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Common Machining Operations

Common Machining Operations. Kalpakjian. Parts of an “Engine” Lathe. Kalpakjian. Typical “Engine” Lathe. Watchmaker’s lathe. www.ticktockpro.com. www.blazingtech.net. Turret Lathe. Big “Engine” Lathe. www.liberatorcrew.com. www.bakerprovan.com.au. Really Big “Engine” Lathes.

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Common Machining Operations

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  1. Common Machining Operations Kalpakjian

  2. Parts of an “Engine” Lathe Kalpakjian

  3. Typical “Engine” Lathe Watchmaker’s lathe www.ticktockpro.com www.blazingtech.net Turret Lathe Big “Engine” Lathe www.liberatorcrew.com www.bakerprovan.com.au

  4. Really Big “Engine” Lathes www.practicalmachinist.com 60 feet c-c www.harrismachinetools.com

  5. CNC Lathe: aka “Turning Center” (carriage is mounted toward back, “upside down”) www.machineryvalues.com

  6. Machining Parameters DeGarmo

  7. Machining: Turning • Depth of Cut = DOC = (Dbefore – Dafter) / 2 • Cutting Speed = Speed of metal moving towards cutting tip • Usually called “Surface Feet per Minute”, SFPM, SFM • Each cutting tool & workpiece material combo has a max SFM for decent tool wear. • HSS & alum: 800 SFM • HSS & 1020 steel: 110 SFM • HSS & 1090 steel: 80 SFM • HSS & hard 4140: 30 SFM • TC & 1020 steel: 1000 SFM • SFM = r*w • = D * RPM * (π/12) • ≈ D * RPM / 4 • RPMmax = 4 * SFM / D • (most useful machining formula) • E.g., find RPM for turning • 2” dia. 1020 steel: • RPM ≈ 4*110/2 = 220 • RPM may need to be less due to chatter! • Most relations are similar • for milling, but D=cutter dia. Kalpakjian

  8. Cutting Forces DeGarmo

  9. Orthoganal Model (2-force) DeGarmo

  10. Orthoganal Model (2-force) DeGarmo

  11. Chip formation: chip types DeGarmo Kalpakjian

  12. Merchant’s Model (Simplified 2-force) DeGarmo

  13. Chatter Vibrational resonance of entire machining system, especially workpiece-cutter. Causes poor surface finish, fast tool wear, noise Factors: stiffnesses of workpiece, cutter, machine cutting params: speed, feed, DOC cutter geometry: rake, clearances Solutions: Change the cutting params esp. speed Increase stiffnesses Kalpakjian

  14. Heat rise in Cutting Kalpakjian

  15. Temperature of Cutting Tip Kalpakjian/Vieregge

  16. Temperature of Cutting Tip Kalpakjian / Chao & Trigger

  17. Max Temperatures of Cutting Materials Kalpakjian

  18. Machining Time of Cutting Materials Kalpakjian/Sandvik

  19. Coated Carbide Cutting Inserts: The norm for production machining Layers are 2-10 microns thick: TiN: titanium nitride (low friction, gold appearance) TiCN: titanium carbonitride (wear resistance) Al2O3: Alumina (chemical stability, wear resistance) Tungsten Carbide substrate (~shock and wear resistance) www.greenleafcorporation.com www.moldmakingtechnology.com Kalpakjian/Kennametal

  20. Cutter Shape and Geometry Kalpakjian

  21. Machining Costs Kalpakjian

  22. References DeGarmo: E.P. DeGarmo et al, Materials and Processes in Manufacturing, Wiley, 2003. Kalpakjian: http://www.nd.edu/~manufact/index3.htm

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