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Removal
Chapter 1
Machining
Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
Assignment No. 1
Perform a literature survey (at least 10 journal
papers published beyond year 2000) to describe
High-Speed Machining, its technical differences
and benefits over Conventional Machining
Processes
Assignments should be hand-written only. Mutually
copied assignments will be cancelled.
Submission deadline: 15-SEP-2014
Machining Operations
Most important machining operations:
Turning
Drilling
Milling
Other machining operations:
Shaping and planing
Broaching
Sawing
Turning
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
http://www.dailymotion.com/video/xl5pua_cnc-machining-5-axis_school
Drilling
Used to create a round hole, usually by means of
a rotating tool (drill bit) with two cutting edges
http://www.wimp.com/squareholes/
Milling
Rotating multiple-cutting-edge tool is moved across
work to cut a plane or straight surface
Two forms: peripheral milling and face milling
http://www.wimp.com/machiningcnc/
Cutting Tools
(a) A singlepoint tool showing rake face, flank, and tool point; and (b)
a helical milling cutter, representative of tools with multiple cutting
edges.
Machine Tools
A powerdriven machine that performs a
machining operation, including grinding
Functions in machining:
Holds workpart
Positions tool relative to work
Provides power at speed, feed, and depth
that have been set
The term is also applied to machines that
perform metal forming operations
Chip Formation
Chip Formation
The mean chip thickness can be obtained by
measuring the length, l, weight, W, of a piece of
chip. The mean thickness, t2, is then
Chip Formation
Shear plane angle () is
the angle formed between
the direction of movement
of the workpiece and the
shear plane represented by
the line OD, from the tool
edge to the position where
chip leaves the work
surface.
The chip is assumed to
form by shear along the
shear plane
Chip Formation
Discontinuous chip
Continuous chip
Continuous chip with Built-up Edge (BUE)
Serrated chip
Discontinuous Chip
Brittle work materials
Low cutting speeds
Large feed and depth
of cut
High toolchip friction
Continuous Chip
Ductile work materials
High cutting speeds
Small feeds and
depths
Sharp cutting edge
Low toolchip friction
http://www.wimp.com/cuttingsteel/
Serrated Chip
Semicontinuous saw-tooth
appearance
Cyclical chip forms
with alternating high
shear strain then low
shear strain
Associated with
difficult-to-machine
metals at high cutting
speeds
F
v
c
H
P
c
3,0
P
H
P
c
c
H
P
gE
gE
P
F
v
c
c
U
=uR
=
tow
M
R
Cutting Temperature
Approximately 98% of the energy in machining
is converted into heat
This can cause temperatures to be very high at
the toolchip interface
The remaining energy (about 2%) is retained
as elastic energy in the chip
.C
0
3
t
v
.T
0
4
U
K
Cutting Temperature
Cutting Temperature
Experimental methods can be used to measure
temperatures in machining
Most frequently used technique is the
toolchip thermocouple
Using this method, Ken Trigger determined the
speedtemperature relationship to be of the
form:
T = K vm
where T = measured toolchip interface
temperature, and v = cutting speed
Problem No. 1
In an orthogonal cutting operation, the tool has a rake angle
= -5. The chip thickness before the cut = 0.012 in and the
cut yields a deformed chip thickness = 0.028 in. Calculate
(a) the shear plane angle and (b) the shear strain for the
operation
Solution:
(a)r = t1/t2 = 0.012/0.028 = 0.4286
Problem No. 1
Problem No. 2
The cutting conditions in a turning operation are: v = 2
m/s, f = 0.25 mm, and d = 3.0 mm. The tool rake angle =
10 which produces a deformed chip thickness t 2 = 0.54
mm. Determine: (a) shear plane angle, (b) shear strain,
and (c) material removal rate. Use the orthogonal cutting
model as an approximation of the turning process.
Solution:
(a)r = t1/t2 = 0.25/0.54 = 0.463
Problem No. 2
(b)
= cot 26.4 + tan (26.4 - 10) = 2.017 + 0.294 =
2.311
(c) MRR = (2 m/s x 103 mm/m)(0.25mm)(3.0mm)
= 1500 mm3/s
Problem No. 3
In a turning operation on plain carbon steel whose Brinell
hardness = 275 HB, the cutting speed is set at 200 m/min
and depth of cut = 6.0 mm. The lathe motor is rated at 25
kW, and its mechanical efficiency = 90%. Using the specific
energy value as 2.8 N-m/mm 3, determine the maximum feed
that can be set for this operation. Use correction factor of 0.9
Solution:
U = 2.8 N-m/mm 3 = 2.8 J/mm3
MRR = vfd = (200 m/min)(103 mm/m)(6 mm)f = 20(103)f mm3/s
Available power Pc = Pg E = 25(103)(0.90) = 22.5 (103) =
22,500W
Problem No. 3
Required power Pc = (2.8 N-m/mm3)( 20 x 103) f =
56,000 f
Setting: available power = required power, 22,500 =
56,000f
f = 22,500/56,000 = 0.402 mm (this should be
interpreted as mm/rev for a turning operation)
For this feed, correction factor = 0.9;
thus U = 2.8(0.90) = 2.52 N-m/mm 3 and an iterative
calculation procedure is required to match the unit
power value with the feed, taking the correction factor
into account.
Required Pc = (2.52)(20 x 103) f = 50,400 f
Problem No. 3
Again setting available power = required power,
22,500 = 50,400 f
f = 22,500/50,400 = 0.446 mm/rev
One more iteration using the correction factor
yields a value around f = 0.45 mm/rev
Problem No. 4
During a turning operation, a tool-chip thermocouple
was used to measure cutting temperature. The following
temperature data were collected during the cuts at three
different cutting speeds (feed and depth were held
constant): (1) v = 100 m/min, T = 505C, (2) v = 130
m/min, T = 552C, (3) v = 160 m/min, T = 592C.
Determine an equation for temperature as a function of
cutting speed that is in the form of the Trigger equation
Solution:
Trigger equation T = KVm
Choose points (1) and (3) and solve simultaneous
equations using T = KVm as the model.
Problem No. 4
(1) 505 = K(100)m and (3) 592 = K(160)m
(1)ln(505) = ln K + m ln(100) and
(2)(3) ln(592) = ln K + m ln(160)
Combining (1) and (3): ln(505) - m ln(100) = ln(592) - m
ln(160)
6.2246 4.6052 m = 6.3835 5.0752 m
0.47 m = 0.1589;
m = 0.338
K = 592/1600.338 = 592/5.561 = 106.45
Check equation with data point (2): T = 106.45(130) 0.338 =
551.87C (pretty close to the given value of 552C)