instructional design document machining mechanics stam interactive solutions

Instructional Design Document

Machining Mechanics

STAM Interactive Solutions

Demo Outline (For reference)

Topic Number Topic Name Page Type

1 Piispanen’s Card Model Animated page

2 Variables in Orthogonal Cutting Animated page

3 Kinematics of Orthogonal Cutting Animated page

4 Forces in Orthogonal Cutting Animated page

5 Merchant’s Force Circle Animated page

6 Energy Dissipation in Cutting Animated page

7 Cutting Temperatures Animated page

8 Simulation Interactive page

Changes Suggested by Prof. Ramesh Singh Changes reflected on slide no.

1 Focus on “Machining Mechanics”, specifically on the influence of Machining Mechanics on tool-selection and machine sizing

All slides

2 Voiceover for initial slide to stress that the question is whether a process is feasible given a depth of cut and cutting speed – relatethis to power required for machining and temperature of the tool.Point out that to figure out the former, we need to know the forces on the tool / workpiece, and the subsequent slides will explore this for orthogonal cutting.

Slide 5

3 Omit chip-formation entirely: instead, use material from slides 3,11, 12, 13, 17 and 19 of lecture notes at me.iitb.ac.in/~ramesh/me338/machining2.pdf.

Slides 6 - 14

4 Voiceover must mention that forces should be compared with theproperties of the workpiece (shear-stress, for eg.,) since theworkpiece must “fail” under the forces applied by the tool.

Slide 10

5 Display the forces Ns, Fs, Ft, F and N on both the tool and thechip and the workpiece

Slides 9 & 10

6 Conclude with graphical display of heat dissipation Slide 14

7 References · Don’t cite the wikipedia· Add books as given

Slide 16

Change Log (as per the minutes pdf)

Note to the reviewer:

The visuals shown on each slide will be graphically enhanced to make explanation easier to follow.

Machining MechanicsAdvanced Manufacturing Process I & II

In the process of workpiece machining, as the depth of cut and the cutting speed increase, cutting forces rise and so does the temperature of the tool and the power consumed by the machining process.

This demo outlines these aspects of orthogonal cutting. It also explores the influence of machining mechanics on tool selection and machine sizing.


Piispanen’s Card Model


Variables in Orthogonal Cutting


Kinematics of Orthogonal Cutting


Forces in Orthogonal Cutting


Merchant’s Force Circle


Energy Dissipation in Cutting


Energy Dissipation in Cutting

Cutting Power:

Shear Zone Power:

Friction Zone Power:


Cutting Temperatures

Heat transfer to environment is negligible


Rake Angle (α):

Width of Cut/Pass:

Cutting Speed (V):

Cutting Force (Fc):

Undeformed Chip Thickness (to):

Vary the cutting speed.

degrees10

2 m/s

0.25 mm

mm2.5

Deformed Chip Thickness (tc): 0.83 mm

890 N

Thrust Force (Ft): 667 N

Cutting Power (Pc): W

Cutting Power Meter (%)

0

100

40

50

30

20

10

80

70

60

90

Simulation

(Range = 0.1 to 4)

(Constant)

(Constant)

(Constant)

(Constant)

(Constant)

(Constant)

Shear Zone Power (Pc): W


Resources

Books:

• Serope Kalpakjian & Steven R. Schmid, “Manufacturing Process for Engineering Materials”, Section 6.3 – Rolling Process

• Ghosh & Malik, “Manufacturing Science”


Shaping Single-point Multi-point

Neither

Planning Single-point Multi-point

Neither

Turning Single-point Multi-point

Neither

Boring Single-point Multi-point

Neither

Milling Single-point Multi-point

Neither

Drilling Single-point Multi-point

Neither

Grinding Single-point Multi-point

Neither

Honing Single-point Multi-point

Neither

Identify the type of cutting process for each of thefollowing:


Machining grey cast iron produces

continuous chips with BUE

continuous chips without BUE

discontinuous chips of irregular shape and size

discontinuous chips of regular shape and size


A low rake angle is

desirable because it reduces the power consumed

not desirable because it weakens the tool

desirable because it reduces BUE

not desirable at all


The thickness of the chip is independent of

cutting speed

depth of cut

tool material

rake angle


The cutting forces affect

the power required

the design of the machine tool

the accuracy of the machined workpiece

depends on the process parameters

instructional design document machining mechanics stam interactive solutions

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