Summer internship report

prepared by: Bayar Houssem Eddine

AU 2017/2018
Sommire :
Chapter 1:
1. History:............................................................................................................................................. 6
2. Mission HPC Group: .............................................................................................................................. 6
3. L’PRECIMOLD company. 6
3.1. Presentation :................................................................................................................................. 7
3.2. The services of the’company PRECIMOLD:................................................................................. 7
3.3. Office d’studies :.......................................................................................................................... 7
3.4. Resources human resources and equipment:................................................................................................ 7
3.4.1. Personnel: ........................................................................................................................... 7
3.4.2. Materials:............................................................................................................................. 7
3.4.3. Tooling:.............................................................................................................................. 8
3.5. Organizational Chart : ............................................................................................................................ 8
1. Mechanical manufacturing processes. 10
1.1. Definition: ....................................................................................................................................... 10
1.2 Types mechanical manufacturing processes. 10
1.2.1 THE FILMING :. 10
MILLING: .............................................................................................................................. 14
2. The machines: ......................................................................................................................................... 16
Milling:. 17
2.2. Filming: ........................................................................................................................................ 17
2.3. Numerical control machine. 18
2.3.1. Introduction:. 18
2.3.2. Interests of MOCN. 19
D’in a general way, the’use of’a MOCN presents a certain number of’advantage:.................. 19
3. Cutting tools: .............................................................................................................................. 20
3.1. Milling tools. 20
3.2. The turning tools. 21
3.2.1. ARS Tools. 21
3.2.2 Carbide tool. 23
4. The cutting conditions:. 23
4.1. Principle : .......................................................................................................................................... 23

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 4.2. Milling cases:. 24
4.3. Shooting case: ............................................................................................................................. 24
4.4. Choice of cutting parameters:. 24
1. Mechanisms of formation of the’sure : ................................................................................................... 27
2. Types of wear :....................................................................................................................................... 28
3. Dependence between wear and time: ................................................................................................... 29
4. Lifespan: .......................................................................................................................................... 30
4.2. Cutting depth, ap:................................................................................................................ 30
4.3 Progress, fn :....................................................................................................................................... 30

4.4 Cutting speed, vc:........................................................................................................................ 31

4.5 Taylor's Law:.................................................................................................................................. 31
5. Optimization of cutting conditions: ................................................................................................... 33
5.1 Generalities:...................................................................................................................................... 33
5.2 The parameters of production:..................................................................................................... 33
5.3 Research production time: ................................................................................................ 33

3
 Introduction

The internship period allowed me to gain valuable experience in the field of

mechanical manufacturing. Indeed, I attended to several tasks of manufacturing parts, as well

that I have

reviewed different methods and tools to address the problems encountered and find solutions

solutions to solve them.

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 Chapter 1:
Company Presentation:

5
 History:
Founded in 1990 in the plastics sector, HPC GROUP offers industrial companies...
transformation of plastics solutions to improve productivity and quality
of their performance in all areas.

2. Mission HPC Group:

HPC offers you a complete range of products and services:

Sale of equipment for the processing of plastic materials.

Technical advice
Installation of factories
After-sales service
Preventive and corrective maintenance.
Inter and intra-company training.

Group companies:

PRECIMOLD
PLASTIC MAINTENANCE
ENI
MECASSEMBLY

3. The company PRECIMOLD

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 [Link] :
My summer internship took place within the company PRECIMOLD.

Since 2010, the year of its founding, PRECIMOLD has been dedicated to design, maintenance and
the manufacturing of tools. It is recognized by its clients in the field of manufacturing and
of the maintenance of plastic injection molds in very diverse sectors:

Automobile
Electricity
Cosmetics
Pharmaceutical
Home automation

[Link] services de l’entreprise PRECIMOLD :

Study and design of molds: equipped with CAD software
Mold fabrication
Maintenance service for tools
Fabrication of control templates
Manufacturing of high precision spare parts
Measurement and dimensional control of precision mechanical parts and components
plastics with the MMT (Three-Dimensional Measurement) machine.

3.3. Research Office:

The implementation of experts in the field of tools capable of developing project studies.
customers

Software:
CREO PARAMETRIC 2.0
SolidWorks
MASTERCAM for CNC programming

[Link] resources and equipment:

3.4.1. Personnel:
The PRECIMOLD team, which consists of 15 experienced and competent technicians and engineers
with a complete mastery of manufacturing processes, is available to study, advise
et trouver la solution optimale pour des pièces de petite et moyennes dimension afin de répondre
to the requirements of productivity and production.

3.4.2. Equipment:
The equipment consists of state-of-the-art preforming machine tools.
Regular investments allow us flexibility and good control over deadlines.
manufacturing of tooling. A machine park of 25 machine tools

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 Numerical Control Machine (CAM)
Conventional milling
Shooting
Rectification plane
Driving
Three-dimensional measuring machine (CMM)
Adjusting

3.4.3. Tools:
All ranges of tools that cover all machining applications such as:

Milling, turning, drilling, boring..., ensuring the precision and conformity of geometries.

3.5. Organizational chart:

Figure 1: Organizational chart of the company PRECIMOLD

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 Chapter 2:
Bibliographic research

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Mechanical manufacturing processes

1.1. Definition:
Set of techniques aimed at obtaining a part or an object by transformation of
raw material. Obtaining the desired piece sometimes requires the successive use of different
manufacturing processes. These manufacturing processes are part of mechanical construction.
Assembly techniques are not part of manufacturing processes; they are involved.
once the different parts have been manufactured.

1.2 Types of mechanical manufacturing processes

1.2.1 THE SHOOTING:
Filming, as its name indicates, concerns a rotating movement. The technique of
Turning therefore consists of rotating the workpiece around a defined axis. This axis is the one
from the spindle of the lathe. The workpiece is fixed to this spindle, the gripping means can
to be a chuck or any other clamping principle. The machine used is called a 'lathe'.

The purpose of the filming is to create revolution shapes such as cylinders, cones, toroids and
other forms of complex revolution.

Turning is a somewhat discipline in the field of machining because it is the only one
for which we have both:

A movable piece

A unique tooth tool

A continuous cut (the material runs continuously on the cutting face of the tool)

These specificities make it a little more difficult than the others when one is interested in
the lifespan of tools.

The principle of turning is as follows: the workpiece is attached to a rotating spindle (so it
(turns) and the tool moves in a plane. The trajectory of the tool in its plane of evolution provides
the generator of the revolution piece.

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 Figure 2: Turning Principle

. Different shapes made with a lathe:

Transport

Operation that involves machining an external cylindrical or conical surface.

Figure 3: Carting

Bore:

Operation that consists of machining an internal cylindrical or conical surface.

Figure 4: Boring

Dressage:

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Operation that involves machining a flat surface perpendicular to the axis of the outer spindle.
my interior

Figure 5: Dressage

Drilling:

Operation that involves machining a hole using a drill.

Figure 6: Drilling

Rainage:

Operation that consists of machining an internal or external groove for the housing of a circlip
or an O-ring for example.

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 Figure 7: Grooving

Beveling:

Operation that involves machining a small cone to remove a sharp edge.

Figure 8: Beveling

Cutting:

Operation that involves machining a groove to the axis of the part in order to detach it.
section.

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 Figure 9: Sawing

Threading:

Operation that involves creating an external or internal thread.

Figure 10: Threading

1.2.2 MILLING :

Milling is a process ofmachiningby material removal. It is characterized by the use of

a machine tool: the milling machine. The tool traditionally used is the mill.

In milling, the removal of material - in the form of chips - results from the combination of two
movements: rotation of the cutting tool on one hand, and advance of the workpiece on the other hand.

The milling machine is particularly suitable for machining prismatic parts and also allows for,
to create all types of shapes, even complex ones.

Current milling machines are frequently automated. In the industry, milling workers
qualified individuals frequently carry out work inshooting csupplementary.

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 Figure 11 : Milling Principle

Types of milling operations:

Visualization Identification of Type of operation Machining diagram

the tool realized
Strawberry size 1 Rolling surfacing
surfacer or of profile

Bell strawberry has End milling or

surfacer face

Strawberry 2 sizes at Surfacing combines a

conical queue predominance in
rolling
Rolling resurfacing

Strawberry 2 sizes at Profile rainwater harvesting

cylindrical queue somewhat imprecise

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 Groove milling cutter for two profile grooves
cut lips in full matter
central groove of
slavery

Strawberry 3 sizes to End rainwater drainage

alternating dentures Usual quality
obtained /9

Strawberry 3 sizes End drainage

extensible to usual quality dentures
alternating obtained 7-8

Surfacing cutter End surfacing

Surfacing mill and to Combined surfacing to

dresser predominance at the end

Grooving cutter Profile rainwater drainage

Strawberry 3 sizes to End irrigation

alternating dentures

2. The machines:
Machines are classified into two categories:

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2.1. Milling:

In the case of milling: the tool rotates, the workpiece moves. Milling centers consist of
generally 3 axes (that can be controlled individually to create shapes
complex (Helixes…) and a rotating platform to present all sides of the piece in front of the
brooch.

One can also imagine mounting the tool at the end of a robotic arm. See the example on the opposite side.

The tool rotates, the piece moves relative to the tool. This allows for the creation of shapes.
plans, molds...

The types of milling machines:

Horizontal and vertical milling machines

Figure 12: Horizontal and vertical milling machines

2.2. Shooting:
The conventional parallel turn:

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This machine is mainly used to machine revolution parts. The part is fixed in the
mandrel. This is rotated by the spindle motor. The tool follows a path that
interferes with the part. The tool is equipped with a cutting edge, which results in a removal of
matter. These small elements of matter are called chips.

Figure 13: The conventional parallel lathe

2.3. Numerical control machine

2.3.1. Introduction:

A Computer Numerical Control (CNC) machine is a machining machine with a cycle

programmable automatic.

The term 'digital command' is generic and has been chosen because the machine is
commanded by digital 'instructions' provided by a computer. In other words, we
can say that the movable parts of the machine are motorized and that an automation ensures the
command and in most cases the control of position and/or speed.

This type of machine consists of two complementary parts:

The operative part (it is the machine tool: it acts directly on the product to be made).
The control part (this is the numerical control: it allows the development of orders in
function of instructions and reports).

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2.3.2. Interests of MOCN
Generally speaking, the use of a MOCN has a number of advantages:

A CNC machine facilitates the machining of complex shapes. Many operations can
to be executed in envelope work, which limits the number of shape tools or
specific tools.
It allows for reducing machining times (optimization of cutting conditions) and the
dead times (high movement speeds, reduced tool change times).
The quality of the product increases (better dimensional accuracy and better condition of
surface).
It helps to reduce the lead times and the changeover time (responsiveness of
the company).

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 Figure 14: Numerical Control Machine

3. Cutting tools:
3.1. Milling tools
Fraise deux tailles ARS Usinages de plans. La
strawberry is in ARS. This
strawberry, one of the most
current, is replaced
by carbide burrs.

Strawberry two sizes at Carbide burr, of

attached plates milling. This cutter
allows drafts
fast, but does not allow
not to dive into the
material (no "cut"
at the center

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 Strawberry 3 sizes Cutter for machining the
grooves. 3 plans are
used in a single
pass.

Surface cutter Carbide surfacing cutter

for machining large ones
plans.

Conical cutter of shape Cutter of shape for

milling grooves of
dovetail.

3.2. The turning tools

We choose the shape of the tool depending on the operation to be performed (roughing or finishing) and the
shape of the piece to be made.

3.2.1. ARS Tools

Tool Standards Silhouette tools ARS
Angle dressing tool NFE 66 364

Threading tool NFE 66 369

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Trolley tool NFE 66 362

Boring tool - facing

Forest

Alésoir

Internal threading tool

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3.2.2 Carbide tool

Figure 15: Carbide tools

4. The cutting conditions:

4.1. Principle:
During machining by material removal, we find ourselves, in the majority of cases, in the
following configuration:
A tool blade penetrates the material and removes a chip.
The tool follows a trajectory relative to the workpiece. These movements are ensured by the
constituent elements of the machine tool.
To achieve satisfactory work (good condition of the machined surface, speed of machining, wear
moderate the tool, ...) we need to adjust the cutting parameters.
There are several criteria that define the parameters of the cut, including:
The type of machine (turning, milling, drilling)
The power of the machine
The machined material (steel, aluminum)
- The material of the tool (ARS, carbide)
The type of operation (drilling, turning, surfacing)
The final objective is to obtain a machined part under good conditions. To achieve this, it is necessary to
determine certain specific parameters:
The cutting speed: Vc

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The advance speed: F
The pass depth: a

4.2. Milling cases:

Designation Unit Calcul
The cutting speed m/min Imposed by the
tool manufacturer
Feed rate in mm/min = × ×
milling
The spindle speed tours/min . .
=
1000
Advance per tooth mm/dents
Name of tooth of the
strawberry
The depth of mm 1/3 of the width of the
radial pass maxi plaque
Average thickness mm
chips
Machined diameter mm

The cutting time min 1

=

4.3. Shooting case:

Designation Unit Calculation
The cutting speed m/min Imposed by the
tool manufacturer
The spindle speed tours/min . .
=
1000
The advance per round mm/tour
The depth of mm 1/3 of the width of the
radial pass maxi plaque.
Average thickness mm
chips
Machined diameter mm

The cutting time min 1

=

4.4. Choice of cutting parameters:

When machining a single unit, it is not necessary to optimize the cutting conditions.
One then content oneself with choosing the conditions for machining to go well. When one does
a series of parts, it becomes interesting to try to optimize one of the parameters.

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Figure 16: Choice of cutting parameters

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 Chapter 3:
Task completed

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1. Mechanisms of wear formation:

The wear of cutting tools is one of the most complex physico-chemical phenomena.
It influences the geometry of the tool as well as the quality of the part. It is due to its
appearance due to the following causes:
Friction tool-chip, tool-workpiece and workpiece-chip (abrasive wear).
Plastic deformations of the material of the active part of the tool.
Significant warming due to cutting.
The fragmentation of the tool (tear-off of small metal particles).
Usury can take several forms:
Abrasive wear is common to all tools, it is the main cause of
the dulling of the tool.
Wear due to plastic deformations of the tool material is especially for tools
in low-alloy steel (high-speed steel).
The wear caused by a high cutting temperature is more pronounced in
carbon steels and high-speed steels, due to their hot resistance
relatively low. Wear is all the faster as the temperature of the active part
is higher as shown in the figure:

Another series of shooting experiments aimed at determining the speed "vc".

depending on the time 'T' for dry machining and another with lubrication, give the
following results:

Figure: Influence of lubrication

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What we observe in the figure is that with well-suited lubrication for the work to be done
allows to significantly increase the lifespan of the tool, resulting in reduced wear.

2. Types of wear:
Depending on the cutting conditions, wear can occur according to the clearance surface.
depending on the attack surface or depending on both surfaces at the same time:
The wear of the chip removal surface (figure II.24a) is specific to tools that remove chips.
of low thickness (less than 0.1mm) with a cutting speed that is too high (greater than 80
m/min) as well as during the machining of brittle chip metals (cast iron, bronze, etc...).

The wear of the attack surface (figure II.24.b) occurs during the machining of plastic materials.
with tools that remove chips thicker than 0.5 mm, the speed is
varied from 20 to 30 m/min, in this zone the reported edge forms which protects the surface of
skin against wear. It begins with the appearance of a small indentation that widens with the
weather.

The simultaneous wear of the spoil and attack surfaces (figure II.24.c) is particular to
tools that remove chips with a thickness ranging from 0.1 to 0.5 mm. The cutting speed is
large enough. The sharp edge disappears, the next cut becomes impossible so the tool must
to be refined.

In the case of carbide tools that usually operate at speeds of

high cuts which prevent the formation of the reported edge. That is why after a
certain time spent during machining, the entire cutting surface including the cutting edge
wears out. The wear of the two surfaces forms a new sharp edge (figure II.25)
that renews during the cup.

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 Figure: Metal carbide tool

3. Dependence between wear and time:

The relationship between the value of wear and time represented by the following curve can be
divided into three periods:

Figure: Wear curve

Period I: Initial wear or break-in (to be avoided for adjustments)

Period II: Normal wear or normal range of tool usage
Period III: Accelerated wear (catastrophic) risk of rupture.

The first period: is the break-in period (initial wear that leads to intense wear,
the smoother the friction surfaces are, the less the wear evolution is in the same.
time interval.

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 The second period: is that of normal wear, it is defined by the progression of wear.
depending on the working hours during the second period, the increase in wear in units
Time is a constant.
The third period is when wear reaches a certain degree. The cutting conditions and
friction changes to establish the third period which is that of accelerated wear (wear
catastrophic.

4. Lifespan:
The three main parameters of cutting conditions, speed, feed, and depth, have
an effect on the lifespan of the tool. To extend the lifespan:
Optimizep(in order to reduce the number of passes)
Optimizern(to reduce cutting time)
Reducec(in order to reduce the heat)

4.2. Cutting depth, ap:

Too weak

Poor chip control

Vibrations
Excessive heat
High cost
Too big

Too much power consumed

Platelet rupture
Larger cutting forces

4.3 Progress, fn :
Too weak

Tangled shavings
Assurance in rapid decline
Reported edge
High cost
Too strong

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Poor chip control
Poor surface condition
Uranium in the crater, plastic deformation
Too much power consumed
Welding of chips
Hammering of chips.

4.4 Cutting speed, vc:

Too weak

Reported edge
Blunt ridge
High cost

Poor surface condition

Too high

Sure in quick spoil

Poor surface condition
Uncertain in a rapid crater
Plastic deformation

4.5 Taylor's Law:

. Prince
A cutting speed Vi is set, and machining is done with the tool until the wear criterion is reached.
reached (generally VB=0.3) and we note the actual cutting time Ti.
By plotting the pairs (Vi, Ti) on a graph, one obtains a curve that has this shape.

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In zone A-B, we can write:
= ×

Simplified TAYLOR model, Cv and k are coefficients.

Represented in a logarithmic coordinate system, the segment A-B is practically a
right.

Log T = Log Cv + k Log V

If we know the lifespan T1 for the cutting speed V1, and the lifespan T2 for the speed
from the V2 cut, we can easily determine Cv and k.

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K depends mainly on the tool. It can only be said that it is between -12 and 1.
Cv mainly depends on the machined material and cutting conditions. It is even more difficult to it
give an order of magnitude: 10^4 < Cv < 10^14
In practice, the cutting speed value will be found in provided databases.
by manufacturers who conducted experimental campaigns to determine the values of
Cv and k as a function of the characteristics of their tools (material, coating, geometry, ...).

5. Optimization of cutting conditions:

5.1 Generalities:
Optimization is the search for the most satisfactory solution according to a chosen criterion.
Examples: Criteria
optimize the machining price of a part minimum cost
optimize the machining time of a part, minimum duration
optimize the stock of equipment, maximum quantity.

5.2 The parameters of production:

The cost of a part:
The components of the cost price of a piece are:
machine cost (depreciation, maintenance, operator salary);
- assembly cost (assembly price to be amortized over the entire series);
cost related to tool wear (inserts, insert holders, machine downtime for adjustments, ...);
The production time:
Auxiliary times (changing parts, taking passes, ...);
The cutting time;
The tool change times.
Problem position:
On a :
Ct = f (pièce, machine, nombre de passes, vitesse de broche (N), vitesse d’avance (f))
The problem is to find the cutting conditions 'N' and 's' such that Ct is minimized.

=0

=0

5.3 Production time research:

Let:

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 . Tt: production time,
. Tc: cutting time,
. Auxiliary time (assembly of the part, disassembly, taking passes)
. Tvb: tool change time (to be distributed over the number of machined parts),
. T: lifespan of the tool, with:
= . (Taylor model)

where: f: advance (mm/tr),

a : profondeur de passe (mm),
V: cutting speed (m/min),
T : (min)

= + +( )× (1)
Tvb divided by the number of machined parts by the same tool.

For example, in shooting,

On a: =
. .
1000.V
Avec : D : diamètre de la pièce,
L: length to be machined

. . . .
(1) Becomes: = 1000. .
+ + 1000. .
. .

. Search for production cost

Let: P0: machine cost (DH/min),
P1: cost price of a cutting edge,
Pa: auxiliary launch cost of the series allocated to one piece.
Pt = [Link] + [Link] + P1.(Tc/T) + Pa

. Optimization according to the criterion: minimum cost

For a given advance 's':

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Let's determine the cutting speed V that will give us the minimum cost price.
=0
− ( +1. ) 1
=√
. . .

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 Conclusion

As part of my summer internship, I had the opportunity to closely explore the field.

of mechanical manufacturing. I was able to apply my theoretical knowledge and the

to deepen in relation to the support received from all members of the company.

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