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7/30/2019 06 Metal Removal
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Page 1
R. Jerz 1 Feb-06
Machining ProcessesMachining Processes
R. Jerz 2 Feb-06
Machining ProcessesMachining Processes
R. Jerz 3 Feb-06
Machining ProcessesMachining Processes
R. Jerz 4 Feb-06
Fundamentals of MachiningFundamentals of Machining
R. Jerz 5 Feb-06
Fundamentals of MachiningFundamentals of Machining
z Machining is a general term describing a
group of processes that consist of the
removal of material an modification of
the surfaces of a workpiece after it hasbeen produced.
R. Jerz 6 Feb-06
Advantages and DisadvantagesAdvantages and Disadvantages
z Advantages
Good dimensional accuracy
Good geometry, sharp edges
Economical
z Disadvantages
Wasted material
More time than some other processes
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Page 2
R. Jerz 7 Feb-06
Elements of MachiningElements of Machining
z Machine (machine tool)
z
Materialz Cutting tool
z Operational plan and settings
feeds, speeds, etc.
z Environment (coolant)
R. Jerz 8 Feb-06
Examples of MachiningExamples of Machining
Figure 21.1 Some examples of common machining operations.
R. Jerz 9 Feb-06
Machine Tools: LatheMachine Tools: Lathe
R. Jerz 10 Feb-06
Milling Machine ToolsMilling Machine Tools
R. Jerz 11 Feb-06
Cutting Material with ToolCutting Material with Tool
Schematic illustration of the turning operation showing various features.
R. Jerz 12 Feb-06
TurningTurning
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Page 3
R. Jerz 13 Feb-06
Chip Making VideoChip Making Video
R. Jerz 14 Feb-06
Chips FormationChips Formation
R. Jerz 15 Feb-06
Chip Examples In ClassChip Examples In Class
R. Jerz 16 Feb-06
Cutting ToolsCutting Tools
R. Jerz 17 Feb-06
Tool TypesTool Types
z Tool steels
z High-speed steel
z Ceramics (aluminum oxide)
z Coated carbides
R. Jerz 18 Feb-06
Some Properties of Tool MaterialsSome Properties of Tool Materials
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Page 4
R. Jerz 19 Feb-06
Characteristics of Tool MaterialsCharacteristics of Tool Materials
R. Jerz 20 Feb-06
Relative Cutting Time
of Tool Materials
Relative Cutting Time
of Tool Materials
R. Jerz 21 Feb-06
Select Proper Tool VideoSelect Proper Tool Video
R. Jerz 22 Feb-06
Wear Patterns on ToolsWear Patterns on Tools
R. Jerz 23 Feb-06
Machined Steel SurfacesMachined Steel Surfaces
R. Jerz 24 Feb-06
Applying Cutting FluidsApplying Cutting Fluids
Figure 22.12 Schematic illustration of the proper methods of applyingcutting fluids (flooding) in various machining operations: (a) turning, (b)milling, (c) thread grinding, and (d) drilling.
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Page 5
R. Jerz 25 Feb-06
Turned Surface Feed MarksTurned Surface Feed Marks
Figure 21.23 Schematic illustration of feedmarks on a surface being turned (exaggerated).
Ra =
f2
8R
where
f= feed
R = tool - nose radius
Surface roughness:
R. Jerz 26 Feb-06
TerminologyTerminology
z Independent Variables
Material
(machinability) Cutting tool
Speed (sfpm)
Depth of cut (in)
Feed (ipr or ips)
Cutting conditions
z Dependant Variables
Metal removal rate
Cut time
Horsepower
Temperature
Surface finish
R. Jerz 27 Feb-06
Feed and Speed SelectionFeed and Speed Selection
R. Jerz 28 Feb-06
Factors Influencing MachiningFactors Influencing Machining
R. Jerz 29 Feb-06
Energy RequirementsEnergy Requirements
R. Jerz 30 Feb-06
Tool Life EconomicsTool Life Economics
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Page 6
R. Jerz 31 Feb-06
Tool LifeTool Life
z Taylors tool life model
z
Fredrick Taylor 1907 (ASME)z VTn = C (.08