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MANUFACTURING PROCESSES
(II)
Mustafizur Rahman
Dept. of Mechanical Engineering
NUS
Topics
1.
2.
3.
Tool materials
4.
5.
Economics of machining
References:
1. Fundamentals of metal machining and machine tools by Geoffrey
Boothroyd, McGraw-Hill Book Company
2. Metal cutting theory and practice by A. Bhattacharya, Central
Book Publishers, India
ME 3162 (II)
Part 1:
Introduction to Machining and Machine Tools
tool
workpiece
Cutting motions
Two directions of motions: rotation of workpiece about its axis and
feed of tool parallel to its axis
Primary motion (-C)
ap : depth of cut
kr : major cutting edge angle
ap
kr
Seconday feed motion (-Z)
Cutting motions
Rotational motion of the
workpiece at V relative to the
tool:
Ve
V nwd
where nw, rotational speed of spindle
and d is diameter of the workpiece
Vf
d
Feed engagement
Major cutting edge
angle kr
ac
Back engagement
(depth of cut)
ap
ac = f sin k r
kr
f
ac
V nwd
nw
Vav
nw d w d m
Z w AcVav
f apVav
dw = dm + 2ap
f ap nw d w d m
2
f ap nw ( d m a p )
Power required
If energy required to remove unit volume of material, is ps; then
power Pm required to perform any machining operation,
Pm= ps Zw
Electrical power consumed
If efficiency of the machine tool motor and drive systems is m, the
electrical power Pe consumed by the machine tool,
Pe = Pm / m
Vertical Milling
Vertical Milling
Feed per revolution
Vf
nt
f
N
Vf
dt
nt
ap
acma
x
Vf
Vertical Milling
Vertical Milling
dt /2
lw
d t /2
(dt /2) - ae
Vertical Milling
f
sin
N
where is given by,
af
cos
acmax
d t / 2 ae
dt / 2
2ae
1
dt
sin 1 cos2
Vertical Milling
2a
cos 1 e
dt
(dt /2) - ae
2 ae / d t (ae / d t ) 2
ac m ax
Vf
nt
f
sin
N
2V f ae
Nnt
ae
(1 )
dt
dt
For small ae / dt
af
ac m ax
acmax
2V f
Nnt
ae
dt
lw 2 ae (dt ae )
where, lw is the length of workpiece
Thus, the machining time
tm
lw 2 ae (d t ae )
Vf
(dt /2) - ae
Vertical Milling
Drilling
Drilling
Most common is a twist drill which has two
cutting edges. On each edge,
dm
f
ac sin k r
2
where kr, is the major cutting edge angle
The machining time tm is given by
kr
tm
lw
f .nt
Drilling
Metal removal rate Zw (cross-sectional area
of hole feed speed Vf)
dm
Zw
d m2 .V f
. f .d m2 .nt
4
kr
Zw
f (d m2 d w2 ).nt
4