter of the work material
Horizontal Boring Machining
Vertical Boring Machining 7
2. Drilling & Related Operations • Geometry of Twist drill – Shank, Neck and Drill body – Helix angle, Point angle, Flute, cutting edge, Chisel edge, Margin
• Cutting conditions
v Feed rate: f = Nf f(in/rev) Spindle: N = r πD πD 2 f r Metal Removal Rate: MRR = t+A 4 Machining time: Tm = f r For a through hole A d Tm = For a blind hole d t fr 8
Twist Drill and Drilling Operations
From Kalpakjian and Schmid (2003)
9
Machine Tool for drilling • Drill press – Upright drill – Bench drill – Radial drill – Gang drill - 2-6 drills together – NC drill
• Vice, Jig and fixture 10
3. Milling • Milling
Up Milling
– A machine operation in which a work part is fed past a rotating cylindrical tool with multiple edges. (milling machine)
• Types
Down Milling
Partial face
Slab
– Peripheral milling • Slab, slotting, side and straddle milling • Up Milling (Conventional) & down milling (Climb)
Cutting conditions • Milling cutters – Plain milling cutters – Form milling cutters – Face milling cutters – End milling cutters
Radial Rake Angle
• Cutting conditions
v N= Spindle rotation speed: πD
Relief Angle Clearance Angle
Feed rate: f r = Nnt f Material Removal Rate: MRR = wdf r
12
Milling Machines •
Knee-and-column Milling Machine – Horizontal and Vertical types – Universal and Ram types
• • •
•
Bed-type Mill Planer-type Mills – the largest category Tracer (profile) Mill – reproduce an irregular part geometry CNC Milling machine
Horizontal
Universal
Vertical
Ram
Bed-type mill 13
Machining Centers • Machining center – highly automated machine tool capable of performing multiple machining operations under CNC control. – Automatic tool changer – Pallet shuttles – Automatic workpart positioning
• CNC turning center 14
A CNC mill-turn center A series of operations without human interactions
Stock
Turning
Milling
Drilling
A part
From a casting From a round stock
From another casting 15
5. Other Machining Operations • Shaping and planing – A single-point tool moves linearly relative to the work part – Shaping - A tool moves – Planing – A workpart moves
• Broaching – Performed by a multiple-tooth cutting tool by moving linearly relative to the work in the direction of the tool axis.
• Sawing – Hacksawing, Bandsawing, and Circular sawing 16
