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Ultrasonic Machining
1. Ultrasonic machining is a non-traditional machining process that uses a vibrating tool to remove material from a workpiece submerged in an abrasive slurry.
2. The tool vibrates at high frequency (typically 20-40 kHz) and is gradually fed into the workpiece. The abrasive grains in the slurry are driven across a small gap by the vibrating tool and impact the workpiece, removing small particles.
3. Ultrasonic machining can machine both conductive and non-conductive materials like ceramics and is well-suited for hard, brittle materials. Key factors that influence the material removal rate include vibration frequency and amplitude,
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Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
Thermal aspects in machining
- The document discusses heat generation in machining and its effects, temperature measurement techniques, types and functions of cutting fluids, and economics of metal cutting operations.
- Heat is generated in three zones during machining: the primary deformation zone, tool-chip interface, and tool-workpiece interface. Heat depends on factors like material properties and cutting parameters.
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Ultrasonic Machining
1. Ultrasonic machining is a non-traditional machining process that uses a vibrating tool to remove material from a workpiece submerged in an abrasive slurry.
2. The tool vibrates at high frequency (typically 20-40 kHz) and is gradually fed into the workpiece. The abrasive grains in the slurry are driven across a small gap by the vibrating tool and impact the workpiece, removing small particles.
3. Ultrasonic machining can machine both conductive and non-conductive materials like ceramics and is well-suited for hard, brittle materials. Key factors that influence the material removal rate include vibration frequency and amplitude,
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The document discusses a proposed settlement agreement between two parties named in a lawsuit over an accident. It outlines details of the settlement such as payment amounts, dismissal of claims, and release of liability. Both parties and their legal representatives would need to sign the agreement to finalize the settlement instead of proceeding to trial.
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this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
Orthogonal & oblique cutting
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
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- The document discusses heat generation in machining and its effects, temperature measurement techniques, types and functions of cutting fluids, and economics of metal cutting operations.
- Heat is generated in three zones during machining: the primary deformation zone, tool-chip interface, and tool-workpiece interface. Heat depends on factors like material properties and cutting parameters.
- High temperatures can damage tools and workpieces. Cutting fluids help reduce temperatures by conduction and convection of heat away from the cutting zone.
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Dies Design - Cutting Operations Part 2
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Unit i and ii
Unconventional machining processes remove material without direct contact between the tool and workpiece using various forms of energy. They are classified based on the shape of material removed, mechanism involved, material removal method, and energy transfer medium. Some key unconventional processes include abrasive jet machining, which uses a high velocity abrasive particle stream; water jet machining, which cuts using high pressure water; and ultrasonic machining, where the tool vibrates at high frequency to erode material with abrasives. These processes allow harder materials to be machined with closer tolerances compared to conventional techniques.
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This document discusses chip formation during metal cutting processes. It begins with an introduction to metal cutting and chip formation. It then describes the mechanics of chip formation, including how shear deformation causes material to be removed from the workpiece in the form of chips. It discusses factors that influence chip type, such as the material properties, cutting conditions, and tool properties. Finally, it describes the different types of chips that can be formed, including continuous chips, discontinuous chips, and continuous chips with built up edges.
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3 forging
Forging is the process of shaping metals by applying compressive forces. It can be done either hot or cold. Common forging operations include drawing, piercing, punching, and swaging. Forging machines include drop hammers, power hammers, mechanical presses, and hydraulic presses. Closed-die forging uses dies to precisely shape parts, while open-die forging uses simpler dies. Proper die material selection and coatings can increase die life. Forging results in an elongated grain structure and improved mechanical properties compared to casting.
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Concept of machinability, machinability index, factors affecting machinability
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3. The objectives of metrology include evaluating new products, determining process capabilities, minimizing inspection costs, and maintaining measurement accuracy. It is important for scientific research, production, and automation.
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Tool wear and tool Life
The document provides information about tool wear and tool life in machining processes. It discusses how tool wear occurs due to forces, temperature, and sliding action during cutting. The three main types of tool wear are flank wear, crater wear, and chipping. Flank wear is caused by abrasion from hard particles in the workpiece while crater wear results from high temperatures and diffusion at the tool-chip interface. Maintaining optimal cutting conditions and tool geometry can increase tool life. The document also covers tool materials, machinability factors, cutting fluids, machining forces, and lathe operations such as turning, facing, and threading.
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To introduce machining process
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To understand methods of machining
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The document provides an overview of the theory of metal cutting. It discusses the mechanics of chip formation, types of chips, cutting tools and their components/angles. It also describes the metal cutting process, orthogonal vs oblique cutting, thermal aspects of cutting, tool wear and life, factors affecting surface finish and machinability. Cutting fluids, their functions and types are also summarized.
EFFECT OF MACHINING PARAMETERS ON TOOL LIFE
This seminar report discusses the effect of machining parameters on tool life. It begins with an introduction to cutting tools, tool wear, and factors that affect tool life. The report then reviews literature on how cutting speed, feed rate, and depth of cut impact tool wear and life. The objectives are to study how these machining parameters influence tool wear and life. The expected outcomes are that tool life decreases with increasing feed rate, cutting speed, and depth of cut. The conclusion is that machining parameters must be optimized to select values that result in maximum tool life and minimum tool wear.
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The document provides an overview of the wire drawing process. It discusses how wire drawing works by pulling a wire through progressively smaller dies to reduce its diameter and increase its length. This cold working process improves the material properties of the wire. Key aspects covered include the types of drawing, processing parameters like die design and lubrication, how drawing machines operate using multiple dies, and common die materials like cemented carbides and industrial diamonds.
Dies Design - Cutting Operations Part 2
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Unit i and ii
Unconventional machining processes remove material without direct contact between the tool and workpiece using various forms of energy. They are classified based on the shape of material removed, mechanism involved, material removal method, and energy transfer medium. Some key unconventional processes include abrasive jet machining, which uses a high velocity abrasive particle stream; water jet machining, which cuts using high pressure water; and ultrasonic machining, where the tool vibrates at high frequency to erode material with abrasives. These processes allow harder materials to be machined with closer tolerances compared to conventional techniques.
Chips formation
This document discusses chip formation during metal cutting processes. It begins with an introduction to metal cutting and chip formation. It then describes the mechanics of chip formation, including how shear deformation causes material to be removed from the workpiece in the form of chips. It discusses factors that influence chip type, such as the material properties, cutting conditions, and tool properties. Finally, it describes the different types of chips that can be formed, including continuous chips, discontinuous chips, and continuous chips with built up edges.
Unit 4 ppt mt1
This document discusses various sheet metal forming processes. It covers shearing operations like punching and blanking. It also discusses bending and drawing operations and how they deform sheet metal. Finally, it introduces special forming processes like hydroforming, rubber pad forming, spinning and explosive forming that can form sheet metal into more complex shapes.
3 forging
Forging is the process of shaping metals by applying compressive forces. It can be done either hot or cold. Common forging operations include drawing, piercing, punching, and swaging. Forging machines include drop hammers, power hammers, mechanical presses, and hydraulic presses. Closed-die forging uses dies to precisely shape parts, while open-die forging uses simpler dies. Proper die material selection and coatings can increase die life. Forging results in an elongated grain structure and improved mechanical properties compared to casting.
ELECTRO CHEMICAL MACHINING PPT.......
This document provides an overview of electrochemical machining (ECM). ECM is a non-conventional machining process that removes metal through an electrochemical process rather than adding it, as in electroplating. In ECM, a tool acts as the cathode and the workpiece the anode, with an electrolyte solution flowing between them. Metal is removed from the workpiece through an electrolysis process governed by Faraday's laws of electrolysis. ECM can machine complex internal and external geometries in hard metals and is well-suited for mass production. Key aspects of ECM covered include the power supply, electrolyte, tool, control system, and principles of operation. Applications and advantages, such as little
Vicker hardness test
The document describes the Vickers hardness test. It uses a diamond pyramid indenter to make an indentation on the material being tested under a specified load ranging from 5 to 120 kg. The indentation left has a square shape regardless of load. The diagonal lengths of the indentation are measured under a microscope and used to calculate the Vickers hardness number, providing a continuous scale of hardness values. Factors like load, indentation shape, and temperature can affect the results. Advantages include consistency of indentation shape and suitability for testing a range of materials and surfaces. A disadvantage is it takes more time than other hardness tests.
UNCONVENTIONAL MACHINING PROCESSES
This document provides an overview of mechanical energy based unconventional machining processes. It discusses abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). For each process, it describes the basic working principles, key components, process parameters that influence material removal rate, advantages, disadvantages, and applications. It also compares different types of transducers used in USM and discusses factors affecting the machining performance of USM.
Introduction to nontraditional machining
Non-traditional machining techniques remove material using various energy sources besides traditional cutting tools. They are divided into mechanical, electrical, thermal, and chemical techniques. Non-traditional techniques are needed for hard or complex materials, and can machine intricate shapes and deep holes. Selection depends on the part geometry, material properties, machining capabilities, and cost effectiveness. While more expensive initially than traditional techniques, non-traditional machining offers higher precision, surface finish, and ability to machine difficult materials.
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
Conventional machining vs. non conventional machining
Conventional machining involves physically removing material from a workpiece using a harder cutting tool, typically through mechanical forces. Non-conventional machining utilizes other forms of energy like thermal, chemical, or electrical instead of mechanical forces and may not require physical contact or chip formation. While conventional machining can be used for most materials economically, non-conventional machining allows for higher precision machining of hard metals and complex parts but requires more advanced equipment and skilled operators.
Submerged Arc Welding
Twin submerged arc welding involves feeding two wires through the same contact tip using a single power source. This increases deposition rates over single-wire welding by 30-40% without significantly higher costs. The two wires can be arranged side by side or one behind the other. For even higher deposition, tandem twin welding uses four wires fed from two welding heads powered by a single source. This process can deposit over 38kg of weld metal per hour. Twin submerged arc welding is used for high-speed fillet welding and butt welding when high productivity is required.
Unit 1 basics of metrology
1. Metrology is the science of measurement and its application. It involves establishing standards of measurement and measurement procedures for accuracy.
2. There are different types of metrology including legal metrology which deals with measurement standards and regulations, and dynamic metrology which measures small continuous variations.
3. The objectives of metrology include evaluating new products, determining process capabilities, minimizing inspection costs, and maintaining measurement accuracy. It is important for scientific research, production, and automation.
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Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool Materials
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The document discusses the parts, types, and classifications of milling machines. It describes the main components of milling machines including the base, column, knee, saddle, table, overhanging arm, front brace, spindle, and arbor. It classifies milling machines as column and knee type, fixed bed type, planner type, and production type. Within these classifications, it provides details about horizontal milling machines, vertical milling machines, universal milling machines, omniversal milling machines, simplex milling machines, and other specific types of milling machines such as drum milling machines and tracer controlled milling machines.
MILLING MACHINE PPT 1: WORKING PRINCIPLE ,MILLING METHODS AND SPECIFICATIONS ...
Milling machines are used to remove materials from a workpiece via a revolving cutting tool. There are two types of milling: up-milling and down-milling. Up-milling involves cutting against the workpiece movement, resulting in varying cutting forces. Down-milling cuts in the same direction as workpiece movement, generating less heat and allowing for a better surface finish. Milling machines can cut flat, curved, or angled surfaces using multiple tooth cutters mounted on an arbor or spindle. They are suitable for machining surfaces, contours, threads, and other cross-sections.
LATHE OPERATIONS PPT POLAYYA CHINTADA
This document discusses lathe operations and provides details on various operations like facing, turning, knurling, parting off, drilling, boring, thread cutting, and taper turning. It explains the basic principles and methods for each operation. The objective of the course is to help students understand different types of lathes, lathe operations, work holders, tool holders, lathe attachments, and automatic lathes. The outcome is for students to be able to use lathe machines and understand the importance of lathe tools and lathes. [/SUMMARY]
LATHE ACCESSORIES PPT BY POLAYYA CHINTADA
The document discusses lathe accessories used in metal cutting and machine tools. It describes chucks (3-jaw, 4-jaw, collet, magnetic, hydraulic), face plates, angle plates, driving plates, lathe dogs, follower rests, steady rests, and mandrels. The accessories are used to properly hold and support workpieces and tools. Chucks clamp workpieces, face plates hold irregular shapes, dogs rotate workpieces, and rests support tubes or long workpieces during turning. Mandrels mount hollow workpieces. The document provides details on the construction and use of various lathe accessories.
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