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Giant Lathe
Discontinuous chips
Continuous chips
Abrasive processes
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Lathe Parts
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holder
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Old Lathe
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Boring
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Old Planer
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Shaper
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Trepanning
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Drilling
(a)
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Milling
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Face Milling
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Horizontal Mill
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Vertical Mill
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Milling Types
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Broach
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Reamers
bridge reamer
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton
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Honing
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internal
external
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Shaping
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Planing
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Material removal rate, MRR = Vwt0 Cutting power, Pc = ucMRR Machining time, tm = L/V
L is the length of cut
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u is composed of:
us, the shear energy per unit volume uf, frictional energy per unit volume chip curl energy chip acceleration kinetic energy surface energy of new surfaces
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u us + uf us 0.75 - 0.8 u
hence
u 1.5 us
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Estimation of u
Assume a simple, rigid-perfectly plastic material:
u s = d = o = fm
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Estimation of u
fm
o 1 HB 2 6
1 2 us HB HB 3 3
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n +1 K 1 d1 = u = n +1
1
u volume = Energy
K = 185,000 psi; n = 0.45
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton
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n +1 K 1 Energy = Aolo n +1
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( 0.5 4
0.482 ) 6
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u us + u f
1 u t0
ME 338: Manufacturing Processes II Instructor: Ramesh Singh; Notes: Profs. Singh/Melkote/Colton
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Turning -MRR
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Turning
Average cutting speed, Vavg = DavgN
Davg is the average diameter of workpiece N is the spindle speed in rpm
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Milling
fr
cutter
N dr
feed
workpiece
da
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Milling Modes
dr
Up Milling
Down Milling
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Milling
Cutting speed, V = DN
D is the cutter diameter
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Example
A slab-milling operation is being carried out on a 25-in. long, 4-in. wide metal block (u = 4.3 hp-min/in3) at a feed of 0.02 in./tooth and a depth of cut of 0.125 in. The cutter has a diameter of 4 in., has eight straight cutting teeth, is 2 inches wide and rotates at 200 rpm. Calculate the material removal rate, the cutting time, and the power required.
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d a= d r= u=
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Summary
General Machining Process Shaping & planing Turning Milling
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