common machining operations
DESCRIPTION
Common Machining Operations. Kalpakjian. Parts of an “Engine” Lathe. Kalpakjian. Typical “Engine” Lathe. Watchmaker’s lathe. www.ticktockpro.com. www.blazingtech.net. Turret Lathe. Big “Engine” Lathe. www.liberatorcrew.com. www.bakerprovan.com.au. Really Big “Engine” Lathes. - PowerPoint PPT PresentationTRANSCRIPT
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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