Common Machining Operations
description
Transcript of Common Machining Operations
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Common Machining Operations
Kalpakjian
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Kalpakjian
Parts of an “Engine” Lathe
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www.blazingtech.net
www.bakerprovan.com.auwww.liberatorcrew.com
www.ticktockpro.com
Watchmaker’s lathe Typical “Engine” Lathe
Turret Lathe Big “Engine” Lathe
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www.harrismachinetools.com
60 feet c-c
www.practicalmachinist.com
Really Big “Engine” Lathes
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CNC Lathe: aka “Turning Center”
(carriage is mounted toward back, “upside down”)
www.machineryvalues.com
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MachiningParameters
DeGarmo
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Kalpakjian
Machining: Turning
Depth of Cut = DOC = (Dbefore – Dafter) / 2
Cutting Speed = Speed of metal moving towards cutting tip • Usually called “Surface Feet per Minute”, SFPM, SFM• Each cutting tool & workpiece material combo has a max SFM for decent tool wear. HSS & alum: 800 SFM HSS & 1020 steel: 110 SFM HSS & 1090 steel: 80 SFM HSS & hard 4140: 30 SFM TC & 1020 steel: 1000 SFM• SFM = r*w = D * RPM * (π/12) ≈ D * RPM / 4• RPMmax = 4 * SFM / D (most useful machining formula) E.g., find RPM for turning 2” dia. 1020 steel: RPM ≈ 4*110/2 = 220• RPM may need to be less due to chatter!• Most relations are similar for milling, but D=cutter dia.
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CuttingForces
DeGarmo
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OrthoganalModel(2-force)
DeGarmo
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OrthoganalModel(2-force)
DeGarmo
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Chip formation: chip types
Kalpakjian
DeGarmo
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Merchant’s Model(Simplified 2-force)
DeGarmo
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Kalpakjian
Chatter
Vibrational resonance of entire machining system, especially workpiece-cutter.Causes poor surface finish, fast tool wear, noiseFactors: stiffnesses of workpiece, cutter, machine cutting params: speed, feed, DOC cutter geometry: rake, clearancesSolutions: Change the cutting params esp. speed Increase stiffnesses
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Heat rise in Cutting
Kalpakjian
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Kalpakjian/Vieregge
Temperature of Cutting Tip
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Kalpakjian / Chao & Trigger
Temperature of Cutting Tip
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Kalpakjian
Max Temperatures of Cutting Materials
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Kalpakjian/Sandvik
Machining Time of Cutting Materials
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www.moldmakingtechnology.com
Layers are 2-10 microns thick:TiN: titanium nitride (low friction, gold appearance)TiCN: titanium carbonitride (wear resistance)Al2O3: Alumina (chemical stability, wear resistance)
Tungsten Carbide substrate (~shock and wear resistance)
Coated Carbide Cutting Inserts:The norm for production machining
Kalpakjian/Kennametal
www.greenleafcorporation.com
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Kalpakjian
Cutter Shape and Geometry
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Machining Costs
Kalpakjian
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References
DeGarmo: E.P. DeGarmo et al, Materials and Processes in Manufacturing, Wiley, 2003.
Kalpakjian: http://www.nd.edu/~manufact/index3.htm