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Notes On “Machining (1) Course 130/64” (Part 1) Prepared By: Dr. Samy Oraby

Notes On “Machining (1) Course 130/64” (Part 1) Prepared By: Dr. Samy Oraby  (Associate Professor)   November 2008. Course Description & Goals. INTRODUCTION. Course Description:

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Notes On “Machining (1) Course 130/64” (Part 1) Prepared By: Dr. Samy Oraby

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  1. Notes On “Machining (1) Course 130/64” (Part 1) Prepared By: Dr. Samy Oraby  (Associate Professor)   November 2008

  2. Course Description & Goals INTRODUCTION Course Description: • This is one of three consecutive courses for machining being the backbone of manufacturing technology. This course provides students with basic theoretical and practical knowledge regarding the use of workshop hand tools and some conventional machining systems. Technical background is given regarding the general safety procedures in the workshop, the skills in manipulating hand tools and work layout. Also, the principle features and use of turning lathe and drilling of main importance. Deartment of Mechanical Production Technology - Machining (1) Course 130/64

  3. Course Goals Upon successful completion of this course the student will be able to: • Distinguish between hand and automatic machining tools and machines. • Demonstrate use of hand tools to assemble and dissemble mechanical components. • Produce simple components reflecting basic operations using some conventional machine tools. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  4. Course Outline • College :Technological Studies • Department :Manufacturing Engineering Technology • Program :Manufacturing Engineering Technology • Course Title :Machining Processes (1) • Course Code :64/130 • Class Size: 20 Workshop: 10 Lab: 10 • Semester: Second Credits: 3 • Hours/Week:5 (2+2+1) Total Hrs: 70 Total Weeks: 14 • Language :English • Pre-requisite(s) :Workshop Technology (64/105) • Co-requisite(s) :None Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  5. Course Contents Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  6. Course Contents continue…… Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  7. Evaluation Strategy Exams 15% Lab 10% Workshop 25% Final 50% Total 100% Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  8. References 1. Machining Fundamentals, From Basic to Advanced Techniques, By John R. WalkerPublisher Goodheart-WillcoxCo; Received edition (January 2000) ISBN: 1566376629 2. Technology of Machine Tools, By S. F. Krar and A. F. Check Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  9. Practical Exercise No. 1 Turning & Related Processes Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  10. Practical Exercise No. 2: Drilling, Boring, Reaming & Tabbing Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  11. SAMPLE PROCESS SHEET Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  12. Introduction to Machining Technology Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  13. Manufacturing System Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  14. Manufacturing Processes Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  15. TURNING MILLING Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  16. Manufacturing by Machining Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  17. Safety Procedures 1. Machine Shop Safety • Safety Glasses • Clothes and Hair • Safe Conduct in the Shop • Safety in Machining Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  18. Safety Glasses • Even when you're not working on a machine, you must wear safety glasses. A chip from a machine someone else is working on could fly into your eye. • EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  19. Clothes and Hair • IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP. • NO LOOSE CLOTHING. • NO GLOVES • REMOVE JEWELERY • WEAR APPROPRIATE SHOES Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  20. Safe Conduct in the Shop • Be aware of what's going on around you. • Concentrate on what you're doing. • Don't hurry. • Don't rush speeds and feeds. • Listen to the machine. • Don't let someone else talk you into doing something dangerous. • Don't attempt to measure a part that's moving. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  21. Safety in Machining • Study the machine. Know which parts move, which are stationary, and which are sharp. • Remove chuck keys and wrenches. • DO NOT LEAVE MACHINES RUNNING UNATTENDED! • CLEAN UP MACHINES AFTER YOU USE THEM! Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  22. Layout tools and Procedures Laying out is the planning of the work on the surface of the material that is to be made into the finished part. It is the scribing of lines which indicates cuts to be made, the centerlines of holes to be drilled, and other details that  guide the worker in completing the job. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  23. Figure 1. Part to be laid out. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  24. 1. Locate and scribe base lines. 2. Locate all circle and arc centerlines. 3. Scribe in all circles and arcs. 4. Locate and scribe in angular lines. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  25. 5. Complete all other object lines. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  26. Hand Tools and Bench Work Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  27. Classificationof CuttingTools Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  28. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  29. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  30. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  31. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  32. Sawing and Cut off Machines Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  33. Metal Sawing - The first step in machining most metal working jobs is to cut the stock to the desired length. Many parts for machines of all kinds are cut from round, square, flat or hexagonal bar stock or tubing. Other parts may be made from structural shapes (such as I beams, channels and angles) cut off to the desired length. This cutting off operation should be done in the shortest possible time consistent with the desired quality. . The cutting action in the power sawing process is accomplished by the action of a continuous series of single point cutting tools as they pass over the work piece. Tool life on the various cutters, or blade (straight, circular or band) is extended because of the sharing of the wear on the individual teeth Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  34. The cutting action in the power sawing process is accomplished by the action of a continuous series of single point cutting tools as they pass over the work piece. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  35. Metal Sawing Machines - power driven sawing machines are used for cutting off stock to the desired length. Such machines are classified according to the kind of motion used in the cutting action. These general types as explained below are in common use in industrial shops. • (a) Reciprocating saw -Manual hacksaw, -Power hacksaw. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  36. (b) Band saw  -Vertical cut off, -Horizontal cut off,-Combination cut off and contour, -Friction blade,-Band filing. • (c) Circular saw -Cold saw,-Steel friction disk,-Abrasive disk. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  37. Reciprocating Saw Machines --The reciprocating power saw is the original and least expensive saw for the cutting off operation. It is perhaps the most common power saw found in most production, tool room and maintenance departments. It is considered to be the simplest of all power sawing machines. A-CoolantB-Saw BladeC-ViceD-Round Stock Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  38. - The speed of power saws may be from 30 strokes per minute - The speed of power saws may be from 30 strokes per minute for large cuts with heavy saws on difficult materials, up to 165 strokes per minute on carbon steels and non-ferrous materials. The hacksaw usually has 4 to 6 different speeds available. -Sawing capacity is expressed as the maximum diameter of metal bar capable of being cut. This is also known as the size of the power hacksaw. Typical sizes are 150x 150 mm to 600 x 600 mm. The motors used will vary from l. H.P. to 10 H.P. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  39. Circular Saw Machines --Circular sawing machines or cold sawing machines are used exclusively for cut off operations. Such machines differ from a power saw or a band saw in respect of the blade or cutter: Circular' sawing machines employ a toothed circular disk cutter which resembles a slitting saw (cutter) used on milling machine or ­the cutting blade used on a woodworking table saw. A-SawB-WorkpieceC-FeedD-Rotation Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  40. Abrasive Disk Cutting-Cutting by means of rotating abrasive disk is really not a sawing operation, but it frequently is classified as such and done on the same equipment, A-OperatingB-Abrasive cutting wheelC-Vise Abrasive Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  41. Saw Blades Types --Saw blades are the cutters used on different sawing machines for cut-off and other operations. Saw blades are made in three basic configuration or types. 1-The first is straight, relatively rigid, and of limited length with teeth on one edge. These are commonly known as Hacksaw' blades. 2-The second type of saw blades is sufficiently flexible so that a long length can be formed into a continuous band with teeth on one edge; these are known as Band saw blades. 3-The third type is a rigid disc, having teeth on the periphery; these are circular saws. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  42. Various Band Saw Blade Tooth Forms- • (i)Regular(ii)Hook(iii) Skip(iv) Carbide insert. • -Regular or standard tooth form is used for all blades of 4 mm pitch. Such blades are most commonly used for all general purpose metal saving. The face of the tooth is straight to rake out chips. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  43. -The hook form is used for blades of 4 mm pitch and coarser. Blades with hook form are ideal for cutting large sections of steel, non-ferrous metals, wood, and plastics. Teeth are designed with a positive rake which gives a cutting action of digging out full chips instead of scraping. The rounded gullets permit chips to clear with ease. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  44. -Skip tooth blades use the same rake and clearance angles as regular tooth blades, but the teeth are shorter and spaced farther apart. Thus, skip tooth design prevents clogging when cutting soft, sticky materials such as aluminium and magnesium. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  45. Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

  46. End of Part (One) BREAK Dept. Mech. Prod. Tech. - Machining (1) Course 130/64 (New Program)

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