Cutting (2)

2017.4.10

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Producing round shapes

Process Characteristics Commercial tolerances

(mm)
Turning Turning and f acing operations on all types of Fine: 0.05-0.13
materials; requires skilled labor; low production rate, Rough : 0.13
but medium to high with turret lathes and au tomatic Skiving: 0.025-0.05
machines, requiring less-skilled labor.
Boring Interna l surfaces or profiles, with characteristics 0.025
similar to turning; stiffness of boring bar important to
avoid chatter.
Drilling Round ho les of various sizes and dep ths; requires 0.075
boring and reaming for improved accuracy; high
production rate; labor skill required depends on ho le
location and accura cy specified.
Milling Variety of shapes involving contours, flat surfaces, 0.13-0.25
and slots; wide variety of tooling; versatile; low to
medium produc tion rate; requires skill ed labor.
Planing Flat surfaces and straight contour profiles on large 0.08-0.13
surfaces; suitable for low-quantity production; labor
skill required depends on part shape.
Shap ing Flat surfaces and straight contour profiles on relatively 0.05-0.13
small workpieces; suitable for low-quantity production;
labor skill required dep ends on part shape .
Broaching External and internal flat surfaces, slots and contours 0.025-0.15
with good surface finish; costly tooling; high
production rate; labor skill required depends on pa rt
shape.
Sawing Straight and contour cuts on flats or structural shap es; 0.8
not suitable for har d materials unless saw has carbide
teeth or is coated with diamond; low produc tion rate;
requires only low labor skill.

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(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

(j)

(k)

(l)

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CNC lathe

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Turning variables

Material removal rate (MRR)

MRR Davg dfN

Volume of material removed per unit time

Cutting force

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6in , 0.5in 304 stainless still 0.48in

. : N = 400rpm; = 8in/min
. , MRR, , , .

0.5 in :

V D0 N
0.5 400 628in/min
D=0.48 .
MRR,

d (0.50 0.48) / 2 0.01

feedrate f N
f feedrate / N 8 / 400 0.02in/rev
MRR 0.49 0.01 0.02 400 0.123in 3 /min
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 t

l 6
t 0.75 min
f N 0.02 400

, statinless still specific energy Table 8.3

, 1.47hp-min/in3

Power 1.47 0.123 0.181hp 71700in - lb/min

, Power = (torque) x () ,

71700in - lb/min
T 29lb in
400rpm 2rad
T 29 2
Fc 118lb
r 0.49
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(3) (4) (5)

(4) (5) (6) (6) (7)

(2) (3)
(7)
(2)
(1)

(1)

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Horizontal milling and vertical milling

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Typical machined parts using milling

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Endmilll

~ rpm

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Up miling and down milling

Up milling





Backlash

Down milling

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Milling equations

Cutting speed: V = D N

f (feed per tooth) = v / (N x n)

v: , N: , n:

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3

A B
5

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Machining center

Computer control: CNC (computer numerical control)
Programmable automatic tool changer (ATC)
Optional: Automatic pallet changer (PC), Tool, part checking equipment

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5

https://www.youtube.com/watch?v=CqePrbeAQoM
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Reconfigurable Machines

FIGURE 8.68 Schematic illustration of a reconfigurable modular machining

center, capable of accommodating workpieces of different shapes and sizes,
and requiring different machining operations on their various surfaces.
Source: After Y. Koren.

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Reconfigurable Machining Center

FIGURE 8.69 Schematic illustration of assembly of different

components of a reconfigurable machining center. Source: After Y.
Koren.

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Hexapod

FIGURE 8.71 (a) A hexapod machine tool, showing its major

components. (b) Closeup view of the cutting tool and its head in a
hexapod machining center. Source: National Institute of Standards
and Technology.
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