MACHINING
CONTENTS
INTRODUCTION
MECHNICS OF MACHINING
TOOL WEAR, TOOL LIFE, SURFACE FINISH, AND MACHINABILITY
TOOL MATERIALS AND CUTTING FLUIDS
SELECTED MACHINE TOOLS AND MACHINING PROCESSES
MACHINING CENTERS
1. INTRODUCTION
US industries spend annually $60 billion to perform metal
removal operations that range from simple clean-up of castings
or welds to high precision work.
What is Machining?
Machining is a process designed to change the size, shape, and
surface of a material through removal of materials that could be
achieved by straining the material to fracture or by thermal
evaporation.
Why Machining?
Offers important benefits such as
Excellent dimensional tolerances
3. Velocity Ratio
If the velocities are considered (see Figure 8.3),
Q = w toV = w tc Vc
V/Cos ( - ) = Vs / Cos = Vc/Sin
4. Shear Strain-rate
d /dt = Vs/d where d = OC ~ 10-3 to 10-4 inch
Shear strain rate is on the order of 103- 106/sec
Thus, it is this combination of large strains and high strain rates
make it difficult to predict chip formation.
B. BUE (continuous)
- Favorable growth conditions such as high strainhardening, low speed, large depth of cut, low rake
angle, and high temperature
- Degrades the surface finish changes tool geometry
- Thin BUE helps to improve the tool life
- Cutting fluids will prevent the formation of BUE
C. Discontinuous
-Occurs in brittle materials
-Inclusions/impurities promote this
- Very low or hi V
-Large depth of cut
-Lack of cutting fluid
Because of the discontinuous nature of the chips, forces vary
continually leading to vibrations and chatter in the machine tool
with the end results of poor surface finish and loose tolerances.
D. Serrated chips
6. Force Analysis
The forces acting on the cutting tool are shown in Figure 8.12.
Except Fc and Ft, all other forces can not be experimentally
measured. A dynamometer (force transducer) mounted on the
workpiece or tool holder is used to measure Fc and Ft. Draw the
These forces are small on the order of few hundred newtons, but
the local stresses are very high due to smaller contact areas
leading to wear, chipping, fracture. The tool-chip contact length
is also small (about 1 mm).
Coefficient of Friction
Shear Angle
This is a challenging parameter to determine. Several theories
are advanced to find the shear angle. One of the earliest analyses
(Merchant's) says, "the shear angle leads to maximum shear
stress".
Hence we write, = Fs/As = R cos( + - )/(w to/sin )
Differentiate the shear stress w.r.to the shear angle and set it
equal to zero (assume that is independent of ), then we find
= 45 + ( - )/2
see Figure 8.17 to see how this equation poorly predicts the
experimental data. Note another equation (8.21) has been
developed but does equally poor in predicting the experimental
data.
Fc = R cos ( - ) = R sin 2
Stresses in shear plane
There are two stresses in the shear plane caused by Fs and Fn.
The average shear stress is:
= Fs/As and = Fn/As
7. Power Analysis
The cutting force system in 3D-turning consists of three forces:
Fc is the largest force that accounts for 99% the power required,
Ft requires very small power because feed rates are very small,
and Fr the radial force contributes very small also because
velocity in the radial direction is negligible.
Ignoring the thrust and radial forces, the total input power to
cutting is given by:
Pc = FcV
Pc = Ps + Pf = FsVs + F Vc
where Ps = power required for shearing
Additional power for creating new surfaces and for momentum changes as the metal crosses the shear plane is
considered small.
In terms of specific energy or UNIT POWER (specific energy, energy per unit volume of material removal), UNIT
POWER IS A MATERIALS PROPERTY.
See Table 8.4 for unit power of different materials. This UNIT POWER has been corrected for motor efficiency,
which is assumed to be 80%. That is, Pmotor = Pc/0.8 . For dull tools, you have to multiply the table data by 1.25.
Mechanisms
Flank
Crater
Chipping, Fracture
-- Cutting time
Surface Finish and Integrity
Finish represents geometric properties while integrity pertains to properties such as fatigue
life, corrosion etc. Read Section 4.2.1 for more information on surface integrity.
Roughness
Waviness
Lay
FlawsIntegrity
Residual stresses
Phase transformation
Plastic deformation
Cracks
Surface profilometer (Figure 4.4) is used to measure surface roughness. Read section 4.3.
Figure 8.33 shows the roughness data for various machining processes. Variables that
influence the roughness are:
Machinability
Machinability is a term that includes several parameters: finish, integrity, tool life, cutting
speed, force, chip formation, composition and properties of material etc. In general, tool life
and surface finish are measures of machinability. The ratings are given for materials. AISI
1112 steel is given rating of 100. What it means is that, the steel can be machined at 100 fpm
for 60 minutes of tool life. Some other materials ratings are:
Material Machinability Rating
AISI 3140 55
Brass 300
2011 Al 200
Gray iron 70
Inconel 30
Tool Materials
Steels
Cast Alloys
Carbides
Ceramics
Carbon
Co-Cr-W
Si3N4, CBN,
Diamond
High-speed
Operations on a Lathe
SEE Figure 8.51. Straight turning, taper turning, grooving,
threading, facing, profiling, drilling, boring, cutting off, and
knurling.
TURNING
Geometry
Advantages
Limitations
Rake Angles
Weakens edges
-5 to 20
Reduce Fc
Difficult to grind
Reduce Temp
Decrease cutting
angles
Relief (about 6)
Reduce friction
Less flank wear
Reduce surface
finish1, Chatter
Up Milling
Down Milling
Advantages
Advantages
Drawbacks
1. Tool chatter
2. Feed marks
Drawbacks
1. Rigid setup is needed due to
3. Clamp workpiece
(work moves up)
WORK OUT PROBLEMS 8.106, 107, 108, 109, 110 and 111.
6. MACHINING CENTERS
READ TEXT SECTION 8.10 (READING ASSIGNMENT)
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