t11 - manufacturing engineering - machine process & tools

8/17/2019 T11 - Manufacturing Engineering - Machine Process & Tools

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HINING PROCESSES AND MACHINE TOOLS

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• Manufacturing Technology

Engineering Materials• Fundamental of the manufacturing technology• Manufacturing method is selected according to

materials

Metal Forming• Rolling• Bulk deformation: forging• Extrusion and drawing• Sheet metal forming

lastic rocessing• Molding

• Extrusion! "n#ection!


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• Manufacturing Technology

3D Printing• SLA: Stereolithography• SLS: Selective laser sintering• SLM: Selective laser melting

• FDM: Fused deposition modeling• …

Microfabrication• ASM nc!• Photolithography• Additive processes: P"D# $"D %$hemical "apor Deposition&• Subtractive processes: 'et etching# Dry etching

• Machining Process


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• Machining rocesses

Machining is the remo&al of material andmodi'cation of the surfaces of a work(iece

Machining in&ol&es secondary and 'nishing

o(erations

Machining is often used after forging or other

(rocesses


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• Material remo&al (rocesses:

*utting: +y cutting tools

,+rasi&e (rocesses: +y small a+rasi&e

(articles ,d&anced machining (rocesses

• Machining o(erations is a system consisting of

the

-ork(iece

*utting tool


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• *utting

*utting (rocess remo&es material from the surfaceof a work(iece +y (roducing chi(s/

*ommon cutting (rocesses

• Turing

• *utting o0

• Sla+ milling

• End milling


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• *utting

"n the turning (rocess! the cutting tool is set at acertain de(th of cut mm3 and tra&els to the left as thework(iece rotates

• *utting tools Material! sha(e3• *utting s(eed

• *utting 4uid

• -ork(iece material


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• Merchant model is known as orthogonal cutting

• It is two dimensional and the forces involved areperpendicular to each other

• Cutting tool has a rake angle of α and a relief or

clearance angle

• Shearing takes place in a shear zone at shear angle Φ


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It can also be shown that

Resultant force is balanced by an eual and oppositeforce along the shear plane

It is resolved into a shear force and a normal force

!hus"

!he magnitude of coefficient of friction is

β β cossin R N R F =⇒=

φ φ

φ φ

cossin

sincos

t cn

t c s

F F F

F F F

+=

−=

α

α µ

tan

tan

t c

ct

F F

F F

N

F

−

+==


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Thrust Force

!he effect of rake angle and friction angle on the direction of thrust

force is

Power

• !he power input in cutting is

• !he power dissipated in the shear plane is

!he power dissipated in friction is

( ) ( )α β α β −=−= tanorsinct t

F F R F

V F Power c

=

s sV F =shearingforPo(er

c FV =frictionforPo(er


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Turning

Milling

5rilling

Boring

Broaching Sawing

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Turning• The (art is rotated while it is +eing machining/• *arried out +y lathe machine• Mainly used to (roduce shaft


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5rilling• *arried out +y drilling machine• Mainly used to make holes


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Milling• Milling is machining o(eration for a &ariety of

con'gurations with the use of a milling cutter

• Most commonly used machining (rocess


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5i0erent kinds of milling

t11 - manufacturing engineering - machine process & tools

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