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    Metal Machining: ME 482 - Manufacturing Systems

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    musthakmech
    This document discusses machining processes and terminology. It introduces various machining types like turning, drilling, and milling. It describes machining tools, materials, surface finish, and key terminology. The document develops cutting models and equations, and analyzes an example calculation for shear strain, stress, and horsepower in orthogonal machining.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Metal Machining: ME 482 - Manufacturing Systems

    Uploaded by

    musthakmech
    115 views24 pages
    This document discusses machining processes and terminology. It introduces various machining types like turning, drilling, and milling. It describes machining tools, materials, surface finish, and key terminology. The document develops cutting models and equations, and analyzes an example calculation for shear strain, stress, and horsepower in orthogonal machining.

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    Ch5-MetalMachining

    Original Title

    Ch5-MetalMachining

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    This document discusses machining processes and terminology. It introduces various machining types like turning, drilling, and milling. It describes machining tools, materials, surface finish, and key terminology. The document develops cutting models and equations, and analyzes an example calculation for shear strain, stress, and horsepower in orthogonal machining.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    115 views24 pages

    Metal Machining: ME 482 - Manufacturing Systems

    Uploaded by

    musthakmech
    This document discusses machining processes and terminology. It introduces various machining types like turning, drilling, and milling. It describes machining tools, materials, surface finish, and key terminology. The document develops cutting models and equations, and analyzes an example calculation for shear strain, stress, and horsepower in orthogonal machining.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    Metal

    Machining

    ME 482 - Manufacturing Systems


    Objectives

    • Introduce cutting terminology and principles


    • Review modern machining technologies and new methods
    (papers)
    • Introduce cutting parameters
    • Develop cutting models
    • Analyze a cutting example

    ME 482 - Manufacturing Systems


    Machining types
    • Turning

    • Drilling

    • Milling

    • Shaping

    • Planing

    • Broaching

    ME 482 - Manufacturing Systems


    Machining tools

    • Single point

    • Multiple point

    ME 482 - Manufacturing Systems


    Machining tool materials

    Most modern cutting tool materials are a matrix of


    materials designed to be very hard. These materials will be
    covered in the next chapter.

    ME 482 - Manufacturing Systems


    Machining surface finish

    ME 482 - Manufacturing Systems


    Machining terminology
    Speed – surface cutting speed (v)
    Feed – advance of tool through the part (f)
    Depth of cut – depth of tool into part (d)

    Rake face – tool’s leading edge


    Rake angle – slant angle of tool’s
    leading edge (a)

    Flank – following edge of cutting tool


    Relief angle – angle of tool’s following edge above part surface
    ME 482 - Manufacturing Systems
    Machining terminology (cont.)

    ls

    Chip thickness – thickness of machined chip (tc ) Orthogonal model

    Depth of cut = to
    Shear plane length – measured along shear plane chip (ls )
    Chip width (not shown) – width of machined chip (w )
    Shear angle – angle of shearing surface measured from tool direction (f)
    ME 482 - Manufacturing Systems
    Cutting conditions
    Note: - Primary cutting due to speed
    - Lateral motion of tool is feed
    - Tool penetration is depth of cut
    The three together form the material removal rate (MRR):
    MRR = v f d
    with units of (in/min)(in/rev)(in) = in3/min/rev (or vol/min-rev)

    Types of cuts:
    Roughing: feeds of 0.015 – 0.05 in/rev depths of 0.1 – 0.75 in

    Finishing: feeds of 0.005 – 0.015 in/rev depths of 0.03 – 0.075 in

    ME 482 - Manufacturing Systems


    Cutting geometry
    Chip thickness ratio = r = to / tc Obviously, the
    assumed failure
    mode is shearing of
    From the shear plane geometry: the work along the
    shear plane.
    r = ls sinf/[ls cos(f - a)]

    which can be arranged to get


    tan f = r cos a /[1 – r sin a]

    ME 482 - Manufacturing Systems


    Cutting geometry
    Note from the triangles in (c) that the shear strain (g) can be
    estimated as

    g = AC/BD = (DC + AD)/BD = tan(f - a) + cot f

    Thus, if know
    r and a, can
    determine f,
    and given f
    and a, can
    determine g.

    ME 482 - Manufacturing Systems


    Cutting forces
    Since R = R’ = R’’, we can get the force balance equations:
    F = Fc sin a + Ft cos a F = friction force; N = normal to chip force
    N = Fc cos a - Ft sin a Fc = cutting force; Ft = thrust force
    Fs = Fc cos f - Ft sin f Fs = shear force; Fn = normal to shear plane force
    Fn = Fc sin f + Ft cos f Forces are presented as function of
    Fc and Ft because these can be
    measured.
    Friction angle = b
    tan b = m = F/N

    Shear plane stress:


    t = Fs/As

    where
    As = to w/sin f
    ME 482 - Manufacturing Systems
    Cutting forces given shear strength
    Letting S = shear strength, we can derive the following
    equations for the cutting and thrust forces*:

    Fs = S As
    Fc = Fs cos ( b - a)/[cos ( f + b - a)]
    Ft = Fs sin ( b - a)/[cos ( f + b - a)]

    * The other forces can be determined from the equations on the previous
    slide.

    ME 482 - Manufacturing Systems


    Merchant equations
    Combining the equations from the
    The previous
    Merchant is a function of a
    slides:
    reln
    and b. Where did these variables
    t = (Fc cos f - Ft sin f)/(t ow/sin
    come f)
    from? Merchant eqn

    The most likely shear angle will minimize the energy. Applying
    Answer - Although the Merchant
    dt/df = 0 gives: eqn is not shown as a direct function
    of a and b, these enter from
    f = 45° + a/2 - b/2 the reln
    Merchant
    equations for Fc and Ft from the
    previous
    What does the Merchant relation slide!
    indicate?

    If we increase the shear angle, we


    - increase in friction angle decreases
    decreaseshear
    the toolangle
    force and power
    requirements!
    - increase in rake angle increases shear angle
    ME 482 - Manufacturing Systems
    Cutting models
    The orthogonal model for turning approximates the complex
    shearing process:
    to = feed (f)
    w = depth of cut (d)

    ME 482 - Manufacturing Systems


    Cutting power
    Power is force times speed:
    P = Fc v (ft-lb/min)
    The cutting horsepower is
    hpc = Fc v/33,000 (hp)
    The unit horsepower is
    hpu = hpc/MRR units?
    Due to efficiency losses (E about 90%), the gross hp is
    hpg = hpc/E

    ME 482 - Manufacturing Systems


    Cutting energy
    Specific energy is
    U = Fc v/(v tow) = Fc /(tow) (in-lb/in3)
    The table shown contains power and specific energy ratings for several work materials
    at a chip thickness of 0.01 in. For other chip thicknesses, apply the figure to get a
    correction factor multiply U by correction factor for thickness different than 0.01”).

    ME 482 - Manufacturing Systems


    Machining example
    In orthogonal machining the tool has rake angle 10°, chip thickness before
    cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
    and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
    cutting speed of 200 ft/min. Determine the machining shear strain, shear
    stress, and cutting horsepower.
    Solution (shear strain):
    Determine r = 0.02/0.045 = 0.444
    Determine shear plane angle from tan f = r cos a /[1 – r sin a]
    tan f = 0.444 cos 10 /[1 – 0.444 sin 10] => f = 25.4°
    Now calculate shear strain from g = tan(f - a) + cot f
    g = tan(25.4 - 10) + cot 25.4 = 2.386 in/in answer!

    ME 482 - Manufacturing Systems


    Machining example (cont.)
    In orthogonal machining the tool has rake angle 10°, chip thickness before
    cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
    and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
    cutting speed of 200 ft/min. Determine the machining shear strain, shear
    stress, and cutting horsepower.
    Solution (shear stress):
    Determine shear force from Fs = Fc cos f - Ft sin f
    Fs = 350 cos 25.4 - 285 sin 25.4 = 194 lb
    Determine shear plane area from As = to w/sin f
    As = (0.02) (0.125)/sin 25.4= 0.00583 in2
    The shear stress is

    ME 482 - Manufacturing Systems t = 194/0.00583 = 33,276 lb/in2 answer!


    Machining example (cont.)
    In orthogonal machining the tool has rake angle 10°, chip thickness before
    cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
    and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
    cutting speed of 200 ft/min. Determine the machining shear strain, shear
    stress, and cutting horsepower.

    Solution (cutting horsepower):


    Determine cutting hp from hpc = Fc v/33,000
    hpc = (350) (200)/33,000 = 2.12 hp answer!

    ME 482 - Manufacturing Systems


    Cutting temperatures
    In machining 98% of the cutting energy is converted into heat. This
    energy flows into the work part, chip, and tool. Cook determined an
    experimental equation for predicting the temperature rise at the
    tool-chip interface during machining:
    Example in text calculates
    DT = 0.4 U (v to /K)0.333/(r
    c)
    DT = 936° total tool
    where temperature, given v =
    DT = mean temperature rise (°F) 200 ft/min, rc = 120 in-
    U = specific energy (in-lb/in3) lb/(in3- °F) and K = 0.125
    v = cutting speed (in/s) in2/s
    to = chip thickness before cut (in)
    rc = volumetric specific heat of the work material (in-lb/(in3-°F))
    K = thermal diffusivity of the work material (in2/s)
    Note - To get total temperature at tool-chip interface, must add in ambient
    ME 482 - Manufacturing Systems temperature!
    Cutters

    Toroid

    ME 482 - Manufacturing Systems


    Cutters

    ME 482 - Manufacturing Systems


    Machining

    What did we learn?

    ME 482 - Manufacturing Systems

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