High speed machining bstract
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High speed machining (HSM) has been used for over 60 years to machine metals and non-metals, including those with hardness over 50 HRC. Conventional machining of steel components between 32-42 HRC involves rough and semi-finishing machining, heat treatment, machining electrodes for electrical discharge, and finishing surfaces. For die and mold manufacturing in leading countries, machining and polishing make up around two thirds of total costs and a significant portion of lead time. High speed machining allows increasing efficiency, accuracy, and quality while decreasing costs and time compared to conventional cutting.
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This document provides information on various manufacturing cutting processes including photochemical cutting, laser cutting, electrical discharge machining, punching and blanking, die cutting, water jet cutting, and glass scoring. It describes the introduction, typical applications, related processes, quality considerations, design opportunities, compatible materials, costs, and environmental impacts for each process.
Advanced cutting tools
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.
D013112636
This document discusses a study that uses regression analysis techniques to estimate surface roughness values based on tribological parameters during hard turning of AISI 52100 steel. Experiments were conducted using a Taguchi L9 orthogonal array with cutting speed, feed rate, and depth of cut as parameters. Linear, quadratic, and cubic regression models were developed to correlate the parameters to surface roughness. The results showed that the estimated correlations predicted roughness with 99.5-99.9% accuracy, with only 6.19% uncertainty in the experiments.
Cutting tools chap_1_7225
This document discusses different types of cutting tool materials. It begins by introducing the importance of selecting the right material for the application. High carbon steel and high-speed steel were early materials but have limitations. Modern materials include cemented tungsten carbide, ceramics, and coatings. Each material has different properties like hardness, toughness, wear resistance, and temperature performance that make it suitable for specific cutting applications. Selecting the optimal material involves balancing quality, cost and tool life.
Seminar 1 m.tech final
This document discusses emerging cutting tool materials that can improve machining performance. It begins by explaining that machining involves cutting tools undergoing high forces and temperatures, so tool life and geometry are important considerations. Different tool materials are then outlined, including tungsten carbide, high-speed steel, ceramics, cermets, cubic boron nitride, polycrystalline diamond, and diamond coatings. Each material has advantages like high hardness, toughness, wear resistance, or thermal conductivity suited for different machining applications. The document concludes that continuous development of new tool materials and treatments can further push the limits of cutting performance.
Thermal cutting
Thermal cutting processes use heat sources like flames, plasma arcs, or laser beams to cut materials. Some key thermal cutting processes described in the document are flame cutting, which uses a heating flame and oxygen stream to cut materials, and plasma cutting, which uses an electrically conductive plasma gas and arc to cut electrically conductive materials. Laser beam cutting is also discussed, which uses a concentrated laser beam to heat and cut materials, achieving very precise cuts up to 12 mm thick in steel. Thermal cutting processes can be automated and are widely used in manufacturing industries for cutting components and preparing welding edges.
Cutting-Tool-Applications.pdf
This document discusses different types of cutting tool materials used in metalworking, including their properties and applications. It begins by introducing high carbon steel and high speed steel as older tool materials. It then focuses on cemented tungsten carbide as a modern cutting tool material. The manufacturing process for tungsten carbide tools is described, including blending tungsten and carbon powders, compacting the blended powder in a die under pressure, and sintering the compact to achieve the final hardness and properties. Other tool materials mentioned include cast alloys, ceramics, and coatings. The document emphasizes selecting the right material for each application based on its hardness, toughness, wear resistance and ability to maintain properties at high
The Design Core notes
Sand casting and die casting were identified as potential processes for manufacturing a connector rod. Die casting has higher tooling and capital costs but can produce parts at a faster rate. For small batch sizes, the cost per part is dominated by fixed capital and tooling costs, making sand casting cheaper. However, as batch size increases, die casting becomes more economical due to its higher production rate reducing the impact of fixed costs per part. An analysis is needed to determine the optimal process based on the specific production volumes required.
Welcome to International Journal of Engineering Research and Development (IJERD)
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5NontraditionalMachining-CH26Wiley.ppt
Nontraditional machining processes remove material using mechanical, thermal, electrical, or chemical energy instead of sharp cutting tools. They were developed after WWII to machine materials that cannot be cut conventionally like hard metals. Examples are ultrasonic machining (uses abrasives in slurry), water jet cutting (high pressure water), electric discharge machining (material removal by electric sparks), and laser beam machining (uses a laser). Nontraditional processes are used for complex parts, hard materials, and when traditional machining causes undesirable effects like high temperatures or residual stresses.
Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool Materials
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
Forging and casting technology
Forging is a process that shapes metal by applying pressure through hammers below the melting point. There are two main forging methods: closed die forging and cold die forging. Closed die forging provides high dimensional accuracy and the ability to create complex shapes in metals like steel, aluminum, and copper alloys. Cold die forging is done at room temperature up to a few hundred degrees Celsius and is used for lower alloy steels, stainless steel, aluminum, brass and bronze.
Casting involves using a pattern to create a cavity in a mold, which is then filled with liquid metal to produce the final product. Common metals cast include carbon and alloy steels, aluminum, and copper alloys.
Mould Steels.ppt
The document discusses various types of tool steels used for mould making. It provides details on the typical cost distribution for manufacturing a mould, with polishing and grinding accounting for around 45% of total costs. Toolmakers' main demands on mould steel are around machinability, polishability, surface finish, and heat treatment properties. M330 and AISI 420 stainless steels are discussed as options for applications like TV glass moulding due to their high polishability and corrosion resistance. Pre-hardened tool steel P20 is also summarized as a vacuum degassed alloy that is supplied hardened and tempered, saving on hardening costs and risks.
electric discharge machining of stainless steel
This document provides an overview of electric discharge machining (EDM) and its application to machining stainless steels. It discusses the principles and parameters of EDM, including electrical parameters like voltage, current, and pulse duration/interval. It reviews research on using EDM variants like wire EDM and micro-EDM to machine different stainless steel grades. The document examines models used to determine optimal EDM conditions and discusses trends and gaps in the research.
Thermal network removal processes
The document discusses various thermal energy-based material removal techniques, focusing on electrical discharge machining (EDM) and wire EDM. EDM works by using electrical sparks to erode metals, with the sparks controlled by a power supply. Wire EDM uses a continuously moving wire to remove material through controlled repetitive sparks in a dielectric fluid. Both processes can machine hard materials and leave minimal burrs. The document also covers laser beam machining, which uses a focused laser beam to melt, vaporize, or ablate material.
Wirecut edm
This document discusses electrical discharge machining (EDM) and wire cut EDM. It begins with a brief history of EDM and an overview of the EDM process, including its working principle, important characteristics, and applications. It then focuses on wire cut EDM, explaining its working principle, major components of the process, advantages, and disadvantages. The document concludes by outlining the scope and plan for investigating the effects of process parameters on material removal rate, surface finish, and kerf width in wire cut EDM.
Nilesh
Non-traditional machining processes are used to manufacture complex precision parts. They use indirect energy like sparks, lasers, heat or chemicals instead of direct tool contact. This allows machining of hard materials with complex shapes. Some common non-traditional processes include electrical discharge machining (EDM), electrochemical machining (ECM), laser beam machining, and abrasive jet machining. These processes remove material using techniques like electrical sparks, electrolysis, focused laser beams or high pressure abrasive jets. Non-traditional machining provides benefits like high accuracy, improved surface finish, less tool wear and greater design flexibility compared to traditional machining.
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High speed machining bstract
- 1. HIGH SPEED MACHINING ABSTRACT Over the past 60 years, high speed machining (HSM) has been applied to a wide range of metallic and non-metallic work piece materials including the production of components with specific topography requirements and machining of materials with hardness of 50 HRC and above. With most steel components hardened to approximately 32-42 HRC, machining operations currently include: Rough machining and semi-finishing of the material Heat treatment to achieve the final required hardness Machining of electrodes and electrical discharge machining of specific parts of the dies or moulds Finishing and super finishing of surfaces In leading industrial countries, in die and mould manufacturing, a significant portion of the lead-time is spent for machining and polishing operations .Therefore the machining and polishing portion of dies and moulds takes approximately two third of total manufacturing costs. If the quality level after machining is poor and if cannot meet the requirements there will be varying need of manual finishing work. Machining with high speeds (HSM) is one of the modern technologies, which in comparison with conventional cutting enables to increase efficiency, accuracy and quality of work pieces and at the same time to decrease costs and machining time.