Microsoft PowerPoint - LECTURE6

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MANUFACTURING MANUFACTURING
PROCESSES PROCESSES
- - AMEM 201 AMEM 201
Lecture 6 Lecture 6: : Machining Processes Machining Processes
DR. SOTIRIS L. OMIROU
Introduction Introduction
Machine Tools Machine Tools
Tool Materials Tool Materials
Cutting Fluids Cutting Fluids
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The machining is the most broad technological
process used in manufacturing.
Generaly, in the field of manufacturing, the term of
Machining means removal of material from a raw
material, by cutting small chips, in order to obtain
the desired shape and dimensions for final part.
The machining is strictly necessary when finished
part has to have very tight tolerances of
dimensions or when the roughness of surfaces
need to be very smooth.
Introduction to Introduction to M Machining achining
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Removal of chips, from a raw material, is performed
by a cutting tool that need a motion relative to raw
material. This motion, named cutting motion, could
be practically a rotation one or a translation one.
The next two examples will illustrate in a synopsis
way the cutting process, the chip removal from a raw
material.
First example is related to the case when the cutting
motion is a rotation one, like in turning machining.
The second example is related to the case when the
cutting motion is a translation one, like in shaping
machining.
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The raw material
performs a rotation
motion (cutting
motion) and to
assure the process
continuity the tool
performs a
translation motion
(feeding motion)
The raw material
performs a rotation
motion (cutting
motion) and to
assure the process
continuity the tool
performs a
translation motion
(feeding motion)
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The figure
presents a
shaping machine.
In this case the
cutting motion is
executed by the
cutter while the
workpiece (raw
material) remain
stationary.
The figure
presents a
shaping machine.
In this case the
cutting motion is
executed by the
cutter while the
workpiece (raw
material) remain
stationary.
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Sloting/
Shaping
Turning Milling Drilling
Cutting with Conventional Tools
(Single point or multi point cutting tools
having a cleary defined geometry)
Grinding Honning Lapping
Cutting with Non-Conventional Tools
(Abrasive tools that have a random
geometru of cutting part)
Traditional machining
Water
jet
Electro/
Chemical
erosion
Laser
beam
Ultra
sonic
Machining by:
Non-Traditional machining
Machining types
(Cutting processes types)
Sloting/
Shaping
Turning Milling Drilling
Cutting with Conventional Tools
(Single point or multi point cutting tools
having a cleary defined geometry)
Grinding Honning Lapping
Cutting with Non-Conventional Tools
(Abrasive tools that have a random
geometru of cutting part)
Traditional machining
Water
jet
Electro/
Chemical
erosion
Laser
beam
Ultra
sonic
Machining by:
Non-Traditional machining
Machining types
(Cutting processes types)
There are many types of machining operation.
A synoptical classification is shown below.
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Definition of M Definition of Machin achines es
Generally a machine
is an equipment
which transform a
type of energy into
another type
Generally a machine
is an equipment
which transform a
type of energy into
another type
Example:
Eolyan Turbine:
Transforms the wind
energy into
mechanical energy
Lathe machine:
Transforms the
electrical energy
into mechanical
energy
Example:
Eolyan Turbine:
Transforms the wind
energy into
mechanical energy
Lathe machine:
Transforms the
electrical energy
into mechanical
energy
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D Definition efinition of t of the he M Machine achine tool tool
The machine tool is a processing machine, that
produces different parts from point of view of
shape accuracy, productivity and other
conditions, using specific technological
process.
Example:
Machine-Tools for chip removal
Machine-Tools for forming processes
The machine tool is a processing machine, that
produces different parts from point of view of
shape accuracy, productivity and other
conditions, using specific technological
process.
Example:
Machine-Tools for chip removal
Machine-Tools for forming processes
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Classification of Classification of machine machine- -tools tools
In this respect different criteria are used, like:
The basic operation of chip removal
The automation level
The complexity level
The production volume
The main shape of part that has to be machined
etc.
In this respect different criteria are used, like:
The basic operation of chip removal
The automation level
The complexity level
The production volume
The main shape of part that has to be machined
etc.
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The machine The machine- -tools tools cla clas ssification sification upon the upon the
basic operation basic operation of chip removal of chip removal
The basic operation Machine
-
tool type
Turning..................... Lathe
Milling....................... Milling machine
Shaping..................... Shaping machine
Grinding..................... Grinding machine
Honing..................... Honing machine
.. ..
Drilling machine Drilling
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Manual Demiautomated
Rigid automation
(Cames)
Flexible automation
(Numerical Control-NC)
Automated
Machine-Tools
with.........Control
Manual Demiautomated
Rigid automation
(Cames)
Flexible automation
(Numerical Control-NC)
Automated
Machine-Tools
with.........Control
level of automation level of automation
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1. Conventional Machine-Tools
2. Machining Centers *
* These have:
-NC
-Tools magazine
-Automated tools changer
-Large number of basic operations
1. Conventional Machine-Tools
2. Machining Centers *
* These have:
-NC
-Tools magazine
-Automated tools changer
-Large number of basic operations
The machine The machine- -tools tools clas class sification ification upon the upon the
level of complexity level of complexity
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Small volume production Medium and large volume Mass production
Machine-Tools for
production volume production volume
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1. Machine-Tools for
revolution parts
Example:
Lathes
Turning machining
centers
Round grinding
machines
revolution parts
Example:
Lathes
Turning machining
centers
Round grinding
machines
prismatic parts
Example:
Milling machines
Machining centers for
drilling and milling
Planar grinding
machines
prismatic parts
Example:
Milling machines
Machining centers for
drilling and milling
Planar grinding
machines
main shape of part main shape of part that has to be machined that has to be machined
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The chip removal The chip removal
Chip removal is a technological
process by that a raw material
is transformed into a final part.
The condition for the existing of chip removal is
a relative motion between the raw material and
tool. This motion is named effective chip removal
motion and it has the speed V.
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The ECONOMIC Chip removal The ECONOMIC Chip removal
There is only one speed V for each pair of raw
material and tool material, when the chip
removal is done in an economical way.
If the motion is a rotation one, then
V = ( . D . n)/1000 [m/min]
where- D [mm] is part or tool diameter
n [1/min] is the rotation freqeunce
There is only one speed V for each pair of raw
material and tool material, when the chip
removal is done in an economical way.
If the motion is a rotation one, then
V = ( . D . n)/1000 [m/min]
where- D [mm] is part or tool diameter
n [1/min] is the rotation freqeunce
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Needed
Outputs:
Machined
part
Inputs:
Row
material
Energy
Infor-
mation
Secondary
Outputs:
Heat
Swarfs
Noise
Secondary inputs:
Cooling liquid.....
The The B Block lock D Diagram iagramfor a for a MACHINE TOOL MACHINE TOOL
Engine
MACHINE TOOL
Part Part Part Part
Clamping
device
Transfer and
adjusting/
transforming
mechanisms
Machining process
Engine
Tool Tool Tool Tool
Clamping
device
Transfer and
adjusting/
transforming
mechanisms
Transfer and
adjusting/
transforming
mechanisms
Engine
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Elements of an Effective Tool Elements of an Effective Tool
High hardness at elevated temperatures High hardness at elevated temperatures
Wear resistance Wear resistance
Strength to resist bulk deformation Strength to resist bulk deformation
Adequate thermal properties Adequate thermal properties
Consistent tool life Consistent tool life
Correct geometry Correct geometry
Chemical stability Chemical stability
Tool Materials Tool Materials Tool Materials Tool Materials Tool Materials Tool Materials Tool Materials Tool Materials
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Wide variety of materials and Wide variety of materials and
compositions are available to choose from compositions are available to choose from
when selecting a cutting tool when selecting a cutting tool
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Tool steels Tool steels - - low end of scale. Used to make some low end of scale. Used to make some
drills, taps, reamers, etc. Low cost equals low tool life. drills, taps, reamers, etc. Low cost equals low tool life.
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High speed steel(HSS) High speed steel(HSS)
Prior to World War II the most common type of lathe Prior to World War II the most common type of lathe
bit was made from high speed tool steel. High speed bit was made from high speed tool steel. High speed
tooling is a tooling is a steel steel alloy alloy with a predetermined percentage with a predetermined percentage
of of tungsten tungsten mixed in. There is also a mixed in. There is also a hardening hardening process process
that makes high speed tooling very ha that makes high speed tooling very har rd and wear d and wear
resistant. These tools are able to withstand high work resistant. These tools are able to withstand high work
temperatures. Tools typically made from high speed are temperatures. Tools typically made from high speed are
end mills end mills, , drills drills, , reamers reamers, , and lathe tool bits and lathe tool bits. .
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Fig. 1: End mill
Fig. 3: Reamer
Fig. 2: Drill
Fig. 4: Lathe tool bit
High speed steel(HSS) High speed steel(HSS)
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Cobalt Cobalt - - one step above HSS, cutting speeds are generally one step above HSS, cutting speeds are generally
25% higher. 25% higher.
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Carbides Carbides - - Most widely used cutting tool today. Most widely used cutting tool today.
Cutting speeds are three to five times faster than Cutting speeds are three to five times faster than
HSS. HSS. Carbides are made by blending micron Carbides are made by blending micron- -sized sized
tungsten carbide and tungsten carbide and cobalt cobalt powders, then pressing powders, then pressing
the mixture in a the mixture in a mold mold and at a temperature high and at a temperature high
enough to cause the cobalt to flow. This process is enough to cause the cobalt to flow. This process is
called " called "sintering sintering" and the resulting tool is called " and the resulting tool is called
"cemented" carbide. "cemented" carbide. In addition to tool composition, In addition to tool composition,
coatings are added to tool materials to increase coatings are added to tool materials to increase
resistance to wear. resistance to wear.
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Carbides Carbides
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Ceramics Ceramics - - Contain pure aluminum oxide and can Contain pure aluminum oxide and can
cut at two to three times faster than carbides. cut at two to three times faster than carbides.
Ceramic tools have poor thermal and shock Ceramic tools have poor thermal and shock
resistance and are not recommended for interrupted resistance and are not recommended for interrupted
cuts. Caution should be taken when selecting these cuts. Caution should be taken when selecting these
tools for cutting aluminum, titanium, or other tools for cutting aluminum, titanium, or other
materials that may react with aluminum oxide. materials that may react with aluminum oxide.
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Inserts Inserts
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Inserts Inserts are individual cutting tool with are individual cutting tool with
severed cutting points. They are clamped on severed cutting points. They are clamped on
tool shanks with locking mechanisms or can be tool shanks with locking mechanisms or can be
brazed to the tools. Clamping is preferred brazed to the tools. Clamping is preferred
method for securing an insert method for securing an insert
Carbide Inserts are available in various shapes Carbide Inserts are available in various shapes- -
Square, Triangle, Diamond and Round Square, Triangle, Diamond and Round
Strength depends on the shape Strength depends on the shape
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Insert Attachment Insert Attachment
Methods of Methods of
attaching inserts attaching inserts
to toolholders : to toolholders :
(a) (a) Clamping Clamping
(b) (b) Wing lockpins. Wing lockpins.
(c) (c) Examples of Examples of
inserts attached inserts attached
to toolholders to toolholders
side screws. side screws.
(d) (d) brazed brazed
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Cutting Fluids Cutting Fluids Cutting Fluids Cutting Fluids Cutting Fluids Cutting Fluids Cutting Fluids Cutting Fluids
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Taylor Tool Life Equation Taylor Tool Life Equation
Relationship is credited to F. W. Taylor Relationship is credited to F. W. Taylor
C vT
n
=
where,
v = cutting speed;
T = tool life;
and n and C are parameters that depend on feed,
depth of cut, work material, tooling material, etc
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TWO MAIN CATEGORIES
(a) Water based for cooling
(b) Oil based for lubricating. (low cutting speed)
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