1.
Turning & Related Operations MACHINING OPERATIONS AND MACHINE TOOLS
1. Turning and Related Operations 2. Drilling and Related Operations 3. Milling 4. Machining & Turning Centers 5. Other Machining Operations 6. Shape, Tolerance and Surface Finish 7. Machinability 8. Selection of Cutting Conditions 9. Product Design Consideration
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Turning a machining v Rotational Speed: N = process in which a Do single-point tool remove Do D f = 2d material from the Feed rate: f r = Nf surface of a rotating L work piece. (Lathe) Time of machining: Tm =
Material Removal Rate:
Do
fr
Df
MRR = vfd
d L f
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Operations related to Turning
Contour turning Chamfering
Work Holding
Mounting between two centers (Dog & Live center) Chuck Collet Face plate
Facing
Taper turning
Form turning
Cutoff
Threading
Boring
Drilling
Knurling
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Engine Lathe
Headstock Tool post Tailstock
Other Lathes & Turning Machine
Toolroom Lathe and Speed Lathe Turret Lathe
The tailstock is replaced with a turret
Carriage Threaded Lead Screw
Bed
Chucking Machines No tailstock Automatic Bar Machine Similar to chuck machine but with a collet
A single- and multiple-spindle bar machines
NC Lathe
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Boring Machining
Boring Cutting is done inside diameter of the work material
2. Drilling & Related Operations
Geometry of Twist drill
Shank, Neck and Drill body Helix angle, Point angle, Flute, cutting edge, Chisel edge, Margin
Cutting conditions
Spindle: N =
Horizontal Boring Machining
Vertical Boring Machining
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Metal Removal Rate: MRR = t+A 4 Machining time: Tm = f r For a through hole A d Tm = For a blind hole d t fr
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Feed rate: f r = Nf
f(in/rev)
D 2 f r
Twist Drill and Drilling Operations
Machine Tool for drilling
Drill press
Upright drill Bench drill Radial drill Gang drill - 2-6 drills together NC drill
Vice, Jig and fixture
From Kalpakjian and Schmid (2003)
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3. Milling
Milling
Up Milling Down Milling Conventional face
Cutting conditions
Milling cutters
Plain milling cutters Form milling cutters Face milling cutters End milling cutters
Radial Rake Angle
A machine operation in which a work part is fed past a rotating cylindrical tool with multiple edges. (milling machine)
Partial face
Types
Peripheral milling
Slab, slotting, side and straddle milling Up Milling (Conventional) & down milling (Climb)
Slab
End
slotting
Relief Angle Clearance Angle
Profile
Cutting conditions
side
Contour
Facing milling
Conventional face, Partial face, End, Profile, Pocket & contour millings
Spindle rotation speed:
Pocket straddle Peripheral Milling Face Milling
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D Feed rate: f r = Nnt f
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N=
Material Removal Rate: MRR = wdf r
Milling Machines
Knee-and-column Milling Machine (Fig. 22.22 and Fig. 22.23)
Horizontal and vertical types Universal and Ram types
Machining Centers
Machining center highly automated machine tool capable of performing multiple machining operations under CNC control.
Automatic tool changer Pallet shuttles Automatic workpart positioning
Bed-type Mill (Fig. 22.24) Planer-type Mills the largest category Tracer (profile) Mill reproduce an irregular part geometry CNC Milling machine
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CNC turning center
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A CNC mill-turn center
A series of operations without human interactions
5. Other Machining Operations
Shaping and planing
A single-point tool moves linearly relative to the work part Shaping - A tool moves Planing A workpart moves
Stock A part
Turning
Milling
Drilling
Broaching
Performed by a multiple-tooth cutting tool by moving linearly relative to the work in the direction of the tool axis.
Sawing
From a casting From a round stock From another casting
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Hacksawing, Bandsawing, and Circular sawing
Broaching & Sawing
Hacksaw - linear reciprocating motion
Bandsaw - linear continuous motion
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