Machining

ver. 1

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Old Machine Shop Edisons lab

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Machining = Chip formation by a tool

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Big lathe with big chips

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Discontinuous chips

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Continuous chips

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Machine Tools and Processes

Turning Boring Milling Planing Shaping Broaching Drilling Filing Sawing Grinding Reaming Honing Tapping

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Lathe (for turning)

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Lathe Parts

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Typical Insert Cutting Tool

insert

holder

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Old Lathe

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Boring

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Old Boring Machine

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Old Planer

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Shaper

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Trepanning

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Drilling
(a)

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Milling

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Face Milling

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Horizontal Mill

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Old Horizontal Mill

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Vertical Mill

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Milling Types

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Broach

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Reamers

bridge reamer
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Honing

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Thread Tap and Die

internal

external

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Idealized Chip-formation Process Orthogonal Cutting

chip shear zone cutting tool

workpiece

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Chip-formation Geometry

primary shear zone

chip

B to workpiece

tc A

tool V (cutting velocity)

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

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Turning vs. Orthogonal Cutting

Terminology used in a turning operation on a lathe, where f is the feed rate (in./rev or mm/rev) and d is the depth of cut. In turning, the orthogonality is to the left in the drawing, hence a change of coordinate system is needed. If you were doing a diametral cut-off (plunge cut) operation, no change would be needed. Note that feed in turning is equivalent to the depth of cut in orthogonal cutting, and the depth of cut in turning is equivalent to the width of cut in orthogonal cutting.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

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Cutting Force Diagram

R Fc R Fs Ns N F V

Ft

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Merchants Force Circle

Fs Fc Ns Ft R F N V

M. Eugene Merchant
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3D Cutting (Oblique)
Z n X, V O e i Y
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Vc

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Typical Insert Cutting Tool

insert

holder

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Tool Coatings

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Chip Types
Basic types of chips and their photomicrographs produced in metal cutting: (a) continuous chip with narrow, straight primary shear zone; (b) secondary shear zone at the chip-tool interface; (c) continuous chip with built-up edge; (d) continuous chip with large primary shear zone; (e) segmented or nonhomogeneous chip and (f) discontinuous chip. Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.

(a)

(b)

(c)

(d)

(e)

(f)

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Chip Types
(a) Continuous chip with narrow primary shear zone
ductile materials at high speed bad for automation (use chip breakers)

(b) Secondary shear zone at chip-tool interface

increased energy dissipation

(c) Continuous chip with built up edge (BUE)

high plastic working bad for automation

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Chip Types
(d) Continuous chip with large primary shear zone
soft metals at low speeds and low rake angles poor surface finish residual stresses

(e) Segmented chip

low thermal conductivity materials

(f) Discontinuous chip

low ductility materials and/or negative rake angles good for automation
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Segmented chips

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Chip Breaker
chip shear zone chip breaker cutting tool

workpiece

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Integral Chip Breakers

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Tool Marks

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Roughness
Roughness AA f
2

18 3 r

f Roughnesst 8r
f

f = feed r = nose radius AA = arithmetic average t = peak-to-valley

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

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Surface Marks
(a) (b)

Surfaces produced on steel by cutting, as observed with a scanning electron microscope: (a) turned surface and (b) surface produced by shaping. Source: J. T. Black and S. Ramalingam.

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Formation of Built-up Edge (BUE)

BUE deposit cutting tool

chip BUE

BUE deposit workpiece

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Chatter
Results from vibration Tool bounces in and out of the workpiece

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Glacial Chatter

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Chip / Tool Interface

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Tool Wear
(a)
Rake

(b)

(c)

Flank

(d)

(e)

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Taylors Equation
VTn = C
V = cutting speed T = tool life n, C = Taylor constants (empirical)
C n log V log T 1
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton

Frederick W. Taylor
1856-1915

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F.W. Taylors Contributions

Metal cutting Time / motion studies
Led to Congressional inquiry and banning of stop watch use by civil servants (1912-1949)

Design of shovels Scientific management

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Cost components
Total Tool changing Min COST Tool Machining Raw material Material handling CUTTING VELOCITY
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Cutting cost example

HSS Vcm N (rpm) 183 T (min) 43.5 Cm 3.1831 Cc 0.1463 Cg 0.2117 Ci 0.699 Cs 0.05 Cr 0.85 Total ($) 5.14 Vtm 200 18.1 2.9125 0.3218 0.4655 0.699 0.05 0.85 5.30 Carbide Vcm 432 5.64 1.3484 0.1793 0.1603 0.699 0.05 0.85 3.29 Vtm 490 3 1.1888 0.2972 0.2657 0.699 0.05 0.85 3.35 Carbide Vcm 432 5.64 1.3484 0.3495 0.3125 0.699 0.05 0.85 3.61 all Vtm 490 3 1.1888 0.3495 0.3125 0.699 0.05 0.85 3.45
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