PROBLEMS DURING MACHINING PROCESS

The major machining processes carried out in agrofab machinaries are 1) DRILLING 2) MILLING

SO, THERE EXIST SOME PROBLEMS DURING THIS PROCESSES. THE PROBLEMS ARE AS FOLLOWS
Drill breakage Chipping of corner edge Chipping of cutting edge Abnormal wear on corner part Large wear and chipping, crushing of the chisel edge Chipping of margin

Margin build-up Tang breakage Noise of chattering Chip rolled around drill One-side wear

Drill Problems Problem Drill breakage Causes In accurate machine Work material deformation Relief angle is too small Feed rate is too high Excessive tool wear Solutions Increase the rigidity of machine, drill and work clamping Regrind correctly Decrease the feed rate Regrind

Select suitable drill (wide flute, high helix oil hole Chip packing drill). Change cutting conditions (feed rate or adopt step drilling). Difficulty entering Select high rigid the material tool & rigid

machine Increase work clamping rigidity Select a low cutting resistance thinning Use centering Work piece should be horizontal Use bush drill Problem Causes Solutions Chipping of In appropriate tool Choose suitable corner material tool material edge Iso static treatment Uneven hardness Change tool, distribution on the material & cutting work material conditions, machining method (EDM) Cutting or feed Reduce cutting speed is too high speed or feed Not enough Change coolant lubrication method Problem Causes Solutions Chipping of Check holder cutting Large run out after and/or select edge attached to another one machine Check run out Loose hold after fixing to the chuck Relief angle is too Regrind correctly small Tool material is Choose suitable not suitable tool material Cutting speed or Reduce cutting

speed or feed Problem Solutions Abnormal Regrind after a Tool late wear on shorter time of regrinding corner part use Bad alignment (for Check/adjust the lathe turning) alignment Cutting speed too Decrease the high cutting speed Point dimensions Select correct are not suitable point dimensions Tool materials not Choose suitable suitable tool material Coolant is not Change coolant suitable Problem Causes Solutions Large wear Feed rate is too Decrease feed and large rate chipping, Point dimensions Select correct crushing of are not suitable point dimensions the chisel Tool materials is Choose suitable edge not suitable tool material Relief angle is too Increase relief small angle Problem Causes Solutions Chipping of Bush diameter is Select correct margin too small bush diameter or Chip packing select drill with between drill & chip breakers bush Problem Causes Solutions Margin High heat built-up generation due to Regrind large wear on the cutting edge

feed is too high Causes

Change drill or the cutting conditions Problem Solutions Tang Take off the breakage defect by honing the surface Change holder or Defect of the inner correct the surface of Morse surface of Morse taper holder taper holder Low accuracy of Regrind correctly regrinding Problem Causes Solutions Noise of Relief angle is too Grind a smaller chattering big relief angle Low rigidity of the Use drill with high tool rigidity Problem Causes Solutions Chip rolled Low extended and around the curly chips Change drill and drill Chips are stubbed cutting conditions in the flute Problem Causes Solutions One side Check holder wear and/or select Large run out after another one attached to Check run out machine after fixing to the chuck Bad alignment (for Check/adjust the lathe turning) alignment

Lubrication is insufficient Coolant is not suitable Bad chip ejection Ductile material Causes Shank slippage due to some kind of defect

Change lubrication method Change coolant

The primary parameters pertaining to drilling technology revolve around safety and economics; the hole must be safe (from personnel, environmental and investment considerations) and it is desired to minimize the drilling cost (the total cost, not just one phase of the activity). A delineation of parameters into categories by which subject areas may be identified may take many forms, but it is convenient to consider that formation properties, hole geometries and equipment conditions (including mud) are of paramount consequence. Formation properties include type of strata, bedding plane information, permeability, porosity, drillability, constitutive relations, anisotropy, etc. Hole geometries are concerned with out-of-roundness, wash-outs, dog-legs, inclination and similar topics. Equipment conditions relate to mud properties, bittoothwear, drill-string mechanics, surface equipment, bearing degradation.... The listings are seemingly endless and specialized technologies have evolved in all of these areas. Some problems are hybrid in nature, involving complex factors: lost circulation, blow-outs, stuck pipe, and off-shore drilling. In general, however, the prime concerns are to maintain the hole; stay on target; avoid blow-outs, stuck pipe, lost circulation; collect as much field or in-situ information as is possible for future drilling in the area; and minimize costs. Current activities are taking advantages of recent advances in computer and instrumentation technologies, both in the laboratory and in the field. New information from research and development in progress will, as in the past, dictate the direction of future activities. The following discusses briefly, areas of current concern, areas where progress is likely and areas that will probably become of interest as data progress is likely and areas that will probably become of interest as data bases and capabilities are expanded.