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MANUFACTURING
MANUFACTURING
PROCESSES
PROCESSES
- - AMEM 201 AMEM 201
Lecture 7 Lecture 7: : Machining Processes Machining Processes
DR. SOTIRIS L. OMIROU
Shaping Shaping Drilling Drilling Broaching Broaching
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Shaping Shaping Shaping Shaping Shaping Shaping Shaping Shaping
Shaping uses a single Shaping uses a single- -point tool that is moved point tool that is moved
horizontally in a reciprocating motion along a slide. It horizontally in a reciprocating motion along a slide. It
is used to create a planar surface, usually to prepare is used to create a planar surface, usually to prepare
rectangular blocks that can later be used as rectangular blocks that can later be used as
workpieces workpieces for machining on a milling machine etc. for machining on a milling machine etc.
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Shaping Shaping Shaping Shaping Shaping Shaping Shaping Shaping
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Broaching is the process of removing metal with a Broaching is the process of removing metal with a
tool which has teeth arranged in a row. Each tool which has teeth arranged in a row. Each
tooth is successively higher than the previous tooth is successively higher than the previous
tooth and removes more material. tooth and removes more material.
Thus the first few sets of teeth remove most of Thus the first few sets of teeth remove most of
the material, while the last few provide a finishing the material, while the last few provide a finishing
cut with very small amount of material removal. cut with very small amount of material removal.
The geometric shape of the last set of teeth is The geometric shape of the last set of teeth is
identical to the required geometry of the designed identical to the required geometry of the designed
part. part.
In broaching, one stroke or cycle of the machine In broaching, one stroke or cycle of the machine
produces a finished part. Broaching is used to produces a finished part. Broaching is used to
produce both internal and external features. produce both internal and external features.
Production rates are high and tolerances of Production rates are high and tolerances of
+/ +/- - 0.01 mm are possible. 0.01 mm are possible.
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching
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Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching Tools Tools Tools Tools Tools Tools Tools Tools
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Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching Tools Tools Tools Tools Tools Tools Tools Tools
Broaching cutter details Broaching cutter details
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Design and construction considerations Design and construction considerations
Material to be broached Material to be broached
Size and shape of cut Size and shape of cut
Quality of surface finish Quality of surface finish
Part tolerance Part tolerance
Productions rates Productions rates
Type of machine Type of machine
Workholding Workholding method method
Strength of the Strength of the workpiece workpiece
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching Tools Tools Tools Tools Tools Tools Tools Tools
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Tool Feed Direction
Gullet
Workpiece
Depth of
cut per tooth
Tool
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching mechanism mechanism mechanism mechanism mechanism mechanism mechanism mechanism
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Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching - -- - - -- - Advantages Advantages Advantages Advantages Advantages Advantages Advantages Advantages
Rough to finish in one pass Rough to finish in one pass
Cutting time is quick Cutting time is quick
Rapid load and unload of parts Rapid load and unload of parts
External and internal features External and internal features
Any form that can be produced on a Any form that can be produced on a
broaching tool can be produced broaching tool can be produced
Production tolerances are excellent Production tolerances are excellent
Surface finishes are equal to milling Surface finishes are equal to milling
Operator skill is low Operator skill is low
Production rates are highs Production rates are highs
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Tooling cost can be high Tooling cost can be high
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching - -- - - -- - Disadvantages Disadvantages Disadvantages Disadvantages Disadvantages Disadvantages Disadvantages Disadvantages
In some cases In some cases-- --not suited for low not suited for low
production rates production rates
Parts to be broached must be strong Parts to be broached must be strong
enough to withstand the forces of the enough to withstand the forces of the
process process
Surface to be broached must be accessible Surface to be broached must be accessible
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Pull broaching Pull broaching - - broach is pulled broach is pulled
through or across stationary work through or across stationary work
Push broaching Push broaching - - broach is pushed broach is pushed
through or across work through or across work
Surface broaching Surface broaching - - either the work or either the work or
the broach moves across the other the broach moves across the other
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching - -- - - -- - Methods of Operation Methods of Operation Methods of Operation Methods of Operation Methods of Operation Methods of Operation Methods of Operation Methods of Operation
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Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching Machines Machines Machines Machines Machines Machines Machines Machines
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Complex hole shapes cut by broaching Complex hole shapes cut by broaching
Broaching Broaching Broaching Broaching Broaching Broaching Broaching Broaching products products products products products products products products
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Drilling is one of the most common machining process.
A large amount of all metal-cutting material removed
comes from drilling operations.
Drilling is one of the most common machining process.
A large amount of all metal-cutting material removed
comes from drilling operations.
Drilling Drilling Drilling Drilling Drilling Drilling Drilling Drilling
By drilling are creating holes that are right circular
cylinders. This operation is accomplished most common
by using twisted drills (that is the tool).
By drilling are creating holes that are right circular
cylinders. This operation is accomplished most common
by using twisted drills (that is the tool).
In order to perform the drilling operation the tool has to
have o rotation motion, that is the cutting motion and
the tool or work part will achieve the feeding motion,
which is a translation one, on the same direction with
rotation axis.
In order to perform the drilling operation the tool has to
have o rotation motion, that is the cutting motion and
the tool or work part will achieve the feeding motion,
which is a translation one, on the same direction with
rotation axis.
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Feeding
motion
Cutting
motion
Work
Part
Twisted
Drill
Drilling Drilling Drilling Drilling Drilling Drilling Drilling Drilling
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Some features of drilling set it apart from other metal cutting
operations. Among these are:
Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling Characteristics of Drilling
* The chips must exit out of the hole created by the
cutting tool, so the friction and as a consequence the
temperature is very high.
* The chip exit can cause problems when chips are large
and/or continuous.
* The drill can wander when the holes are deep
* For very deep holes the coolant may need to be
delivered through the drill shaft to the cutting front
area
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Drilling, Drilling, Drilling, Drilling, Drilling, Drilling, Drilling, Drilling, Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping Reaming, Boring, Tapping
All four methods produce holes of different types.
Drilling produces round holes of different types.
Reaming is used to improve the dimensional
tolerance on a drilled hole.
Boring uses a special machine operating like a
lathe, to cut high precision holes.
Tapping creates screw-threads in drilled holes.
For drilling in brick, stone,
concrete, slate, plaster
and other masonry materials
For drilling cast iron
or non-ferrous material.
For drilling cast iron, plastic
or non-ferrous materials
These heavy duty drills feature
a regular helix and polished flutes
for rapid chip removal. Ideal for
drilling steel, cast iron, and non-
ferrous materials.
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Tools Tools Tools Tools Tools Tools Tools Tools
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Straight shank taper
length drills are standard for
general purpose work in drilling
relatively deep holes.
Shanks are of the same diameter
as the drill body
Especially suitable for deep hole
drilling in low tensile
strength materials,
such as aluminum magnesium
and zink alloys
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Tools Tools Tools Tools Tools Tools Tools Tools
Counterbore drills have
multiple diameters. They make a
chamfered/stepped hole, which is
useful for inserting screws/bolts.
The larger diameter part of the hole
accommodates the screw/bolt head;
For countersinking, chamfering,
and deburring holes. Produces
a smoother finish.
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Tools Tools Tools Tools Tools Tools Tools Tools
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D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Tools Tools Tools Tools Tools Tools Tools Tools
Center-drills
It is common to machine a small hole in the material, called a center-hole, before utilizing
the drill. Center-holes are made by special drills called center-drills.
They also provide a good way for the drill bit to get aligned with the location of the hole
center.
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Suitable for general purpose
through hole reaming
For accurate hand reaming of Morse
Taper holes in sockets, sleeves and
spindles
Is especially suited for use in stringy
materials or in through holes where a
slot or keyway is present.
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Tools Tools Tools Tools Tools Tools Tools Tools
For general reaming in deep holes
requiring precision tolerances.
Reamers
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Drilling
head
Vertical
Column
Machine table
Base
Vertical guides
Main
spindle
Twisted
drill
The work part that have to be machined
is clamped on the machine table and the
tool (twisted drill) is monted on the main
spindle. The main spindle, with tool, will
perform both the cutting (rotation) and
feeding (translation) motion.
The work part that have to be machined
is clamped on the machine table and the
tool (twisted drill) is monted on the main
spindle. The main spindle, with tool, will
perform both the cutting (rotation) and
feeding (translation) motion.
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools
Column
Radial beam
Radial guides
Work Part
Bed
Drilling head
Tool
Vertical motion
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Rotation motion
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Radial motion
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1,2,3 Auxiliary motions for adjusting the
relative position between the work part and tool
The radial drilling machines are used for machining of large work parts.
Here, it is so difficult to adjust the relative position between the tool
and work part by moving a heavy part. For this reason there are three
auxiliary motions. The cutting and feeding motions are performed by
tool.
The radial drilling machines are used for machining of large work parts.
Here, it is so difficult to adjust the relative position between the tool
and work part by moving a heavy part. For this reason there are three
auxiliary motions. The cutting and feeding motions are performed by
tool.
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools
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Drilling head
Portal frame
Z
Y
X
Machine
Table
Z Screw
Y Screw
X Screw
Bed
X Guides
Z Guides
Y Guides
D DD D D DD Drilling rilling rilling rilling rilling rilling rilling rilling Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools Machine Tools