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Machining
Objectives
Introduce cutting terminology and principles
Review modern machining technologies and new methods
(papers)
Introduce cutting parameters
Develop cutting models
Machining types
Turning
Drilling
Milling
Shaping
Planing
Broaching
ME 482 - Manufacturing Systems
Machining tools
Single point
Multiple point
Machining terminology
Speed surface cutting speed (v)
Feed advance of tool through the part (f)
Depth of cut depth of tool into part (d)
Rake face tools leading edge
Rake angle slant angle of tools
leading edge (a)
ls
Orthogonal model
Depth of cut = to
Shear plane length measured along shear plane chip (ls )
Chip width (not shown) width of machined chip (w )
Shear angle angle of shearing surface measured from tool direction (f)
ME 482 - Manufacturing Systems
Cutting conditions
Note: - Primary cutting due to speed
- Lateral motion of tool is feed
- Tool penetration is depth of cut
The three together form the material removal rate (MRR):
MRR = v f d
with units of (in/min)(in/rev)(in) = in3/min/rev
(or vol/min-rev)
Types of cuts:
Roughing:
Finishing:
Cutting geometry
Chip thickness ratio = r = to / tc
Obviously, the
assumed failure
mode is shearing of
the work along the
shear plane.
Cutting geometry
Note from the triangles in (c) that the shear strain (g) can be
estimated as
g = AC/BD = (DC + AD)/BD = tan(f - a) + cot f
Thus, if know
r and a, can
determine f,
and given f
and a, can
determine g.
ME 482 - Manufacturing Systems
Cutting forces
Since R = R = R, we can get the force balance equations:
F = Fc sin a + Ft cos a
N = Fc cos a - Ft sin a
Fs = Fc cos f - Ft sin f
Fn = Fc sin f + Ft cos f
Friction angle = b
tan b = m = F/N
Fs = S As
Fc = Fs cos ( b - a)/[cos ( f + b - a)]
Ft = Fs sin ( b - a)/[cos ( f + b - a)]
* The other forces can be determined from the equations on the previous
slide.
ME 482 - Manufacturing Systems
Merchant equations
The
Merchant
reln
is a function of a
Combining the equations from
the
previous
slides:
The most likely shear angle will minimize the energy. Applying
Answer - Although the Merchant
dt/df = 0 gives:
eqn is not shown as a direct function
of a and b, these enter from
the reln
Merchant
equations for Fc and Ft from the
previous
slide!
What does the Merchant relation
indicate?
f = 45 + a/2 - b/2
Cutting models
The orthogonal model for turning approximates the complex
shearing process:
to = feed (f)
w = depth of cut (d)
Cutting power
Power is force times speed:
P = Fc v
(ft-lb/min)
hpc = Fc v/33,000
(hp)
units?
Cutting energy
Specific energy is
U = Fc v/(v tow) = Fc /(tow)
(in-lb/in3)
The table shown contains power and specific energy ratings for several work materials
at a chip thickness of 0.01 in. For other chip thicknesses, apply the figure to get a
correction factor multiply U by correction factor for thickness different than 0.01).
Machining example
In orthogonal machining the tool has rake angle 10, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear strain):
Determine r = 0.02/0.045 = 0.444
Determine shear plane angle from tan f = r cos a /[1 r sin a]
answer!
answer!
answer!
Cutting temperatures
In machining 98% of the cutting energy is converted into heat. This
energy flows into the work part, chip, and tool. Cook determined an
experimental equation for predicting the temperature rise at the
tool-chip interface during machining:
Cutters
Toroid
Cutters
Machining