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Boring Process: In machining, boring is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting tool (or of a
boring head containing several such tools), for example as in boring a gun
barrel or an engine cylinder. Boring is used to achieve greater accuracy of the
diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed
as the internal-diameter counterpart to turning, which cuts external diameters.
Drilling process: Drilling is a cutting process that uses a drill bit to cut or
enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary
cutting tool, often multipoint. The bit is pressed against the workpiece and
rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the workpiece, cutting off chips (swarf) from
the hole as it is drilled.
with cutting tools such as tool bits or milling cutters), and until recent decades
it was the only practical way to machine such materials as hardened steels.
Turning Process:
Turning is a form of machining, a material removal
process, which is used to create rotational parts by
cutting away unwanted material. The turning
process requires a turning machine or
lathe, workpiece, fixture, and cutting tool. The
workpiece is a piece of pre-shaped material that is
secured to the fixture, which itself is attached to
the turning machine, and allowed to rotate at high
speeds. The cutter is typically a single-point cutting
tool that is also secured in the machine, although
some operations make use of multi-point tools. The
cutting tool feeds into the rotating workpiece and cuts away material in the form of
small chips to create the desired shape.
Turning is used to produce rotational, typically axisymmetric, parts that have many features, such as holes,
grooves, threads, tapers, various diameter steps, and even
contoured surfaces. Parts that are fabricated completely
through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom
designed shafts and fasteners. Turning is also commonly
Tooling
The various angles, shapes, and sizes of a single-point cutting tool have direct relation
to the resulting surface of a workpiece in machining operations. Different types of
angle such as rake angle, side rake angle, cutting-edge angle, relief angle, nose
radius exist and may be different with respect to the workpiece. Also, there are many
shapes of single-point cutting tools, such as V-shaped and Square. Usually, a special
toolholder is used to hold the cutting tool firmly during operation.
Turning Theory
Forces
The relative forces in a turning operation are important in the design of machine tools.
The machine tool and its components must be able to withstand these forces without
causing significant deflections, vibrations, or chatter during the operation. There are
three principal forces during a turning process:
The cutting or tangential force acts downward on the tool tip allowing
deflection of the workpiece upward. It supplies the energy required for the
cutting operation.The specific cutting force required to cut the material is
called specific cutting force.Cutting force is depends on the material.
The axial or feed force acts in the longitudinal direction. It is also called the
feed force because it is in the feed direction of the tool. This force tends to
push the tool away from the chuck.
The radial or thrust force acts in the radial direction and tends to push the
tool away from the workpiece.
The distance the tool advances into the material in one revolution is called
"feed". It is specified as mm per revolution (mm/rev).
MPM
SFM
Steel
15 to 18
50 to 60
Cast iron
18 to 24
60 to 80
Alloy steels
20 to 37
65 to 120
Carbon steels
21 to 41
70 to 130
Stainless steel
23 to 40
75 to 130
Bronze
24 to 45
80 to 150
Mil steel
30 to 38
100 to 125
35 to 69
115 to 225
Aluminum
75 to 105
250 to 350
Brass
90 to 210
300 to 700
Leaded steel
91
300
Cutting Parameter:
In turning, the speed and motion of the cutting tool is specified through several
parameters. These parameters are selected for each operation based upon the
workpiece material, tool material, tool size, and more.
Cutting feed - The distance that the cutting tool or workpiece advances during one
revolution of the spindle, measured in inches per revolution (IPR). In some operations
the tool feeds into the workpiece and in others the workpiece feeds into the tool. For
a multi-point tool, the cutting feed is also equal to the feed per tooth, measured in
inches per tooth (IPT), multiplied by the number of teeth on the cutting tool.
Cutting speed - The speed of the workpiece surface relative to the edge of the
cutting tool during a cut, measured in surface feet per minute (SFM).
Spindle speed - The rotational speed of the spindle and the workpiece in revolutions
per minute (RPM). The spindle speed is equal to the cutting speed divided by the
circumference of the workpiece where the cut is being made. In order to maintain a
constant cutting speed, the spindle speed must vary based on the diameter of the cut.
If the spindle speed is held constant, then the cutting speed will vary.
Feed rate - The speed of the cutting tool's movement relative to the workpiece as the
tool makes a cut. The feed rate is measured in inches per minute (IPM) and is the
product of the cutting feed (IPR) and the spindle speed (RPM).
Axial depth of cut - The depth of the tool along the axis of the workpiece as it makes
a cut, as in a facing operation. A large axial depth of cut will require a low feed rate,
or else it will result in a high load on the tool and reduce the tool life. Therefore, a
feature is typically machined in several passes as the tool moves to the specified axial
depth of cut for each pass.
Radial depth of cut - The depth of the tool along the radius of the workpiece as it
makes a cut, as in a turning or boring operation. A large radial depth of cut will require
a low feed rate, or else it will result in a high load on the tool and reduce the tool life.
Therefore, a feature is often machined in several steps as the tool moves over at the
radial depth of cut.
PROCEDURE
The work piece is fixed in the 4-jaw chuck with sufficient overhang.
Adjust the machine to run the job to a required cutting speed.
Fix the cutting tool in the tool post and do the centring of then workpiece so
that its axis coincides with the axis of the lathe machine.
Change the feed rate of the machine while keeping the RPM and the depth of
cut constant and measure the corresponding MRR BY weight loss.
Observe the variation (graphically) between feed and MRR.