Chapter 24
Chapter 24
Chapter 24
➢ Machinability
➢ Tolerances and Surface Finish
➢ Selection of Cutting Conditions
➢ Product Design Considerations in
Machining
Machinability
Relative ease with which a material (usually
a metal) can be machined using
appropriate tooling and cutting conditions
➢ Depends not only on work material
➢ Type of machining operation, tooling, and
cutting conditions are also important
factors
Machinability Criteria in Production
➢ Tool life – how long the tool lasts for the
given work material
➢ Forces and power – greater forces and
power mean lower machinability
➢ Surface finish – better finish means better
machinability
➢ Ease of chip disposal – easier chip
disposal means better machinability
Machinability Testing
➢ Mosttests involve comparison of work
materials
⚫ Performance of a test material is measured
relative to a base material
⚫ Relative performance is expressed as a
machinability rating (MR)
⚫ MR of base material = 1.00 (100%)
⚫ MR of test material > 1.00 (100%) means
better machinability
Machinability Tests
➢ Tool life (most common test)
➢ Tool wear
➢ Cutting force
➢ Power required in the operation
➢ Cutting temperature
➢ Material removal rate under standard test
conditions
Mechanical Properties that
Affect Machinability
➢ Hardness
⚫ High hardness means abrasive wear
increases so tool life is reduced
➢ Strength
⚫ High strength means cutting forces, specific
energy, and cutting temperature increase
➢ Ductility
⚫ High ductility means tearing of metal as chip is
formed, causing chip disposal problems and
poor surface finish
Tolerances and Surface Finish
in Machining
➢ Tolerances
⚫ Machining provides high accuracy relative to
most other shape-making processes
⚫ Closer tolerances usually mean higher costs
➢ Surfaceroughness in machining is
determined by:
⚫ Geometric factors of the operation
⚫ Work material factors
⚫ Vibration and machine tool factors
Geometric Factors
➢ Machiningparameters that determine
surface geometry:
⚫ Type of machining operation, e.g., milling vs.
turning
⚫ Cutting tool geometry, especially nose radius
⚫ Feed
➢ Thesurface geometry that would result
from only these factors = "ideal" or
"theoretical" surface roughness
Effect of
Nose
Radius
Effect of
Feed
Effect of End
Cutting Edge
Angle
Ideal Surface Roughness
2
Ri = f
32NR
Tc = Th + Tm + Tt/np
IE316 Manufacturing
Engineering I - Processes
➢ Design machined parts with features
that can be produced in a minimum
number of setups
➢ Example: Design part with geometric
features that can be accessed from one
side of the part