This document provides an overview of fundamental machining processes including turning, milling, drilling, broaching, and shaping. It discusses key concepts such as chip formation, cutting forces, tool angles, friction at tool-chip interfaces, and sources of chatter vibration. Examples are provided to calculate speeds, feeds, cutting times, and metal removal rates for different machining setups and operations.
Cutting power & Energy Consideration in metal cuttingDushyant Kalchuri
Cutting power is an important parameter, especially in the case of rough operations, as it makes it possible to:
select and invest in a machine with a power output suited to the operation being carried out
obtain the cutting conditions that allow the machine's power to be used in the most effective way possible, so as to ensure optimal material removal rate while taking into account the capacity of the tool being used.
In this report the basic design principles and the current state-of-the-art for cutting tools specially designed to be applied on difficult-to-cut materials are described. One by one, the main aspects involved in tool design and construction will be explained in depth over the following sections, completing a general view of the tool world, to provide easy comprehension of the whole book. Materials for the substrates, coatings, and geometry are explained, with special attention to recent developments. A section is devoted to new machining techniques such as high-feed and plunge milling, turn milling and trochoidal milling.
Cutting power & Energy Consideration in metal cuttingDushyant Kalchuri
Cutting power is an important parameter, especially in the case of rough operations, as it makes it possible to:
select and invest in a machine with a power output suited to the operation being carried out
obtain the cutting conditions that allow the machine's power to be used in the most effective way possible, so as to ensure optimal material removal rate while taking into account the capacity of the tool being used.
In this report the basic design principles and the current state-of-the-art for cutting tools specially designed to be applied on difficult-to-cut materials are described. One by one, the main aspects involved in tool design and construction will be explained in depth over the following sections, completing a general view of the tool world, to provide easy comprehension of the whole book. Materials for the substrates, coatings, and geometry are explained, with special attention to recent developments. A section is devoted to new machining techniques such as high-feed and plunge milling, turn milling and trochoidal milling.
Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool MaterialsMechbytes
Concept of machinability, machinability index, factors affecting machinability
Different mechanism of tool wear types of tool wear (crater, flank etc.), Measurement and control of tool wear
Concept of tool life, Taylor's tool life equation (including modified version)
Different tool materials and their applications including effect of tool coating
Introduction to economics of machining
Cutting fluids: types, properties, selection and application methods
Manufacturing Engineering 2, cutting tools and tool holdersGaurav Mistry
Detail study of cutting tool materials, some special materials, carbide tip tools, carbide inserts, types, carbide insert holders, ISO designation of carbide inserts, single point cutting tool nomenclature and angles, tool geometry, Tool life, tool wear and types, machinability
this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool MaterialsMechbytes
Concept of machinability, machinability index, factors affecting machinability
Different mechanism of tool wear types of tool wear (crater, flank etc.), Measurement and control of tool wear
Concept of tool life, Taylor's tool life equation (including modified version)
Different tool materials and their applications including effect of tool coating
Introduction to economics of machining
Cutting fluids: types, properties, selection and application methods
Manufacturing Engineering 2, cutting tools and tool holdersGaurav Mistry
Detail study of cutting tool materials, some special materials, carbide tip tools, carbide inserts, types, carbide insert holders, ISO designation of carbide inserts, single point cutting tool nomenclature and angles, tool geometry, Tool life, tool wear and types, machinability
this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
a cutting tool or cutter is any tool that is used to remove material from the work piece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, planing and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip
Palestine last event orientationfvgnh .pptxRaedMohamed3
An EFL lesson about the current events in Palestine. It is intended to be for intermediate students who wish to increase their listening skills through a short lesson in power point.
The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
How to Create Map Views in the Odoo 17 ERPCeline George
The map views are useful for providing a geographical representation of data. They allow users to visualize and analyze the data in a more intuitive manner.
Students, digital devices and success - Andreas Schleicher - 27 May 2024..pptxEduSkills OECD
Andreas Schleicher presents at the OECD webinar ‘Digital devices in schools: detrimental distraction or secret to success?’ on 27 May 2024. The presentation was based on findings from PISA 2022 results and the webinar helped launch the PISA in Focus ‘Managing screen time: How to protect and equip students against distraction’ https://www.oecd-ilibrary.org/education/managing-screen-time_7c225af4-en and the OECD Education Policy Perspective ‘Students, digital devices and success’ can be found here - https://oe.cd/il/5yV
How to Make a Field invisible in Odoo 17Celine George
It is possible to hide or invisible some fields in odoo. Commonly using “invisible” attribute in the field definition to invisible the fields. This slide will show how to make a field invisible in odoo 17.
How to Split Bills in the Odoo 17 POS ModuleCeline George
Bills have a main role in point of sale procedure. It will help to track sales, handling payments and giving receipts to customers. Bill splitting also has an important role in POS. For example, If some friends come together for dinner and if they want to divide the bill then it is possible by POS bill splitting. This slide will show how to split bills in odoo 17 POS.
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
The Art Pastor's Guide to Sabbath | Steve ThomasonSteve Thomason
What is the purpose of the Sabbath Law in the Torah. It is interesting to compare how the context of the law shifts from Exodus to Deuteronomy. Who gets to rest, and why?
2. Machining is the process of removing unwanted material from a workpiece
in the form of chips. If the workpiece is metal, the process is often called
metal cutting or metal removal.
What makes this process so unique and difficult to analyze?
10. 1. For a turning operation, you have selected an HSS tool and turning a hot rolled free machining steel, Bhn
300. Your depth of cut will be 0.150 in. The diameter of the workpiece is 1.00 inches.
a. What speed and feed would you select for this job?
b. Using a speed of 105 sfpm and a feed of 0.015, calculate the spindle rpm for this operation.
c. Calculate the metal removal rate.
d. Calculate the cutting time for the operation with a length of cut of 4 in. and .10-in. allowance.
14. 2. For a slab milling operation using a 5-in.-diameter, 11-tooth cutter. the feed per
tooth is 0.005 in./tooth with a cutting speed of 100 sfpm (HSS steel). Calculate the
rpm of the cutter and the feed rate (fm) of the table, then calculate the metal removal
rate, MRR, where the width of the block being machined is 2 in. and the depth of cut
is 0.25 in. Calculate the time to machine (Tm) a 6-in.-long block of metal with this
Setup. Suppose you switched to a coated-carbide tool, so you increase the cutting
speed to 400 sfpm. Now recalculate the machining time (Tm) with all the other
parameters the same.
15. DRILLING PROCESS
D = diameter of the
drill which rotates 2
cutting edges at rpm
Ns.
V = velocity of
outer edge of the lip of
the drill.
Ns = 12V/ΠD.
Tm = cutting time
= (L + A)/frNs
.
where fr is the feed rate in in. per rev. The allowance A = D/2.
The MRR =
which is approximately 3DVfr
16.
17. 3. The power required to machine metal is related to the cutting force (Fc) and the
cutting speed. For Problem 1, estimate cutting force Fc for this turning operation.
(Hint:You have to estimate a value of HPs for this material.)
18. 4. In order to drill a hole in the material described in Problem 1 using an HSS drill, you
have to select a cutting speed and a feed rate. Using a speed of 105 sfpm for the HSS drill,
calculate the rpm for a -in.-diameter drill and the MRR if the feed rate is 0.008 inches per
revolution.
19. BROACHING PROCESS
The Tm for broaching is Tm = L /12V.
The MRR (per tooth) is 12tWV in.3/min
where V = cutting velocity in fpm,
W is the width of cut, t = rise per tooth.
20.
21.
22.
23.
24.
25. Usually, 30 to 40% of the total energy goes into friction and 60 to 70% into the
shear process.
26. Doubling speed or depth of cut
In general, increasing the speed, the feed, or the depth of cut will increase the power
requirement. Doubling the speed doubles the horsepower directly. Doubling the feed
or the depth of cut doubles the cutting force Fc. In general, increasing the speed does
not increase the cutting force Fc, a surprising experimental result.
However, speed has a strong effect on tool life because most of the input energy is
converted into heat, which raises the temperature of the chip, the work, and the tool,
which effect the tool life.
27.
28. The angle that the tool makes with respect to a vertical from the workpiece is called
the back rake angle a. A positive angle is shown in the schematic. The chip is formed by
shearing. The onset of shear occurs at a low boundary deformed by angle f with respect
to the horizontal.
29. In metal cutting, we observe that the onset of shear (to form the chip) is delayed by
increased hardness (so f increases directly with hardness).
30. If the work material has hard second-phase particles dispersed in it, they can act as
barriers to the shear front dislocations, which cannot penetrate the particle. The
dislocations create voids around the particles. If there are enough particles of the right
size and shape, the chip will fracture through the shear zone, forming segmented chips.
Free-machining steels, which have small percentages of hard second-phase particles
added to them, use this metallurgical phenomenon to break up the chips for easier chip
handling.
32. The shear angle can be measured statically by instantaneously interrupting the cut
through the use of quick-stop devices. These devices disengage the cutting tool from
the workpiece while cutting is in progress, leaving the chip attached to the workpiece.
Optical and scanning electron microscopy is then used to observe the direction of
shear.
33. It is assumed that the resultant force R acting
on the back of the chip is equal and opposite to
the resultant force R acting on the shear plane.
The resultant R is composed of the friction
force F and the normal force N acting on the
tool–chip interface contact area.
The resultant force R’ is composed of a shear
force Fs and normal force Fn acting on the
shear plane area As
Since neither of these two sets of forces can
usually be measured, a third set is needed, which
can be measured using a dynamometer (force
transducer) mounted either in the workholder or
the tool holder.
34. The only symbol in this figure as
yet undefined is b, which is the
angle between the normal force
N and the resultant R. It is called
friction angle b and is used to
describe the friction coefficient
m on the tool–chip interface area,
which is defined as F/N so that
35.
36. Unit power is sensitive to material properties (e.g., hardness), rake angle,
depth of cut, and feed, whereas ts is sensitive to material properties only.
43. LOBE DIAGRAM
The amplitude of chatter vibration may be more safely limited by temporary
reduction of the feed per tooth until a preferred speed and stable depth of cut have
been established.