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MACHINING OPERATIONS AND MACHINE TOOLS.pptx
1.
MACHINING OPERATIONS AND MACHINE
TOOLS 1. Turning and Related Operations 2. Drilling and Related Operations 3. Milling 4. Machining Centers and Turning Centers 5. Other Machining Operations 6. Machining Operations for Special Geometries 7. High Speed Machining ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
2.
Machining Material removal
process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains Most common application: metal parts Most versatile of all manufacturing processes for producing a variety of part shapes and geometric features with high precision and accuracy Casting can also produce a variety of shapes, but in general is not as accurate as machining ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
3.
Rotational -
(a) cylindrical or disk-like shape Nonrotational - (b) block-like and plate-like ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Classification of Machined Parts
4.
Machining Operations and
Part Geometry Each machining operation produces a characteristic part geometry due to two factors: 1. Relative motions between tool and workpart • Generating – part geometry determined by feed trajectory of cutting tool 2. Shape of the cutting tool • Forming – part geometry is created by the shape of the cutting tool ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
5.
Generating shape:
(a) straight turning, (b) taper turning, (c) contour turning, (d) plain milling, (e) profile milling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Generating Shape
6.
Forming to
create shape: (a) form turning, (b) drilling, and (c) broaching ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Forming to Create Shape
7.
Combination of
forming and generating to create shape: (a) thread cutting on a lathe, and (b) slot milling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Forming and Generating
8.
Turning Single point
cutting tool removes material from a rotating workpiece to generate a cylindrical shape Performed on a machine tool called a lathe Variations of turning performed on a lathe Facing Contour turning Chamfering Cutoff Threading ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
9.
©2013 John Wiley
& Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Turning Operation
10.
Turning Operation Close-up
view of a turning operation on steel using a titanium nitride coated carbide cutting insert (photo courtesy of Kennametal Inc.) ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
11.
Operations Related to
Turning (a) Facing, (b) taper turning, (c) contour turning ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
12.
More Operations Related
to Turning (d) Form turning, (e) chamfering, (f) cutoff ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
13.
More Operations Related
to Turning (g) Threading, (h) boring, (i) drilling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
14.
Engine Lathe Diagram
of an engine lathe showing its principal components and motions ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
15.
Methods of Holding
Workpiece in a Lathe (a) Holding the work between centers, (b) chuck, (c) collet, and (d) face plate ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
16.
Other Production Turning Machines
Turret lathe Chucking machine Bar machine Automatic screw machine Multiple spindle bar machine ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
17.
Turret Lathe Tailstock
replaced by “turret” that holds up to six tools Tools rapidly brought into action by indexing the turret Tool post replaced by four-sided turret to index four tools Applications: high production work that requires a sequence of cuts on the part ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
18.
https://youtu.be/OehmgbZBVmc ©2013 John
Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
19.
Chucking Machine Uses
chuck in its spindle to hold workpart No tailstock, so parts cannot be mounted between centers Cutting tool actions controlled automatically Operator’s job: to load and unload parts Applications: short, light-weight parts ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
20.
©2013 John Wiley
& Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
21.
Bar Machine Similar
to chucking machine except collet replaces chuck, permitting long bar stock to be fed through headstock At the end of the machining cycle, a cutoff operation separates the new part Highly automated Computer numerical control Applications: high production of rotational parts ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
22.
©2013 John Wiley
& Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
23.
Automatic Screw Machine
Same as automatic bar machine but smaller Applications: high production of screws and similar small hardware items ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
24.
Multiple Spindle Bar
Machines More than one spindle, so multiple parts machined simultaneously by multiple tools Example: six spindle automatic bar machine works on six parts at a time After each machining cycle, spindles (including collets and workbars) are indexed (rotated) to next position ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
25.
(a) Part;
(b) sequence of operations: (1) feed stock to stop, (2) turn main diameter, (3) form second diameter and spotface, (4) drill, (5) chamfer, and (6) cutoff ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Six Spindle Bar Machine
26.
Boring Difference between
boring and turning: Boring is performed on the inside diameter of an existing hole Turning is performed on the outside diameter of an existing cylinder In effect, boring is internal turning operation Boring machines Horizontal or vertical - refers to the orientation of the axis of rotation of machine spindle ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
27.
Vertical Boring Mill
Applications: Large, heavy workparts that have low L/D ratio ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
28.
Creates a
round hole in a workpart Compare to boring which can only enlarge an existing hole Cutting tool called a drill or drill bit Machine tool: drill press ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Drilling
29.
Through Hole vs.
Blind Hole (a) Through hole - drill exits opposite side of work and (b) blind hole – drill does not exit opposite side ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
30.
Operations Related to
Drilling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e (a) Reaming, (b) tapping, (c) counterboring
31.
More Operations Related
to Drilling (d) Countersinking, (e) center drilling, (f) spot facing ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
32.
Upright drill
press stands on the floor Bench drill similar but smaller and mounted on a table or bench ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Drill Press
33.
Radial Drill Press Large
drill press designed for large parts (photo courtesy of Willis Machinery and Tools) ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
34.
Milling Machining operation
in which work is fed past a rotating tool with multiple cutting edges Axis of tool rotation is perpendicular to feed Cutting tool called a milling cutter Cutting edges called teeth Machine tool called a milling machine Interrupted cutting operation Basic milling operation creates a planar surface Other geometries possible ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
35.
Two Forms of
Milling (a) Peripheral milling and (b) face milling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
36.
Peripheral Milling vs. Face
Milling Peripheral milling Cutter axis parallel to surface being machined Cutting edges on outside periphery of cutter Face milling Cutter axis perpendicular to surface being milled Cutting edges on both the end and outside periphery of the cutter ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
37.
Types of Peripheral
Milling (a) Slab milling, (b) slotting, (c) side milling, (e) straddle milling, and (e) form milling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
38.
Types of Face
Milling (a) Conventional face milling, (b) partial face milling, and (c) end milling ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
39.
Types of Face
Milling (d) Profile milling, (e) pocket milling, and (f) surface contouring ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
40.
Face Milling High
speed face milling operation using indexable inserts (photo courtesy of Kennametal Inc.) ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
41.
Knee-And-Column Milling Machines (a)
Horizontal and (b) vertical knee-and-column milling machines ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
42.
Machining Center Highly
automated machine tool that can perform multiple machining operations under CNC control in one setup with minimal human attention Typical operations are milling and drilling Three, four, or five axes Other features: Automatic tool-changing Pallet shuttles Automatic workpart positioning ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
43.
CNC Machining Center ©2013
John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e (Photo courtesy of Cincinnati Milacron)
44.
CNC Turning Center
- Industrial Robot to Load and Unload Parts ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e (Photo courtesy of Cincinnati Milacron)
45.
Mill-Turn Centers Highly
automated machine tool that can perform turning, milling, and drilling operations in one setup General configuration of a turning center Can position a cylindrical workpart at a specified angle so a rotating cutting tool (e.g., milling cutter) can machine features into outside surface of part Conventional turning center cannot stop workpart at a defined angular position and does not include rotating tool spindles ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
46.
(a) Part
and (b) sequence of operations : (1) turn second diameter, (2) mill flat, (3) drill hole, and (4) cutoff ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Operation of Mill-Turn Center
47.
Similar operations,
both use a single point cutting tool moved linearly relative to the workpart ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Shaping and Planing
48.
Shaping and Planing
A straight, flat surface is created in both operations Interrupted cutting operation Subjects tool to impact loading when entering work Typical tooling: single point high speed steel tools Low cutting speeds due to start-and-stop motion ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
49.
©2013 John Wiley
& Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Shaper
50.
©2013 John Wiley
& Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Planer
51.
A multiple
tooth cutting tool is moved linearly relative to work in direction of tool axis ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Broaching
52.
Broaching Advantages: Good
surface finish Close tolerances Variety of work shapes possible Cutting tool called a broach Owing to complicated and often custom-shaped geometry, tooling is expensive ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
53.
(a) External
and (b) internal broaching (cross- hatching indicates surface broached) ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e Broaching
54.
Sawing Cuts narrow
slit in work by a tool consisting of a series of narrowly spaced teeth Tool called a saw blade Typical functions: Separate a workpart into two pieces Cut off unwanted portions of part Cut outline of flat part ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
55.
Sawing (a) Power
hacksaw, (b) bandsaw (vertical), and (c) circular saw ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
56.
Machining Operations for Special
Geometries Screw threads Gear teeth ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
57.
Cutting Screw Threads
Methods for producing external threads Single-point threading Threading die Thread chasing using self-opening threading dies Thread milling Methods for producing internal threads Tapping - using a solid tap Collapsible taps - cutting teeth retract for quick removal from hole ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
58.
Cutting External Screw
Threads (left) Single-point thread cutting and (right) threading die ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
59.
Thread Milling Using
a Form-Milling Cutter ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
60.
Principal Operations for Machining
Gear Teeth Form milling - use of a form milling cutter Gear hobbing - also milling but using a special cutter called a hob Gear shaping - two forms Single point tool to gradually shape each gear tooth spacing Cutter has general shape of the gear but with cutting teeth on one side Gear broaching - for internal and external gears ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
61.
Form Milling of
Gear Teeth The form milling cutter has teeth with the shape of the spaces between teeth on the gear Gear blank is indexed between each pass to establish correct size of the gear tooth ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
62.
Gear Hobbing Hob has
a slight helix and its rotation is coordinated with much slower rotation of the gear blank Special milling machines (called hobbing machines) accomplish the relative speed and feed motions between cutter and gear blank ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
63.
Gear Shaping To
start the process, cutter is gradually fed into gear blank Then, cutter and blank are slowly rotated after each stroke to maintain tooth spacing Performed on special machines called gear shapers ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
64.
Gear Broaching Applicable
for both external gears and internal gears (teeth on inside of gear) Cost of tooling (broach) is high due to its complex geometry For internal gears, broach consists of a series of gear-shaped cutting teeth of increasing size to form the gear teeth in successive steps as broach is drawn through starting hole For external gears, broach is tubular with inward- facing cutting teeth ©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
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