this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
this presentation tries to explain the various heat zones that are developed during the metal cutting process. furthermore, how much heat is dissipated from the various zones. lastly the possible methods of temperature reduction in brief.
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
this presentation tries to explain the various heat zones that are developed during the metal cutting process. furthermore, how much heat is dissipated from the various zones. lastly the possible methods of temperature reduction in brief.
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
Theory of Metal cutting - Principles of Metal cutting, orthogonal and oblique cutting, Merchant circle diagram, cutting forces, power requirements, Economics of machining,problems
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Fundamentals of Metal cutting and Machining Processes
MACHINING OPERATIONS AND MACHINING TOOLS
Turning and Related Operations
Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
High Speed Machining
Surface roughness metrology deals with basic terminology of surface,surface roughness indication methods,analysis of surface traces, measurement methods,surface roughness measuring instruments such as Stylus Probe Instrument, Profilometer, Tomlinson Surface Meter ,The Taylor-Hobson Talysurf etc.This is very useful for diploma,degree engineering students of mechanical,production,automobile branch
A tool that has a single point for cutting purpose is called single point cutting tool. It is generally used in the lathe machine, shaper machine etc. It is used to remove the materials from the workpiece.
This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
Dynamo meters are the electronic devices that are widely used to the purpose of force analysis in various field of operations. There is various types of dynamometers such as
Lathe tool dynamometer
Milling tool dynamometer
Drilling tool dynamometer
Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting tools– nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear, tool life, surface finish, cutting fluids and Machinability.
Theory of Metal cutting - Principles of Metal cutting, orthogonal and oblique cutting, Merchant circle diagram, cutting forces, power requirements, Economics of machining,problems
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Fundamentals of Metal cutting and Machining Processes
MACHINING OPERATIONS AND MACHINING TOOLS
Turning and Related Operations
Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
High Speed Machining
Surface roughness metrology deals with basic terminology of surface,surface roughness indication methods,analysis of surface traces, measurement methods,surface roughness measuring instruments such as Stylus Probe Instrument, Profilometer, Tomlinson Surface Meter ,The Taylor-Hobson Talysurf etc.This is very useful for diploma,degree engineering students of mechanical,production,automobile branch
A tool that has a single point for cutting purpose is called single point cutting tool. It is generally used in the lathe machine, shaper machine etc. It is used to remove the materials from the workpiece.
This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
Dynamo meters are the electronic devices that are widely used to the purpose of force analysis in various field of operations. There is various types of dynamometers such as
Lathe tool dynamometer
Milling tool dynamometer
Drilling tool dynamometer
Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting tools– nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear, tool life, surface finish, cutting fluids and Machinability.
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
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
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See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
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The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
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Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
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https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
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https://alandix.com/academic/papers/synergy2024-epistemic/
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https://arxiv.org/abs/2306.08302
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• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
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Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
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https://www.rttsweb.com/jmeter-integration-webinar
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Theory of metal cutting
1.
2. 1. Overview of Machining Technology
2. Theory of Chip Formation in Metal
Machining
3. Force Relationships and the Merchant
Equation
4. Power and Energy Relationships in
Machining
5. Cutting Temperature
3. A family of shaping operations, the common feature
of which is removal of material from a starting
workpart so the remaining part has the desired
geometry
Machining – material removal by a sharp cutting
tool, e.g., turning, milling, drilling
Abrasive processes – material removal by
hard, abrasive particles, e.g., grinding
Nontraditional processes - various energy
forms other than sharp cutting tool to remove
material
4. Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
(a) A cross sectional view of the machining process, (b) tool with‑
negative rake angle; compare with positive rake angle in (a).
Machining
5. Variety of work materials can be machined
◦ Most frequently used to cut metals
Variety of part shapes and special geometric
features possible, such as:
◦ Screw threads
◦ Accurate round holes
◦ Very straight edges and surfaces
Good dimensional accuracy and surface finish
6. Wasteful of material
◦ Chips generated in machining are wasted material, at
least in the unit operation
Time consuming
◦ A machining operation generally takes more time to
shape a given part than alternative shaping processes,
such as casting, powder metallurgy, or forming
7. Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
◦ Other processes create the general shape of the
starting workpart
◦ Machining provides the final shape, dimensions, finish,
and special geometric details that other processes
cannot create
8. Speed is the relative movement between tool and
w/p, which produces a cut
Feed is the relative movement between tool and
w/p, which spreads the cut
9. Most Important Machining Operations:
◦ Turning
◦ Drilling
◦ Milling
Other Machining Operations:
◦ Shaping and Planing
◦ Broaching
◦ Sawing
10. Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
Three most common machining processes: (a) turning,
Turning
11. Used to create a round hole, usually by means of
a rotating tool (drill bit) with two cutting edges
Drilling
12. Rotating multiple-cutting-edge tool is moved across
work to cut a plane or straight surface
Two forms: peripheral (side) milling and face
(end) milling
(c) peripheral milling, and (d) face milling.
Milling
13. 1. Single-Point Tools
◦ One dominant cutting edge
◦ Point is usually rounded to form a nose radius
◦ Turning uses single point tools
2. Multiple Cutting Edge Tools
◦ More than one cutting edge
◦ Motion relative to work achieved by rotating
◦ Drilling and milling use rotating multiple cutting edge
tools
14. (a) A single point tool showing rake face, flank, and tool point; and (b)‑
a helical milling cutter, representative of tools with multiple cutting
edges.
Cutting Tools
15. Three dimensions of a machining
process:
◦ Cutting speed v – primary motion
◦ Feed f – secondary motion
◦ Depth of cut d – penetration of tool below
original work surface
For certain operations, material
removal rate can be computed as
RMR = v f d
where v = cutting speed; f = feed; d =
depth of cut
17. In production, several roughing cuts are usually taken
on the part, followed by one or two finishing cuts
Roughing - removes large amounts of material from
starting workpart
◦ Creates shape close to desired geometry, but leaves
some material for finish cutting
◦ High feeds and depths, low speeds
Finishing - completes part geometry
◦ Final dimensions, tolerances, and finish
◦ Low feeds and depths, high cutting speeds
18. A power‑driven machine that performs a machining
operation, including grinding
Functions in machining:
◦ Holds workpart
◦ Positions tool relative to work
◦ Provides power at speed, feed, and depth that have
been set
The term is also applied to machines that perform
metal forming operations
19. where r = chip thickness ratio; to
= thickness
of the chip prior to chip formation; and tc
=
chip thickness after separation
Chip thickness after cut is always
greater than before, so chip ratio always
less than 1.0
c
o
t
t
r =
21. Based on the geometric
parameters of the orthogonal
model, the shear plane angle φ can
be determined as:
where r = chip ratio, and α = rake angle
α
α
φ
sin
cos
tan
r
r
−
=
1
22. Figure 21.7 Shear strain during chip formation: (a) chip formation
depicted as a series of parallel plates sliding relative to each other, (b)
one of the plates isolated to show shear strain, and (c) shear strain
triangle used to derive strain equation.
Shear Strain in Chip Formation
23. Shear strain in machining can be
computed from the following equation,
based on the preceding parallel plate
model:
γ = tan(φ - α) + cot φ
where γ = shear strain, φ = shear plane
angle, and α = rake angle of cutting tool
24. Friction force F and Normal force to friction N
Shear force Fs
and Normal force to shear Fn
Forces in metal cutting:
(a) forces acting on the
chip in orthogonal cutting
Forces Acting on Chip
25. Vector addition of F and N = resultant R
Vector addition of Fs
and Fn
= resultant R'
Forces acting on the chip must be in balance:
◦ R' must be equal in magnitude to R
◦ R’ must be opposite in direction to R
◦ R’ must be collinear with R
36. Thus equations can be derived to relate the forces
that cannot be measured to the forces that can be
measured:
F = Fc
sinα + Ft
cosα
N = Fc
cosα ‑ Ft
sinα
Fs
= Fc
cosφ ‑ Ft
sinφ
Fn
= Fc
sinφ + Ft
cosφ
Based on these calculated force, shear stress and
coefficient of friction can be determined
37. Significance of Cutting forces
In the set of following force balance equations:-
F = Fc sin α + Ft cos α F = friction force; N = normal to chip force
N = Fc cos α - Ft sin α Fc = cutting force; Ft = thrust force
Fs = Fc cos φ - Ft sin φ Fs = shear force; Fn = normal to shear plane force
Fn = Fc sin φ + Ft cos φ
Friction angle = β
tan β = µ = F/N
Shear plane stress:
τ = Fs/As
where
As = to w/sin φ
Forces are presented as function ofForces are presented as function of
FFcc and Fand Ftt because these can bebecause these can be
measured.measured.
Forces are presented as function ofForces are presented as function of
FFcc and Fand Ftt because these can bebecause these can be
measured.measured.
38. Shear stress acting along the shear plane:
φsin
wt
A o
s =
where As
= area of the shear plane
Shear stress = shear strength of work material during cutting
s
s
A
F
S =
39. Cutting forces given shear strength
Letting S = shear strength, we can derive the following
equations for the cutting and thrust forces*:
Fs = S As
Fc = Fs cos ( β − α)/[cos ( φ + β − α)]
Ft = Fs sin ( β − α)/[cos ( φ + β − α)]
* The other forces can be determined from the equations on the previous
slide.
40. Machining example
In orthogonal machining the tool has rake angle 10°, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear strain):
Determine r = 0.02/0.045 = 0.444
Determine shear plane angle from tan φ = r cos α /[1 – r sin α]
tan φ = 0.444 cos 10 /[1 – 0.444 sin 10] => φ = 25.4°
Now calculate shear strain from γ = tan(φ - α) + cot φ
γ = tan(25.4 - 10) + cot 25.4 = 2.386 in/in answer!
41. Machining example (cont.)
In orthogonal machining the tool has rake angle 10°, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear stress):
Determine shear force from Fs = Fc cos φ - Ft sin φ
Fs = 350 cos 25.4 - 285 sin 25.4 = 194 lb
Determine shear plane area from As = to w/sin φ
As = (0.02) (0.125)/sin 25.4= 0.00583 in2
The shear stress is
42. Machining example (cont.)
In orthogonal machining the tool has rake angle 10°, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (cutting horsepower):
Determine cutting hp from hpc = Fc v/33,000
hpc = (350) (200)/33,000 = 2.12 hp answer!
43. Shear Plane Angle Ф = tan-1
[(r cos α )/(1 – r sin α)]
Shear Strain γ = tan(φ - α) + cot φ
Forces in Cutting:
F = Fc sinα + Ft cosα
N = Fc cosα ‑ Ft sinα
Fs = Fc cosφ ‑ Ft sinφ
Fn = Fc sinφ + Ft cosφ
Forces Fc and Ft in terms of Fs:
Fc = Fs cos ( β − α)/[cos ( φ + β − α)]
Ft = Fssin ( β − α)/[cos ( φ + β − α)]
Merchant Relation:
φ = 45 + α/2−β/2
Shear Stress:
τ = Fs/As
where As = to w/sin φ
Cutting Power:
P = V Fc / 33,000 hp (V in ft /s and Fc in lb)
P = V Fc / 1000 kW (V in m /s and Fc in N)
PG = Pc / E