Manufacturing Technology-Metal Cutting

8/9/2019 Manufacturing Technology-Metal Cutting

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MANUFACTURING TECHNOLOGY 1

MCB 1043

WEEK 11-12

METAL CUTTING PROCESSES

Last Upat!"1

PowerPoint® Slidesby Dr. Turnad Lenggo Ginta


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Last Upat!"2

Cutting

Sawing

Shaping (or planing),

Broaching, drilling,

Grinding,

Turning

Milling

Processes that involve removal of material from solid workpiece


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Last Upat!"3

Sawing

A process to cut components, stock, etc

Process character ! Precision! "ver# low,, ver# high$% M&&! low


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Last Upat!"4

Sawing

band saw

hand-held circular saw hand-held hacksaw

band saw

hand-held circular saw hand-held hacksaw

circular saw blade

wave teeth (for sheet-metal)

right-left teeth (for soft materials)

band saw blade and blade types

raker teeth (for hard, brittle materials)

circular saw blade

wave teeth (for sheet-metal)

right-left teeth (for soft materials)

band saw blade and blade types

raker teeth (for hard, brittle materials)


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Last Upat!"'

Shaping

chip

slidetool-postpivot

chip

tool-post rotates asslide returns;

workpiece shifted;

next stroke

(a) (b) (c)

chip

chip

slidetool-postpivot

slidetool-postpivot

chip


workpiece shifted;

next stroke

c

hip


workpiece shifted;

next stroke

(a) (b) (c)

A process to plane the surface of a workpiece (or to reduce part thickness

Process character ! 'igh M&&, medium Surface finish, dimension control


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Last Upat!")

PLANING AN* SHAPING

Planing a+ shaping a$! s,,.a$ /p!$at,/+s( , ,!$ ,+ t!

,+!at,s /5 t! p$/!ss6 P.a+,+7 ,s a a,+,+7 /p!$at,/+ ,+ ,t! p$,a$& %tt,+7 /t,/+ ,s p!$5/$! #& t! /$p,!! a+ 5!!/t,/+ ,s ,pa$t! t/ t! %tt,+7 t//.6 I+ sap,+7( t! p$,a$&/t,/+ ,s p!$5/$! #& t! t//.( a+ 5!! #& t! /$p,!!"


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8/58Last Upat!" 8 LMS SEG, C/..!7!:

BROACHING

Broaching ,s a a,+,+7 /p!$at,/+ tat ,+;/.;!s t! %s! /5 a%.t,p.!-t//t %tt,+7 t//. /;! .,+!a$.& $!.at,;! t/ t!

/$p,!! ,+ t! ,$!t,/+ /5 t! t//. a


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Drilling, Reaming, Boring

pade drill! for

large, deep holesCore drilling! to increase

diameter of existing holes"wist drilltep drill! for

stepped holes

#

d

Countersink Counterbore $eamer Center drill %un drill with holes for coolant

pade drill! for

large, deep holesCore drilling! to increase

diameter of existing holes"wist drilltep drill! for

stepped holes

#

d

Countersink Counterbore $eamer Center drill %un drill with holes for coolant

Processes to make holes Process character ! 'igh M&&, heap, Mediumhigh surface, dimension control


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Drilling basics

softer materials small point angle% hard, -rittle material! larger point angle

.ength/0iameter ratio is large gun-drilling (./0 ratio 1 233)

er# small diameter holes (eg 4 35 mm)! can6t drill (wh#7)

Φ

drilled hole 8Φ

drill! vi-rations, misalignments, 9

Tight dimension control! drill ream

Spade drills! large, deep holes

Coutersink /counterbore drills! multiple diameter hole

screws/-olts heads


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C%tt,+7 /+,t,/+s ,+ #/$,+7

S,+! #/$,+7 ,s a+ /p!$at,/+ >%,t! s,,.a$ t/ t%$+,+7( t!sa! t&p! /5 %tt,+7 /+,t,/+s /%. #! /+s,!$!6


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12

*RILLING AN* REAMING

IntroductionDrilling ,s a p$/!ss /5 p$/%,+7 $/%+ /.!s ,+ a s/., at!$,a. /$!+.a$7,+7 !%a.,t& /5 a.$!a& $,..! /.!s #&

!a+s /5 %tt,+7 t//.s a..!reamers6 *$,..,+7 a+ $!a,+7 a$!p!$5/$! /+ a drilling press(a.t/%7 /t!$ a,+! t//.s a+a.s/ p!$5/$ t,s /p!$at,/+( 5/$,+sta+! .at!s( ,..,+7 a,+!s(

a,+,+7 !+t!$s6I+ $,..,+7 a+ $!a,+7( t! p$,a$&/t,/+ ,s t! $/tat,/+ /5 t! %tt,+7t//. !. ,+ t! sp,+.!6*$,..s a+ $!a!$s !

@+,s,+7 $!a,+7 /p!$at,/+s a$!a+%a.6


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C%tt,+7 /+,t,/+s ,+ $,..,+7


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1'

Drilling ,s %s! t/ $,.. a $/%+ #.,+ /$ t$/%7 /.! ,+ a s/., at!$,a.6 I5 t!/.! ,s .a$7!$ ta+ 30 ( ,ts a 7// ,!a t/ $,.. a sa..!$ p,./t /.! #!5/$!/$! $,..,+7 t! @+a. /+!6 F/$ /.!s .a$7!$ ta+ '0 ( t$!!-st!p $,..,+7 ,s$!/!+!

Core drilling ,s %s! t/ ,+$!as! t! ,a!t!$ /5 a+ !


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1)

Grinding, Abrasive Machining

Processes to finish and smooth surfaces

Process character ! ver# low M&&, ver# high surface, dimension control

1. To improve the surface finish of a manufactured part

(a) :n;ection molding die! milling manual grinding/electrogrinding

(-) #linders of engine! turning grinding honing lapping

2. To improve the dimensional tolerance of a manufactured part

(a) -all-earings! forging grinding "control! 4


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Abrasive tools and Machines

abrasive wheels, paper, tools diamond grinding wheel for slicing silicon wafers diamond dicing wheel for siliconabrasive wheels, paper, tools diamond grinding wheel for slicing silicon wafers diamond dicing wheel for silicon

%rinding machine

%rinding wheels

Centerless grinding

%rinding machine

%rinding wheels

Centerless grinding


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Last Upat!"1:


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Last Upat!"1=

C%tt,+7 /+,t,/+s ,+ 7$,+,+7


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Last Upat!"20

T! cutting velocit ? ,+ 7$,+,+7 ,s ;!$& ,76 It ,s $!.at! t/ t!$/tat,/+a. sp!! /5 t! !!. #&

V = π D N

!$! ,s t! !!. ,a!t!$( a+ N ,s t! $/tat,/+a. sp!! /5 t!7$,+,+7 !!.6

Depth of cut d ,s a..! infeed a+ ,s !@+! as t! ,sta+!#!t!!+ t! a,+! a+ /$ s%$5a!s6As t! /p!$at,/+ p$/!!s(t! 7$,+,+7 !!. ,s 5! .at!$a..& a$/ss t! /$ s%$5a! /+ !a

pass #& t! /$pa$t6

T! ,sta+! at , t! !!. ,s 5! ,s a..! a crossfeed 6 T!$/ss5!! ,s at%a..& t! width of cut w6 T! $/ss5!! %.t,p.,! #&,+5!! !t!$,+!s t! cross-sectional area o! cut ( CSA"CSA $/ss5!! ,+5!!

T! $/ss-s!t,/+a. a$!a ,+ 7$,+,+7 ,s $!.at,;!.& sa.. /pa$! t//t!$ t$a,t,/+a. a,+,+7 /p!$at,/+s6 T! /$pa$t /;!s past t!!!. at a !$ta,+ .,+!a$ /$ $/tat,/+a. ;!./,t& a..! a !eed ?6

T! material removal rate( $$( ,s !@+! #&

$$ ? CSA


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Last Upat!"21

Abrasive materials

T! abrasive materials /5 7$!at!st /!$,a. ,p/$ta+! t/a& a$!.,st! ,+ t! ta#.!"

G , ,


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Last Upat!"22

G$,+,+7/p!$at,/+s

G$,+,+7 /p!$at,/+s a$! a$$,! /%t ,t a ;a$,!t& /5 !!.-/$pa$t/+@7%$at,/+s6 T! #as, t&p!/5 7$,+,+7 a$!

sur!ace grinding(

clindrical grinding( a+ centerless grinding6


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Last Upat!"23

S%$5a! 7$,+,+7

S%$5a! 7$,+,+7 ,s a+ a#$as,;! a,+,+7 p$/!ss ,+ , t! 7$,+,+7!!. $!/;!s at!$,a. 5$/ t! p.a,+ at s%$5a!s /5 t! /$p,!!6


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Last Upat!"24

S%$5a! 7$,+,+7


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Last Upat!"2)

T$!! t&p!s /5 5!! /t,/+ a$! p/ss,#.! a/$,+7 t/ t! ,$!t,/+ /55!! /t,/+(

T$!! t&p!s /5 &.,+$,a. 7$,+,+7" From le!t to right D t$a;!$s! 5!! 7$,+,+7( p.%+7!7$,+,+7( a /#,+at,/+ /5 #/t p$!;,/%s t&p!s6

traverse !eed grinding a.s/ through !eed grinding( cross-!eedingD ,+, t! $!.at,;! 5!! /t,/+ ,s pa$a..!. t/ t! sp,+.! a


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Last Upat!"29

C!+t!$.!ss 7$,+,+7

E


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Last Upat!"2:

Turning

Processes to cut c#lindrical stock into revolved shapes

Process character ! high M&&, high surface, dimension control

feed, f

depth of cut, d

feed, f

depth of cut, d

spindle chuck tool-post

carriage

tail-stock

carriage wheel cross-slide wheel

tail-stock wheel

lead-screw

spindle chuck tool-post

carriage

tail-stock

carriage wheel cross-slide wheel

tail-stock wheel

lead-screw


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Last Upat!"2=

Turning operations

turning taper profile cut groove cut cut-off thread cut

facing face groove boring, internal groove drillingknurling

turning taper profile cut groove cut cut-off thread cut

facing face groove boring, internal groove drillingknurling

feed, f

depth of cut, d

feed, f

depth of cut, d


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Last Upat!"30

Fituring parts !or turning

part in a &-'aw chuck -'aw chuck holding a non-rotational part

collet type work-holder; collets are common inautomatic feeding lathes * the workpiece is a long

bar; each short part is machined and then cut-off;

the collet is released, enough bar is pushed out tomake the next part, and the collet is pulled back to

grip the bar; the next part is machined, and so on+

long part held between live center (at spindle)

and dead center (at tailstock)

steps

part in a &-'aw chuck -'aw chuck holding a non-rotational part

collet type work-holder; collets are common inautomatic feeding lathes * the workpiece is a long

bar; each short part is machined and then cut-off;

the collet is released, enough bar is pushed out tomake the next part, and the collet is pulled back to

grip the bar; the next part is machined, and so on+

long part held between live center (at spindle)

and dead center (at tailstock)

steps

T%$+,+7


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Last Upat!"31

T%$+,+7

T%$+,+7 ,s a a,+,+7 p$/!ss t/ p$/%! pa$ts $/%+ ,+ sap! #& as,+7.! p/,+t t//. /+ lathes6 T! t//. ,s 5! !,t!$ .,+!a$.& ,+ t! ,$!t,/+pa$a..!. /$ p!$p!+,%.a$ t/ t! a


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Last Upat!"32

C%tt,+7 /+,t,/+s ,+ t%$+,+7

Cutting speed ,+ t%$+,+7 ? ,+ s ,s $!.at! t/ t! $/tat,/+a. sp!! /5t! /$p,!! #& t! !>%at,/+" ? * N!$! * ,s t! ,a!t!$ /5 t! /$p,!!( N ,s t! $/tat,/+a. sp!!/5 t! /$p,!!( $!;s6

Feed ,+ t%$+,+7 ,s 7!+!$a..& !%at,/+( a$! %st #! !


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Last Upat!"33

Milling

ersatile process to cut ar-itrar# 20 shapes

Process character ! high M&&, high surface, dimensioncontrol

"source! wwwhitachi(toolcom;p$"source! wwwphorncouk$

"source! wwwhitachi(toolcom;p$"source! wwwhitachi(toolcom;p$"source! wwwphorncouk$"source! wwwphorncouk$


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Last Upat!"34

Common vertical milling cutters

rogrammed pointon cutter rogrammed pointon cutter

>lat

Ballnose

Bullnose


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Last Upat!"3'

T&p!s /5 ,..,+7

T!$! a$! t/ #as, t&p!s /5 ,..,+7( as s/+ ,+ t! @7%$!"

down "climb# milling( !+ t! %tt!$ $/tat,/+ ,s ,+ t! sa! ,$!t,/+ ast! /t,/+ /5 t! /$p,!! #!,+7 5!(

up "conventional # milling( ,+ , t! /$p,!! ,s /;,+7 t/a$s t!%tt!$( /pp/s,+7 t! %tt!$ ,$!t,/+ /5 $/tat,/+"

T/ t&p!s /5 p!$,p!$a. ,..,+76 N/t! t! a+7! ,+ t! %tt,+7 5/$! ,$!t,/+6


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Last Upat!"3)

P!$,p!$a. ,..,+7 /p!$at,/+s ,t +a$$/%tt!$s" aD s./tt,+7( #D st$a.! ,..,+7(a+ D s.,tt,+76

PERIPHERAL MILLING

P!$,p!$a. s.a# ,..,+7/p!$at,/+6


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Last Upat!"39

Fa! ,..,+7

Pa$t,a. 5a! ,..,+7 /p!$at,/+6 T!

5a!,..,+7 %tt!$ a,+!s /+.&/+! s,! /5 t! /$p,!!6

C/+;!+t,/+a. 5a! ,..,+7 /p!$at,/+6 T!

5a!-,..,+7 %tt!$ a,+!s t! !+t,$!s%$5a!6 T! %tt!$ ,a!t!$ ,s 7$!at!$ta+ t! /$pa$t ,t6


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Last Upat!"3=

Tool wear" observations and models

'igh stresses, 'igh friction, 'igh temp (


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Last Upat!"41

Built#up edge $B%&'

0eposition, work hardening of a thin la#er of the workpiece material

on the surface of the toolnegative rake angle(for cutting hard, brittle materials)negative rake angle(for cutting hard, brittle materials)negative rake angle(for cutting hard, brittle materials)

B* poor surface finish

.ikelihood of B* decreases with

(i) decrease in depth of cut,

(ii) increase in rake angle,

(iii) use of proper cutting fluid during machining

#on $raditional %achining


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Last Upat!"42

#on-$raditional %achining

A a,+,+7 p$/!ss ,s a..! non-traditional ,5 ,ts

at!$,a. $!/;a. !a+,s ,s #as,a..& ,!$!+tta+ t/s! ,+ t! t$a,t,/+a. p$/!ss!s

*,!$!+t 5/$ /5 !+!$7& ,s app.,! t/ $!/;! t!

!


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Last Upat!"43

I+ t$a,t,/+a. a,+,+7( t! %tt,+7 t//. a+ /$p,!! a$! a.a&s ,+ p&s,a./+tat6 I+ +/+-t$a,t,/+a. p$/!ss!s( t!$! ,s +/ p&s,a. /+tat #!t!!+ t!t//. a+ /$p,!!6

Mat!$,a. $!/;a. $at! /5 t! t$a,t,/+a. p$/!ss!s ,s .,,t! #& t! !a+,a.p$/p!$t,!s /5 t! /$ at!$,a.6 N/+-t$a,t,/+a. p$/!ss!s !as,.& !a. ,t s%,%.t-t/-%t at!$,a.s .,! !$a,s a+ !$a, #as! t//. at!$,a.s( @#!$$!,+5/$! at!$,a.s( a$#,!s( t,ta+,%-#as! a../&s

I+ t$a,t,/+a. p$/!ss!s( t! $!.at,;! /t,/+ #!t!!+ t! t//. a+ /$p,!! ,st&p,a..& $/ta$& /$ $!,p$/at,+76

Ma,+,+7 /5 sa.. a;,t,!s( s.,ts( #.,+ /$ t$/%7 /.!s ,s ,%.t ,t t$a,t,/+a.p$/!ss!s( !$!as ,t ,s a s,p.! /$ 5/$ s/! +/+-t$a,t,/+a. p$/!ss!s

N/+-t$a,t,/+a. p$/!ss!s $!>%,$! !%,p!+t a+ t//.,+7 as !.. ass,..! .a#/$( , ,+$!as!s s,7+,@a+t.& t! p$/%t,/+ /st

T$a,t,/+a. a,+,+7 ;s N/+ T$a,t,/+a.Ma,+,+7

W N t ,t, . M , ,


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Last Upat!"44

W& N/+-t$a,t,/+a. Ma,+,+7 +!!!

t!$! ,s a +!! t/ p$/!ss s/! +!.& !;!./p! ,%.t-t/-

%t at!$,a.s( a,+,+7 /5 , ,s a/pa+,! #& !


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Last Upat!"4'

C.ass,@at,/+ /5 +/+-t$a,t,/+a. p$/!ss!s

%echanical processes" E


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Last Upat!"4:

The fluid is pressuri'ed at )*%*** +a to produce -etvelocities of )*%** m/s. The fluid flow rate is typically from*.) to 2.) l/min. The -et have a well behaved central regionsurrounded by a fine mist


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'lectro discharge machining


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Last Upat!"'1

'lectro discharge machining

0n electro discharge processes, the wor& material is removed by a seriesof spar&s that cause locali'ed melting and evaporation of the material on

the wor& surface.

The two main processes in this category are56 electric discharge machining, and6 wire electric discharge machining.

Only on electrically conducting wor& materials.


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E.!t$/ *,sa$7! Ma,+,+7


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Last Upat!"'3

E.!t$/ *,sa$7! Ma,+,+7E*MD


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W,$! E.!t$/ *,sa$7! Ma,+,+7


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Last Upat!"''

W,$! E.!t$/ *,sa$7! Ma,+,+7

Wire Electro Discharge Machining ("ire 78+! is a special form of 78+ thatuses a small diameter wire as the electrode to cut a narrow &erf in the

wor&."ire diameters rangefrom *.*1 to *.*mm,

8ielectric fluids include deioni'ed water or oil.

"asers and other beams


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Last Upat!"')

"asers and other beams

Laser beam machining (L9+!

Laser beam machining (L9+! uses the light energy from a laser to removematerial by vapori'ation and ablation.

The types of lasers used in L9+are basically the carbon dioxide($O2! gas lasers.

Lasers produce collimatedmonochromatic light withconstant wavelength.

The light produced by the laserhas significantly less power than

a normal white light, but it canbe highly focused, thusdelivering a significantly higherlight intensity and respectivelytemperature in a very locali'edarea.

E.!t$/+ #!a a,+,+7 EBMD


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Last Upat!"'9

E.!t$/+ #!a a,+,+7 EBMD

7lectron beam machining uses a high%velocity stream of electronsfocused on the wor&piece surface to remove material by melting andvapori'ation.

An electron beam gungenerates a continuousstream of electrons thatare focused through an

electromagnetic lens onthe wor& surface. Theelectrons are acceleratedwith voltages of approx.)*,*** : to createvelocities over 2**,***

&m/s.

The process is generally limited to thin parts in the range from *.2 to 3

mm thic&.


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Manufacturing Technology-Metal Cutting