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Metal Cutting

Metal Cutting. Manufacturing Processes. Outline. Metal Cutting Chip Formation Processes Control Conditions Back rake angle Shear angle Chip Formation Continuous formation Built up edge formation Discontinuous formation Effects Chip formation Shear angle. Chip Formation Processes.

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Metal Cutting

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  1. Metal Cutting Manufacturing Processes

  2. Outline Metal Cutting • Chip Formation Processes • Control • Conditions • Back rake angle • Shear angle • Chip Formation • Continuous formation • Built up edge formation • Discontinuous formation • Effects • Chip formation • Shear angle

  3. Chip Formation Processes • Shaping • Turning • Milling • Drilling • Sawing • Broaching • Grinding

  4. Machining Operations

  5. Machining Operations

  6. Machining Operations - Sawing

  7. Machining Operations - Grinding

  8. Basic Cutting – Face Cutting

  9. Basic Cutting – Pocket Cutting

  10. Basic Cutting – Turning Diameters

  11. Basic Cutting – Thread Cutting

  12. Basic Cutting – Surface Grinding

  13. Chip Formation Processes • Control • Feed • Speed • Depth of Cut • Conditions • Machining Process • Machine Limitations • Material • Tool Type • Tool material • Surface Finish • Tolerances

  14. Chip Formation Processes • Back rake angle, α The angle that the tool makes with respect to a vertical from the workpiece • The chip is formed by shearing along the shear plane The shear plane or shear angle Φ is measured with respect to the horizontal Flank of the tool is the bottom of the tool not in contact with the material (clearance angle δ)

  15. Cutting Definitions

  16. Chip Formation

  17. ContinuousChip Formation

  18. Built Up Edge(BUE) Formation

  19. DiscontinuousChip Formation

  20. Chip Formation Three Characteristic types of chips • Discontinuous • Continuous • Continuous with built-up edge

  21. Three Types of Chips

  22. Resulting Finishes of Chip Formation

  23. Effect of Shear Angle

  24. Summary Chip formation processes are designed to shear off layers of metal Control and conditions determine the type of chip formation The type of formation affects the resulting finish of the workpiece

  25. The End ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████ ███████████████████████████████████████

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