MACHINE LAB 1

Technical Report Submitted to: Dept. of Industrial and Manufacturing Engineering

Prof. Edward C. De Meter
310 Leonard Building
The Pennsylvania State University
University Park, PA 16802
Submitted by:
Team: 8
Roman Kozakov
Abdulrahman Almannaa
Taylor Smith

Date: 7/4/2016

TABLE OF CONTENTS

Table of Contents

Investigation Results

INVESTIGATION RESULTS
5.1 Face Milling Process Parameters
Axial Depth = 0.047
Axial depth = Diameter * 1 = 0.047

Cutting Speed. Vc = n * 0.047 * 6000

Vc = 885.9 in/min

Radial Depth, Dr = Diameter * 0.5

Dr = 0.0235

Linear feed rate, Vf = f * n

F = 0.0166 in/min

Material removal rate, Q = fm * Dr * Vf

Q = 0.0235 * 0.047 * 10
Q = 0.011 in3/min

Power requirement = P = Uc * Material removal rate

P = 0.196 W

5.2 Cutting Fluid Application

The fluid allows for less dust and cutting debris to fly around everywhere in the work area,
resulting in a cleaner work environment.

5.3 Face Milling Geometric Error Assessment

There are not significant differences, they are all within .006 of each other. However, they are
not all the same because of part distortion and chatter. This face milling process wouldnt satisfy
the tolerance, so wed recommend doing a much finer face milling process by making many

more passes with the milling machine each with a much finer width to reach the final thickness
and tolerance.

5.4 End Mill Capability

This end mill is made of high speed steel. Center cutting provides the capability for the end mill
to make a hole by drilling into the work piece via axial motion. Yes, center cutting capability is
needed to make shoulders.

5.5 Resultant Chamfer Geometry

The hole diameter is 3/8 with a 90 degree chamfer.

5.6 Standard Drill Sizes

The four series are screw machine length, Jobbler length, long series, and center drill size drills.
U-size drills have a diameter of .368.

5.7 Thread Specifications and Tapping

The angle for the relation of the pitch diameter, pitch, and helix angle is as follows
tan^-1((2*(pitch diameter-minor diameter))/(pitch/2) = helix angle

5.8 Hole Finishing

Hole 1 Average

Hole 1 Standard
Deviation
.000471
.000257

Hole 3 Average

Hole 3 Standard
Deviation
.000136
.000116

Size Error (in.)

.00197
.000225
Circularity Error .000927
.000292
(in.)
Ra (micro-in.)
214.6
22.3
15.2
8.24
From this data its clear that the reaming process improves the overall error by reducing size
error, circularity error, and surface roughness. Its not possible to fabricate holes that have a
tolerance of .0007 because the average size error of the holes that were just drilled with no
reaming had an average size error of .00197, which is past the tolerance of .0007. For holes that
have a diameter tolerance of .01, drilling should be the last hole making process since the holes
that were just drilled with no reaming had an average size error of .00197, which is within the
tolerance of .01 for the holes. Reaming the holes would be an unnecessary waste of time.

5.9 Mechanical Clamping

In this fixture amplifies rghe force exerted by the worker on the workpiece, so mechanical
advantage usually is greater than 1 because output force, Fout > Fin
Mechanical Advantage, MA Fout / Fin = Torque Out / Torque In

For ACME thread 5/8

Major Diameter = 0.625
Pitch Diameter = 0.5562
Taking moment about fixed point
Fin * (6 + 0.625) = Fout * (6 0.5562)
Mechanical Advantage MA = 1.216

5.10 Insert Nose Angle

Nose angle affect the machining of work piece through cutting tool. With increase in nose angle
the cutting force and cutting power increase. With this large nose angle of the tool, the
machining of the finish increase, so produces better surface finish.

5.11 Insert Coatings

Coating is a process by which we provide additional mechanical strength and change their
chemical composition of the outer layer so that they can withstand the environmental effects
such as rain, sunlight, humidity, corrosion, etc. So to make these stronger the carbides are coated.
The coating also helps to decrease the temperature associated with the cutting process and
increase the life of the tool.
Some examples & types of coatings are:

TiN (titanium nitride)

TiC (titanium carbide)
Ti(C)N (titanium carbide-nitride)
TiAlN (titanium aluminum nitride)

5.12 Peck Drilling

The drilling in and out of the hole is done to remove the shaving that are produced during the
drilling process. By pecking the shaving are naturally brought out during the drilling process
allowing for the drill to move farther.

5.13 Boring Processes

The Radius from the center axis to the edge of the cutting tool on the boring mechanism limits
the diameter of the whole. The ability to bore holes with large depth to diameter ratios is limited
because the moment on the edge of the boring rod is greatly increased when the length is
increased and the thickness of the boring bar cannot be increased due to the diameter of the
whole which results in the bending of the boring bar outwards and a discrepancy in the
tolerances of the hole.