Lecture No 1

12

Metal Removal Processes

Dr. Ramon E. Goforth

Adjunct Professor of Mechanical
Engineering
Southern Methodist University
Lecture No 2
12 Outline of Lecture
• Basic information on material removal
• Factors involved in material removal Lecture 10
• Independent variables
Lecture 11
• Dependent variables
• Machining Processes Lecture 12
• Machining Economics
• Machines
Lecture No 3
12 Basic Cutting Processes

• Rotating part - turning

– Creates round shapes
• Stationary part - milling, drilling, sawing,
etc
Lecture No 4
12 Basic Turning
• Part of cylindrical cross section clamped
in a "chuck" so that it can rotate about its
axis
• Part is rotated at fixed speed
• A cutting tool is brought to bear on the
moving surface of the part cutting of
material
• The "chuck" is a kind of vice which has
rotational symmetry
Lecture No 5
12 Turning Process Parameters
f

N
Lecture No 6
12 Turning Parameters
•Tool Geometry
– Rake angles
– Side rake angle - more important than
– Back rake angle
– Cutting edge angles
Lecture No 7
12 Turning Parameters
• Tool Geometry
• Tool Materials
• Feeds and speeds, N,d,f
– (see table 22.4 for recommendations)
• Cutting fluids
• Material Removal rates
– =  Davg d f N
• Where Davg is the average diameter, d is the depth of
cut, f is the feed rate and N the rotational speed
• Forces and power used
• Surface finish (scallops)
Lecture No 8
12 Power used
• Power used is the material removal rate,
MRR, times the specific energy
Lecture No 9
12 Feed Marks in Turning
• Scallops created
• The depth depends on the feed rate, surface
velocity and tool shape

Scallops
 Machining
Lecture No Processes for Round
10
12
Shapes
• Turning
• Facing
• Boring
– Produces circular internal profiles in hollow
workpieces
• Drilling
– Produces round holes
• Reaming
– Produces more accurate holes than drilling
• Parting
• Threading
• Knurling
 Machining
Lecture No Processes for Round
11
12
Shapes

Kalpakjian p 663
Lecture No 12
12 Turning Guidelines
• Avoid long skinny parts
• Request wide accuracy and surface finish
parameters
• Avoid sharp corners and tapers
• Avoid major dimensional changes
• Design blanks to be as close to final
dimensions as possible
Lecture No 13
12 Turning Guidelines
• Allow for travel of tools across surfaces of
workpiece
• Design features so that standard tools can be
used
• Choose machinable materials

• Minimize overhang of tool

• Support workpiece
• Use machines with high rigidity
Lecture No 14
12 Non Round Machining Processes

• The operation
– Clamp the workpiece onto a stationary bed
or one that can move in multiple directions
slowly
– Bring a rotating tool to bear on the surface
to be shaped
– Move the rotating tool over the part or
move the part past the rotating tool to
shape it
Lecture Non
No Round Machining - Slab
15
12 Milling
• Milling
– Slab/Peripheral
– Cutter rotation axis parallel to
workpiece surface
• Conventional/up
– Maximum chip thickness
at end of cut
– Low impact of tool with workpiece
• Climb/down
– Maximum chip thickness at beginning
of cut
– High low impact of tool with workpiece
 Non
Lecture No Round Machining - Face
16
12
milling
– Axis of rotation
perpendicular to
workpiece surface
– Large multi-insert cutter
 Non
Lecture No Round Machining - Face
17
12
Milling
• Difference between climb and
conventional face milling

Action of an insert in face milling

Climb Milling Conventional milling

Parameters in face milling

Lecture No 18
12 Non Round Machining
Lecture No 19
12 Generic Milling formula
• Cutting (peripheral) speed,
– V =DN
– where D is the cutter diameter and N its
rotational speed
• Feed per tooth,
– f = v/Nn
– where v is the linear speed or feed rate of
the workpiece, and n is the number of teeth
• Undeformed chip thickness, (chip depth of
cut),
– tc = 2 f (d / D)
– Where f is the feed per tooth, d is the depth
of cut
 Lecture No 20
12 Generic Milling formula
• Cutting time, t = (l + 2lc)/ v
– where v is the feed rate of the workpiece, l is the length
of the workpiece and lc is the extent of the cutter’s first
contact with the workpiece
• Material removal rate, MRR
– MRR = lwd/t = wdv
– assuming the lc<<l and where w is the width of the cut
– Power is equal to the MRR times the specific energy
Lecture No 21
12 Feed Marks from Milling
Lecture No 22
12 Design Guidelines for Milling
• Design for standard cutters
• Use chamfers instead of radii
• Avoid internal cavities and pockets with sharp
corners
• Design workpieces with sufficient rigidity
Lecture No 23
12
Other Non Round Machining
Processes
• Drilling
• Straddle milling
• Planing
• Broaching
• Sawing
– Generally used for cutting off pieces to be
worked on by other processes
• Filing and finishing
• Gear machining
Lecture No 24
12 Drilling Practices
• Type of drill bit, drill point geometry
• Type of machine
– Drill, press, radial drills, gang drills, NC
controlled
– Capabilities of drilling and boring operations (p
633)
– HP used = Spec. Energy times MRR (D2fN/4)
Lecture No 25
12 Drilling Operations and Drill bits
Lecture No 26
12 Drilling Guidelines
• Design holes perpendicular to the surface
• Do not design interrupted/overlapping
holes
• Design bottoms to match standard drill-
point angles
• Through holes are preferred over blind
holes
• If need large diameter holes design in
smaller hole for casting
• Design to minimize fixturing
• Avoid reaming blind or intersecting holes
Lecture No 27
12 Machining Economics

• Cost per piece decreases with cutting

speed
• Tool cost increases with cutting speed
• Tool change time increases with cutting
speed
• Total cost goes through a minimum
• Time spent removing material usually
small fraction (<5%) of total time on
machine
Kalpakjian p 775/698
Lecture No 28
12 Machining Economics
Lecture No 29
12

Metal Removal Machines

Lecture No 30
12 Basic Lathe
Lecture No 31
12 Turning Machine Components
• Bed
– Supports all other major components
– Top part has two ways
• Carriage
– Slides along the ways
– Consists of the cross-slide, tool post and
apron
Lecture No 32
12 Turning Machine Components
• Headstock
– Fixed
– Contains the motors, pulley and belts to drive
the spindle
– Spindle has fixtures for attaching the
workpiece
• Tailstock
– Can slide along the ways
– Supports the other end of the workpiece
• Feed rod and lead screw
– Provides motion to the carriage and cross
slide
Lecture No 33
12 A Manual Lathe
Lecture No 34
12 Turning Machines

• Lathes
– Tracer
– Automatic
– Automatic bar machines
– Turret
– Vertical
• For very large diameters
– Boring
• Vertical
• Horizontal (like a milling machine)
– Computer controlled
Lecture No 35
12 Turret Lathe
 MORI
Lecture No SEIKI SL-3 SLANT BED36CNC
12
LATHE
Lecture No 37
12 Vertical Boring Mill
Lecture No 38
12 Milling Machines
• Column and Knee type
– Horizontal spindle
– Vertical spindle
• Bed type
– Skin mills
• Other types
– Planer type
– Rotary tables
– Duplicating machines
– Profiling milling
– More than three axes
 #4NoVERTICAL
Lecture MILLING MACHINE
39
12
W/SLIDING HEAD
Lecture No 40
12 Machining and Turning Centers
• Combines turning with milling
• Computer control essential
• Multiaxis capabilities
• Replacing simple lathes or milling machines
Lecture No 41
12 NC Turning Center
Lecture No 42
12 Giddings& Lewis dv15-l smart turn twin-
spindle vertical production center
Lecture No 43
12 Drilling Machines
• Drill presses
• Radial machines
• CNC Three axis drilling machine
Lecture No 44
12 Trends
• High speed machining
• Dry machining
• Combining milling, drilling and turning
operations
• New, stiffer and highly damped machine tools
– Graphite epoxy, ceramics (high modulus)
• Modular machines
• Multiple loading stations
• More sensors
• More and more automation
– Automated program generation
Lecture No 45
12 Summary
• There are many different types of
machining operations
• That is what makes it so versatile and
attractive to industry
• The basic cutting process is the same in
all
• Must consider the cutting operation as a
system
• Actual cutting time is a small fraction of
the total time to create a part by
machining