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Shaping, Planing and Slotting Process

Shaping
What is shaper & shaping ?
Principle of working ?
Shaper Mechanism ?
Applications ?
Operations Performed ?
 Planing
 What is Planer & Planing ?
 Principle of working ?
 Applications ?
 Operations performed ?
 Slotting
 What is Slotter & Slotting ?
 Principle of working ?
 Applications ?
Tool Wear Concept
 How can we describe tool wear?
 How can we define Tool wear?
 Tool wear dependent parameters?
 Tool wear affecting items?
 Types of tool wear?
 Characteristics of tool wear?
 Reason for tool wear?
 Effects of tool wear?
 Causes of tool wear or mechanism?
Causes of Tool wear mechanism
 Abrasive wear or Hard Particle wear – due to impurities,
low cutting speeds.
Adhesive wear – due to high pressure & temperature
leading to weld points.
 Diffusion wear – due to atomic transfer b/w
materials in contact
Ways of diffusion – Gross softening of tool, Major tool
constituents into work, Work material component into
tool, Chemical wear.
 Chemical wear – due to chemical exposure
 Fracture wear – due to breaking of edge at
end or length
Growth of Tool wear
Initial or Rapid wear
 Causes?
Steady wear
Severe wear
Other forms of Tool wear:
 Thermo-electric wear

 Thermal cracking & tool fracture


 Cyclic thermal & mechanical load wear

 Edge chipping tool wear


Entry or Exit Failure Tool wear
Effects of tool wear
 Increase in Cutting forces
 Increase in surface roughness
 Increase in chatter or vibration
 Decrease in dimensional accuracy
 Tool life
Different method of expressing the tool life
 The volume of metal removal grind
 Number of work machined per Grind
 Unit of time
 The factors affecting tool life:
Cutting speed
Tool geometry
Work material and cutting fluid
Tool material
Feed and depth of cutting
Rigidity of work, machine and tool
Cutting speed

Surface finish obtained


Cutting fluid used
Tool geometry
Rate of feed and depth of cut
Workpiece material
Machining method
Mechanical Working of Metals
Introduction of Mechanical working process

Metal forming
NON-CUTTING SHAPING &
REMOVAL OF IMPURITIES CUTTING SHAPING
PLASTIC DEFORMATION
PLASTICITY, DUCTILITY, PHENOMENA
MALLEABILITY
Recyrstallization
Hot working

Effect of hot working of Mechanical properties of


metals

Merits & Demerits of Hot working


Merits of Hot Working
 No strain hardening.
 Higher the temperature, higher the ductility.
 Refinement of grain structure leads to improvised
properties.
 Low porosity.
 Properties are least affected.
 Metal deforms at low force.
 Rate of working & temp properly controlled.
 No residual stresses.
 Dissolving of Concentrated impurities.
 Uniformity of material.
DeMerits of Hot Working
 Poor surface finish.
 Loss of surface strength.
 Fatigue failure of component due to low surface strenth.
 Brittle at high temperatures.
 Dimensional accuracy.
 High cost of tooling.
 Handling and maintenance.
Classification of Hot Working Process
 Hot rolling
 Hot Drawing

 Hot Spinning
 Hot piercing or seamless tubing

 Hot Extrusion
Cold working

Effect of Cold working of Mechanical properties of


metals

Merits & Demerits of Cold working

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