IE 312 Product Design and Manufacturing Processes

Machining Lab #1: Introduction to Prismatic and Rotational Machining Processes

Prerequisite Reading: Kalpakjian, Chapter 8 Material Removal Processes: Cutting
Processes)
Lab Execution Requirements: Watch Machining Lab #1 video
Final report Requirements: Download IE 312 Machining Lab #1 Data.xls, complete final
lab report and electronically submit it to the course website by 5:00 pm of the assigned due
date in the course syllabus.

1. LAB SUMMARY
The purpose of this lab is for you to:
Become familiar with a variety of machining processes and cutting tools used to create
surfaces within a machining center and turning center
Become familiar with the use of Computer Aided Manufacturing (CAM) software to
generate CNC programs
Become familiar with the geometric accuracy and surface finish that can be imparted by
various machining processes
Diagnose machining system errors
This lab consists of two parts. In the first part, you will observe:

The use of a machining center to machine a prismatic workpiece

The use of a turning center to machine a rotational workpiece
The use of CAM software to generate the programs used to machine the parts

In the second part of this lab, you will use your text book and the internet to conduct research on
various facets of the machining processes that you observed. You will also analyze geometric
error data to assess the capability of various machining processes and to diagnose machining
system errors.

2. MACHINING CENTER PROCESSES

You will observe the machining of the part illustrated in Figure 1. The workpiece that is loaded
into the machine tool originates from a 4 length of extruded, 6061-T6 aluminum, bar stock.
The extruded cross section dimensions are 2 x 1.5. The 4 dimension is realized through a
sawing process used to part the workpiece from the original 12' length.
The machining center used to machine the part is illustrated in Figure 2. It is a Haas VF2
vertical machining center. It has three translational axes (X, Y, and Z) and a 20 hp spindle. The
spindle has a maximum rotational velocity of 7500 RPM. The workpiece is held using a general
purpose vise, which is mounted on to the machining center table.
A machining process involves the automatic loading of a cutting tool from the tool magazine into
the spindle, and the subsequent movement of the rotating tool relative to the workpiece. Nine
processes are used to generate the surfaces on the finished part. Eight different cutting tools are
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used (two processes use the same tool). The eight cutting tools are illustrated in Figures 3 8.
The machining datum reference frame to which the cutting tools are positioned is illustrated in

z
x

Figure 1. Prismatic Workpiece to be

Machined from 6061 Aluminum Bar Stock

Figure 3. Face Mill with 4 Cutting

Diameter and Six Coated Carbide Cutting
Inserts (SEAN1504AFE)

Figure 2. Haas VF 2 Machining Center

Figure 4. HSS End Cutting End Mill with

3/4 Cutting Diameter and Four Cutting
Flutes

Figure 5. HSS Two Flute, 5/8 X 90

Spot Drill

Figure 6. HSS Two Flute, Twist Drills:

a) 5/16 Dia.; b) 3/8 Dia.; c) U size Dia.;

Figure 7. HSS 3/8-16 Spiral, Three Flute

Tap

Figure 8. HSS 3/8 Six Flute Reamer

Figure 1 relative to the finished part. Note that the X-Y plane is coincident with the finished, top
planar surface.
The face mill (Figure 3) is used to rough machine the top planar surface of the workpiece in a
single pass, leaving .003 of material to be removed in a subsequent face milling process. The
end mill (Figure 4) is subsequently used to rough and finish machine the shoulder along the top
periphery.
The spot drill (Figure 5) is then used to drill .210 deep into the top surface at the three hole
locations. This process will leave behind three, blind conical surfaces. Each will serve as a
guide for the twist drill to be used in a subsequent drilling process. The residual conical surface
will serve as the hole chamfer.
The 3/8 twist drill (Figure 6b) is subsequently used to rough drill the leftmost hole illustrated in
Figure 1. The 5/16 drill (Figure 6a) is subsequently used to rough drill the middle hole. A
3/8-16 tap (Figure 7) is then used to machine internal threads into the middle hole. The U size
drill (Figure 6c) is subsequently used to rough drill the hole to the far right. This hole is
subsequently finish machined using a 3/8 reamer (Figure 8). As a final process, the face mill is
used to machine away the .003 layer of material from the finished part surface.
During the machining of this part, the instructor will stop the process after each tool change.
This will give you an opportunity to see the surfaces generated in the previous process as well as
ask questions.
3. TURNING CENTER PROCESSES
You will observe the machining of the part illustrated in Figure 9. The workpiece that is loaded
into the machine tool originates from a 6 length of extruded 6061 aluminum, bar stock. The
extruded cross section diameter is 2. The 6 dimension is realized through a sawing process
used to part the workpiece from the original 12'.

The machine tool used to machine the part is illustrated in Figure 10. It is a Haas SL20 turning
center. It has two translational axes (X and Z) and a 20 hp spindle. The spindle has a maximum

x
z
Figure 9. Rotational Workpiece to be
Machined from 6061 Aluminum Bar Stock

Figure 10. Haas SL 20 Turning Center

rotational velocity of 7500 RPM. The workpiece is held using a hydraulically actuated, three
jawed chuck, which is mounted to the spindle. The cutting tools are mounted in a turret.
A machining process involves the automatic rotation of the turret to bring the proper tool into
cutting position and the subsequent movement of the tool relative to the rotating workpiece. Ten
processes are used to generate the surfaces on the finished part. Nine different cutting tools are
used (two processes use the same tool). The eight cutting tools are illustrated in Figures 11 19.
The machining datum reference frame to which the cutting tools are positioned is illustrated in
Figure 9 relative to the finished part. Note that the X-Z plane is coincident with the end planar
surface.
The 80 roughing insert (Figure 11) is used first to rough and finish the planar face at the end of
the part. The 35 finishing insert (Figure 12) is used to rough and finish the majority of the front
spherical geometry and finish the thread OD. The square end grooving tool (Figure 13) is used
to subsequently machine additional relief between the front spherical surface and the end of the
thread. The threading tool (Figure 14) is then used to machine a Unified National 1-1/8-8
thread on the end of the workpiece in multiple passes. Subsequently the spot drill (Figure 15) is
used to create a pilot hole for the main bore and to leave residual geometry for a hole chamfer.
The twist drill (Figure 16) is then used to rough out the bore. The boring bar and insert (Figure
17) is then used to finish the bore geometry. The radius tipped profiling insert is subsequently
used to rough and finish the rear spherical surface of the part. In the last process, the cut-off tool
(Figure 19) is used to part the completed workpiece from the stock held in the chuck.
During the machining of this part, the instructor will stop the process after each tool change.
This will give you an opportunity to see the surfaces generated in the previous process as well as
ask questions

Figure 11. 1 Square Shank Tool Holder with

a CNMG 432 Coated Carbide Insert
(Roughing Insert with a 80 Nose Angle)

Figure 13. 1 Square Shank Tool Holder with

a CB2B Coated Carbide Insert (.156 Wide
Square End Grooving-Cut-Off Insert)

Figure 15. HSS Two Flute, 5/8 X 90

Spot Drill

Figure 12. 1 Square Shank Tool Holder with

a DNMG-432 Coated Carbide Insert (Finishing
Insert with a 35 Nose Angle)

Figure 14. 1 Square Shank Tool Holder with

a NT3R Coated Carbide Insert (OD Threading
Insert)

Figure 16. HSS Two Flute, 47/64

Twist Drill

Figure 17. Boring Bar with CCMT 21.51

/ 1.5 Coated Carbide Insert

Figure 18. 1 Square Shank Tool

Holder with a Coated Carbide, 3/16
OD Profiling Insert

Figure 19. 1 Square Shank Tool

Holder with a Carbide, 3/16 Wide Cut
Off Insert

4. CAM SOFTWARE DEMONSTRATION

The CNC programs used to control the machining center processes described in section 2 and the
turning center processes described in section 3 were created using Computer Aided
Manufacturing (CAM) software. The specific software that was used is MasterCam. Using
MasterCam, the programmer can:
1. Create or import a geometric model of the finished part and create other constructive
geometry
2. Identify a specific manufacturing process to be executed, and specify the workpiece
surface(s) to be machined, the cutting tool to be used, and process specific varables such
as: cutting speed, feed rates, depths of cut, etc.
3. Utilize the tool path planning function to generate a series of tool paths that will generate
the finished surface geometry using the prescribed cutting tool and process variables
4. Simulate the geometric removal of the workpiece material during the process for the
purpose of tool path verfication and collision detection (See Figures 20 and 21).
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5. Post process the tool path-process variable data into a CNC program that can be directly
downloaded and executed within a specified machine tool

Your lab insructor will demonstrate this software for both the machining center and turning
center applications.

Figure 20. Geometric Simulation of Machining Center

Processes within the MASTERCAM Software

Figure 21. Geometric Simulation of Turning Center

Processes within the MASTERCAM Software

5. MACHINING PROCESS RESEARCH AND DATA ANALYSIS

You are to research and derive answers to the following questions using your course text and the
internet. Make sure to cite the source of your information.

5.1 Face Milling Process Parameters

Critical face milling process variables include:

S: cutting speed (ft/min)

f: feed rate (in./th)
D: face milling cutting diameter (in.)
N: spindle speed (rev/min)
nt: number of inserts in the face mill
V: linear feed rate (in./min)
d:axial depth of cut (in.)
w: radial depth of cut (in.)
MRR: material removal rate (in.3/min)
Uc: Specific Cutting Power (hpmin/in.3)
Pc: Power deliverd by the spindle to the cut region (hp)

During the rough face milling process, the axial depth of cut is .047, the spindle speed is 6000
RPM, and the linear feed rate is 10 in./min. Based on your observation of the process, what is
the radial depth of cut? Likewise what are the cutting speed and feed rate? Lastly what are the
material removal rate and the approximate power that must be delivered by the spindle to enable
the cutting process?

5.2 Cutting Fluid Application

Cutting fluid was flooded into the cut zone for both the machining center processes and the
turning center processes. What are the principal benefits of applying a cutting fluid during
machining?

5.3 Face Milling Geometric Error Assessment

Three parts were machined using the processes described in section 2. Part #1 was loaded and
machined by the lab technician. Parts 2 and 3 were machined by the graduate teachining
assistants. Refer to Figure 22. Using a micrometer, two point measurements were taken from
three parts that were face milled. Measurements were taken at the four locations illustrated. In
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? A
4

Figure 22. Locations 1 4 for Two

Point Measurements and Parallelism
Measurement

addition, the parallelism error relative to datum feature A (bottom extruded surface) was
measured using a digital indicator and surface plate. The measurement data can be found in the
EXCEL spreadsheet entitled: IE 312 Machining Lab #1 Data.
In your opinion, are the results similar across all three parts or are there significant differences?
If the latter, provide a technical explanation for the most likely cause(s).
Assume that a dimensional tolerance of 1.450 .001 were assigned to the two parallel planar
surfaces comprised of the face milled surface and datum feature A. Would it be possible to use
the face milling processes to satisfy this tolerance? If not, what changes to the face milling
processes do you recommend?

5.4 End Mill Capability

The end mill used to machine the shoulder is a HSS, diameter, 4 flute, end cutting, end mill.
What material is this end mill made of? What capability does center cutting provide? Is
center cutting capability needed to machine the shoulders in the part?

5.5 Resultant Chamfer Geometry

Consider the chamfer on hole #1 in Figure 23. The nominal geometry of this chamfer was
generated through the combination of spot drilling, drilling, and milling. What are the nominal
chamfer specifications?

? X ?

Figure 23. Resultant Chamfer of Hole #1

5.6 Standard Drill Sizes

The American National Standard defines four series of nominal drill diameters that are used
throughout the world. What are the four series? What is the numerial diameter associated with a
U-size drill?

5.7 Thread Specifications and Tapping

All practical thread geometries are modifications of a theoretical sharp thread such as the one
illustratred in Figure 24. The nominal geometric parameters of a theoretical sharp thread are:
major diameter, minor diameter, included angle, helix angle, pitch, and pitch diameter. Using a
drawing similar to the one shown in Figure 24, you are to illustrate the meaning of each
parameter.

Figure 24. Theoretical Sharp Thread

The pitch diameter, pitch, and helix angle are interdependent. If you specify two, you dictate the
third. What is the equation that governs this relationship?

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For english unit threads, the Unified National Standard is commonly used for threaded fastners
and corresponding threaded holes. You are to specify the theoretically sharp geometric values
for a theoretical UN 3/8-16 thread.
In general, actual thread geometry used in practice differs from theoretical due to the necessity of
eliminating pointed crest profiles and pointed root profiles. Flats or radii are used to replace
points at the roots and flats are used to replace points at the crests. This in turn implies a change
in major diameter and minor diameter from nominal. What are the dimensonal limits for the
major diameter and minor diameter of a class 2, UN 3/8-16 internal thread?
With regard to the Unified 3/8-16 internal thread that was machined in lab, what is its nominal
minor diameter?
The feed rate for a tapping process is expressed in in./rev. This value cannot be chosen
independently. Instead it is a function of the thread geometry that must be created. Which of the
five nominal geometric parameters is the feed rate related to? Likewise what is the feed rate
necessary to tap a Unified 3/8-16 thread?

5.8 Hole Finishing

Consider hole #1 and hole #3 illustrated in Figure 25. Hole #1 was created using a drilling
process, which is generally considered to be a hole roughing process. Hole #3 was created by a
drilling process followed by a reaming process. A reaming process is generally considered to be
a hole finishing process.
Using a Zeiss CMM, cross section measurements were taken from both holes, and size error and
circularity error were assessed. Afterwards the parts were cut in half with a saw along a center
plane containing the hole axes, leaving the semi-cylindrical hole surfaces exposed. The
Mitutoyo profiliometer was used to measure the roughness of the hole surfaces using a cut-off
wave length of .03. The complete set of measurment data can be found in the EXCEL
spreadsheet entitled: IE 312 Machining Lab #1 Data.
You are to compute the sample average and sample standard deviation for each data set and post
the results in a table. The table must clearly expresss the average and standard deviation for
each measurment and for each hole. Based on the results, you are to comment on the ability of
the reaming process to improve hole size error, circularity error, and surface roughness.

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?
.375 ?

?
.375 ?

Figure 25. Measurements taken from

Holes #1 and #3

Steel dowel pins are commonly used to locate mating components in a product assembly. The
dowel pins are typically press fitted into holes in one component, and hence require an
interference fit. In turn the pins mate with holes in the other component using a slidinglocational fit. The size tolerance on slip holes with diameters close to 3/8 is typically .0007.
The same holds true on the press fit holes. Based on the data collected, is it possible to fabricate
these types of holes with drilling alone? Make sure you provide a quantitative argument.
Threaded fastners such as bolts are commonly used to hold mating components together in a
product assembly. Threaded holes are machined in one component while clearance holes are
machined in the other. The nominal diameter and size tolerances on the clearance holes are
sufficient to insure no jamming between the fastner and the clearance hole during product
assembly. The size tolerance for clearance holes with diameters close to 3/8 is typically .01.
Based on the data collected, what should be the last hole making process applied (drilling or
reaming) to create these types of clearance holes? Make sure you provide a quantitative
argument.

5.9 Mechanical Clamping

Fixtures utilizing manually actuated clamps are commonly used for low to mid-volume
machining applications. The clamping mechanisms amplify the force exerted by the operator to
the one exerted on the workpiece. This allows the operator to establish a system of large
preload, contact forces acting normal to the workpiece surfaces. In turn these enable the contact
regions to exert large frictional forces without slip. In combination, all of the contact forces
prevent workpiece slip during machining.

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Unfortunately the large pre-load forces also elastically deform the workpiece. This is especially
problematic for compliant, tight tolerance parts. This problem is excerbated by the fact that the
operator is desensitized to the forces exerted on the workpiece due to the mechanical advantage
of the clamping system.
To illustrate this, consider the machinist vise used to hold the workpiece in the machining center
(Figure 26). The vise utilizes an ACME 5/8-7 threaded lead screw to drive the moveable jaw
and a 6 handle. Compute the mechanical advantage ratio (Fout / Fin) for this vise.

Fin

Fout

Figure 26. Machinist Vise with Illustrated Input

and Output Force

5.10 Insert Nose Angle

The cutting tools illustrated in Figures 11 and 12 are typical of those that are used to generate the
exterior profile of a workpiece during rotational processing. A roughing insert typically has a
substantially larger nose angle than a finishing insert. What is the rationale for this?

5.11 Insert Coatings

Most carbide inserts in use are coated. What are the principal advantages gained through the use
of a coating? Provide three examples of coatings that are in common use.

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5.12 Peck Drilling

During the drilling of the 47/64 hole, the drill was pecked in and out of the hole. Why is this
done?

5.12 Boring Processes

During a boring process, what process variable controls the diameter of the hole? What
detrimental physical phenomon limits the ability of a boring process to machine holes with large
depth to diameter ratios?

6. REPORT REQUIREMENTS
The results of your laboratory are to be presented in a technical report. The report must contain
the following elements:

Title Page
Table of Contents
Investigation Results
References

The contents of these sections are as follows.

TITLE PAGE
The organization of the title page is:
TITLE OF REPORT IN CAPITAL LETTERS
Technical Report Submitted to: Dept. of Industrial & Manufacturing Engineering
Prof. Edward C. De Mete
310 Leonhard Building
The Pennsylvania State University
University Park, PA 16802

Submitted by:
Team: Team Number
Names of Team Members
Date: Submission Date
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TABLE OF CONTENTS
The technical report must be paginated. The title page is not numbered. The table of contents
appears on page 1. It should list the page number of every section and subsection, including the
appendix. Note that the title page should not have a page number.

INVESTIGATION RESULTS
This section should provide the results of your research pertaining to the questions posed in
section 5. A subsection should be devoted to each investigation. The subsection heading should
be equivalent to the corresponding heading in section 5. Make sure you cite all sources of
information, including your text.

REFERNCES
Provide reference data for all sources cited in this report.

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