BACHELOR OF ENGINEERING

MANUFACTURING TECHNOLOGIES

LINEAR CUTTING PROCESSES

by Endika Gandarias

2 by Endika Gandarias

Dr. ENDIKA GANDARIAS MINTEGI Mechanical and Manufacturing department Mondragon Unibertsitatea - www.mondragon.edu (Basque Country) www.linkedin.com/in/endika-gandarias-mintegi-91174653

Further presentations: www.symbaloo.com/mix/manufacturingtechnology

3

CONTENTS

BIBLIOGRAPHY SHAPING AND PLANING BROACHING SAWING GLOSSARY

by Endika Gandarias

4

BIBLIOGRAPHY

BIBLIOGRAPHY

by Endika Gandarias

5

The author would like to thank all the bibliographic references and videos that

have contributed to the elaboration of these presentations.

For bibliographic references, please refer to:

• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)

• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)

For videos, please refer to:

• www.symbaloo.com/mix/manufacturingtechnology

BIBLIOGRAPHY

by Endika Gandarias

6

SHAPING AND PLANING

by Endika Gandarias

SHAPING AND PLANING

7

• Similar operations: • They differ in the kinematics of the process. • Both use a single point cutting tool moved linearly relative to the workpiece. • A straight, flat surface is created in both operations.

• Low cutting speeds due to start-and-stop motion.

• Typical tooling: single point high speed steel (HSS) tools.

SHAPING AND PLANING

Feed motion

(tool)

Speed motion (workpiece)

Shaping Planing

Feed motion (workpiece)

Speed motion (tool)

by Endika Gandarias

VIDEO

8

SHAPING AND PLANING

by Endika Gandarias

Components of a shaper. Components of a slotter machine.

• Tool has reciprocating motion. • Workpiece is clamped on the table

which is stationary.

(HORIZONTAL) SHAPING MACHINE VERTICAL SHAPING MACHINE OR SLOTTER MACHINE

• Identical machine to a horizontal shaping machine but inclined 90º.

• It allows a higher cutting power as the workpiece is better hold on the working table.

Shaping

VIDEO VIDEO VIDEO

9

SHAPING AND PLANING

by Endika Gandarias

Components of a planer.

Parts made by a shaping and planing.

• Tool is stationary. • Workpiece is clamped on the table which has

reciprocating motion. • It allows machining of much larger parts.

Planing

VIDEO

10

BROACHING

by Endika Gandarias

BROACHING

11

• It is a machining process that uses a multiple-tooth cutting tool, called broach, moved linearly relative to the workpiece. Each tooth is successively higher than the previous tooth.

• The material is removed in one stroke (pulling or pushing) (main difference in comparison with shaping and planing).

• Most broaches are made of HSS, although carbide inserts (brazed or mechanically attached) also exist. • It works best on soft materials: aluminium, bronze, brass, wood, plastics, composites, graphite,…

Dimensional tolerance ~ IT6 – IT8 Surface finish (Ra) ~ 6,3 – 25 μm

Advantages: • Suitable for mass production. • Cutting time is quick. • Variety of work shapes possible. Disadvantages: • Owing to complicated and often

custom-shaped geometry, tooling is expensive. • Valid only for light cuts. • Only through hole and surfaces can be machined.

BROACHING

by Endika Gandarias

VIDEO

12

BROACHING

Parts made by surface broaching Surface broaching machine

Surface broaching

by Endika Gandarias

• It is used to cut flat surfaces.

• The tool is a simple flat bar with multiple rows of cutting teeth.

• Surfaces may be flat, concave, convex, serrated or cam-shaped.

VIDEO VIDEO VIDEO

13

• It is used for enlarging long holes.

• A starting hole must be predrilled in the part to insert the broach at the beginning of the stroke.

BROACHING

by Endika Gandarias

Typical parts made by internal broaching Internal broaching machine

Internal broaching

VIDEO VIDEO VIDEO VIDEO

14

SAWING

by Endika Gandarias

SAWING

15

SAWING

by Endika Gandarias

• Sawing consists in cutting a narrow slit in a workpiece using a tool consisting of a series of narrowly spaced teeth.

• The tool is called a saw blade and the teeth are typically made of carbon steel, HSS, carbide or diamond.

• Typical functions: • Separate a workpart into two pieces. • Cut off unwanted portions of part .

Teeth are deviated in order to reduce friction between saw blade and part.

16

Teeth type depending on the cutting material

SAWING

by Endika Gandarias

HSS teeth welded on a steel blade

Carbide inserts brazed to blade teeth

50 HRC

17

SAWING

by Endika Gandarias

Manual hacksaw

Circular saw

Hacksaw or reciprocating saw machine

Band saw machine

HORIZONTAL VERTICAL

Sawing machines

VIDEO

VIDEO VIDEO

VIDEO

VIDEO VIDEO

18

Examples of various sawing operations.

SAWING

by Endika Gandarias

Sawing operations

19

GLOSSARY

GLOSSARY

by Endika Gandarias

20

GLOSSARY

by Endika Gandarias

ENGLISH SPANISH BASQUE

Band saw Sierra de cinta Zintazko zerra Bar Barra Baraila Brass Latón Letoi Brazed Soldado Soldatua Broach Brocha Brotxa Broaching Brochado Brotxaketa Bronze Bronce Brontze Cam Leva Espeka Carbide Carburo Karburo Circular saw Sierra de disco Disko erako zerra Clamp Abrazar Lotu Clearance angle Ángulo de incidencia Eraso angelua Custom A medida Neurrira Cutting speed Velocidad de corte Ebaketa abiadura Enlarge Agrandar Haunditu Feed Avance Aitzinamendu Gullet depth Profundidad de garganta/diente Hortz sakonera Hack-saw Sierra de arco Arkuzko zerra Head Cabezal Buru HSS - High Speed Steel Acero rápido Altzairu lasterra Ingot Lingote Lingote Linear cutting processes Procesos de corte lineal Mozte zuzeneko prozesuak Mass production Producción en masa Masako ekoizpen Narrow Estrecho Estu Overall En general Orokor Planer Cepilladora Arrabotaketa makina Planing Cepillado Arrabotaketa Pull Tirar Tira egin

21

GLOSSARY

by Endika Gandarias

ENGLISH SPANISH BASQUE

Push Empujar Bultz egin Rake angle Ángulo de desprendimiento Jaulkitze angelu Raker tooth Triscado estandar Entrama estandar Ram Carnero Zikiro Rear Trasero Atzeko Ripping Desgarrar / Cortar Mozte Root Raíz Erro Row Fila Lerro Saw blade Hoja de sierra Zerra orri Sawing Aserrado Zerraketa Shank Mango Kirten Shape Forma Forma / Itxura Shaping Limado Karrakaketa Slice Rebanar Xerratu Slit Raja / hendidura Xerra / Pitzadura Slotting machine Mortajadora Mortaia makina Speed Velocidad Abiadura Stack Apilar Metatu Steel Acero Altzairu Straight tooth Triscado derecha-izquierda Ezker-eskuin entrama Stroke Trazado / Desplazamiento Marratze / Desplazamendu Through hole Agujero pasante Alderik aldeko zulo Tool Herramienta Erraminta Tooth (Teeth) Diente ( dientes) Hortz ( hortzak) Wafer Oblea Olata Wave tooth Triscado ondulado Entrama ondulatu Weld Soldar Soldatu Width Anchura Zabalera

22

GLOSSARY

by Endika Gandarias

ENGLISH SPANISH BASQUE

Workpiece Pieza Pieza Worktable Mesa de trabajo Lan mahai