ENMF417

Lect. 9: Abrasive Material Removal

Dr. Simon Park

simon.park@ucalgary.ca
SP

Announcements

ENMF417

SP

Learning Objectives
Fundamental Cutting Operations
Machinability Tool Materials Chatter Abrasive Methods - Grinding

ENMF417

Video: SME Tool Material, PM, Grinding (if time permitted)

SP

Machinability
a measure of relative ease of machining operations longer tool life, lower force, better surface finish, easier chip disposal, higher MRR means Good Machinability Ex.
AISI 1112 steel: MR (Machinability rating) = 1 Titanium: MR=0.2 (poor machinability) Aluminum: MR = 2 (good machinability)
SP

ENMF417

Tool Materials
Important properties Toughness avoid fracture Hot (high temp) hardness resist abrasion Wear resistance

ENMF417

SP

ENMF417

High Speed Steel (HSS)

Carbides (the most common)

SP

ENMF417

Ceramics/Cermets (Ceramic and metal)

Diamond (Polycrystalline Diamond PCD)

Cubic Boron Nitride (CBN)

SP

Cutting Fluids
Reduces _____ generation at shear and friction zones (_________) Reduce ________ between tool and chip (_________) Aid __________ removal Oil and water mixture (less usage)
Flood, mist
SP

ENMF417

Chatter (self-excited vibration)

ENMF417

SP

ENMF417

How to Avoid Chatter?

SP

Chatter Simulation

ENMF417

SP

ENMF417

Example (Modern Chatter Theory) in milling

Controlling spindle speed so that it matches with chatter frequency (~ wn)

Wn = 2000 Hz 2 Fluted Cutter Chatter free speed: 2000 Hz / 2 flute x 60 sec/min = 60,000 rpm RUN the machine at 60,000 rpm, 30,000 rpm, 20,000 rpm, .

Stability Lobes
SP

Selection of Cutting Conditions

Cutting Conditions:
Speed, feed, depth of cut, and cutting fluids Machining Handbook or Tool Catalogs Recommendations Horsepower and torque Machine tool and rigidity Strength of cutting tool Chatter Tolerances

ENMF417

Limitations:

Selection of Feed and Speed

Select Cutting the Depth and Speed minimize chatter vibration Select Feed roughing or finishing While maintain good MRR
SP

Surface Integrity
1. Strain hardening of a surface

ENMF417

2. Cracks formed in low speed cutting

3. Phase transition due to high temp. 4. Residual stress

SP

ENMF417

Abrasive Machining

SP

Material removal by abrasive particles

Grinding is the most common abrasive machining (others ex: honing, lapping, buffing)

Abrasive Machining

ENMF417

1. The material is too hard to be machined economically. (The material may have been hardened in order to produce a low-wear finish, such as that in a bearing raceway.) 2. Tolerances required preclude machining. Grinding can produce flatness tolerances of less than 0.0025 mm (0.0001 in) 3. Machining removes excessive material.

Reasons for grinding are:

SP

 Cutting speeds are higher Higher negative rake angle Self-sharpening as each abrasive falls off

Abrasive Machining (Different than Milling)

ENMF417

SP

Grinding Mechanism
Specific Energy is greater than machining Size effects (small chip size causes energy to remove each unit volume) Extremely negative rake angles (low shear plane angles and high shear strains) Part of grits is engaged in cutting Shearing (knife), plowing (plastic and elastic deformation), and rubbing (friction)

ENMF417

SP

Honing
For internal holes or bores

ENMF417

SP

Lapping
Lapping is a loose abrasive machining process to form a slurry to form an abrasive film between the plate and the parts to be lapped.

ENMF417

SP

Polishing/Buffing

ENMF417

Before

After

Toyota MR2 Intake Manifold

SP

Abrasive types
Aluminum oxide Silicon Carbide CBN Diamond

ENMF417

SP

Dressing
Dressing is
Conditioning worn grains by producing sharp new edges Truing producing a true circle on a wheel

ENMF417

Usually uses a diamond point tool

SP

ENMF417

SP