Professional Documents
Culture Documents
Machines&Machining
Issues
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#1
GATEWAY
MaterialRemovalProcess
Mechanical Machining
Turning
Milling
Drilling
Grinding
All hard materials
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#2
GATEWAY
MachiningDOF(DegreesofFreedom)
DOF- # of independently controllable axes of motion-- excluding spindle
rotation or tool translation responsible for cutting.
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TurningOperations
Turning(Performedonlathe)
Partismovingandtoolisstationary.
Usedtomakepartsofroundcrosssection
Screws,shafts,pistons....
Numberofvariouslatheoperations
Turning,facing,boring,drilling,parting,threading
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#4
GATEWAY
LatheComponents
MachineComponents(Mainitems)
Bed:Supportsallothermachineparts
Carriage:Slidesalongthemachineways
Headstock:Powertrainofsystem(spindleincluded)
TailStock:Fixespieceatendoppositetothehead
stock
Swing:Maximumdiameterofthemachinablepiece
Leadscrew:controlsthefeedperrevolutionwitha
greatdealofprecision
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#5
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Lathe
Spindle
Speed
Selector
Headstock
Spindle
Ways
Tool Post
Cross Slide
Carriage (saddle)
Center Tailstock quill
Feed change
gear box
Compound
Rest &
Slide (swivels)
Tailstock
Apron Bed
Lead
Screw
Feed
Rod
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#6
Ref: Fig. 8.52, Kalpakjian. Manufacturing Processes for Engineering Materials 2nd Ed, Addison-Wesley 1991.
GATEWAY
LatheTools
Lathetools
Lefthanded
Righthanded
Threading
Boring
Groove
Parting(CutOff)
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#7
GATEWAY
LatheOperations
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#8
Ref: Fig. 8.51, Kalpakjian. Manufacturing Processes for Engineering Materials 2nd Ed, Addison-Wesley 1991.
GATEWAY
CuttingSpeeds
TypicalLatheCuttingSpeeds
Nominally30800ft./min.
Roughingcuts
Depthofcutgreaterthen.02in
Feedspeedof.008.08in/rev.
FinishingCuts
Lowerthanroughingcuts.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#9
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Milling
TypesofMillingMachines
HorizontalMillingMachine
VerticalMillingMachine
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#10
GATEWAY
MillCuttingDirection
Cutting direction- Depending on the orientation of the workpiece
feed w.r.t. the rotation of the cutting tool.
Conventional (Up) Milling- Maximum thickness of chip at end of cut
Ref: Figure J-48, Kibbe ,et al. Machine Tool
Practices 5th Ed, Prentice Hall,1995.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#11
GATEWAY
VerticalKneeMillingMachine
Base and Column- support structure
Knee- Connected to slide on column- can
move up and down
Saddle- Engages slide on top of knee- can
be moved in and out.
Table- Engages slide atop of saddlemoved lengthwise. Holds workpiece.
Ram- Engages swiveling slide atop
column.
Toolhead- Attached to end of ram,
contains motor and quill.
Quill- Non rotating, but contains rotating
spindle. Can be moved up and down.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#12
Ref: Kibbe ,et al. Machine Tool Practices 5th Ed, Prentice Hall,1995, p 550-551
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VerticalMillingMachine
Flexible
Versatile
Newermachines
moreDOF
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#13
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BedMill
Similartoverticalkneemillingmachines
Lessversatilethankneemill
NokneeBeddoesnotmoveupanddown
Verticalmotionpossibleinheadonly
Controllablerangeofmotionofheadlargerthanin
kneemill(totalrangeofmotionless)
Bedmillstifferthankneemill
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#14
GATEWAY
VerticalMillingApplications
Collet
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#15
Ref:ProcessSelection,KGSwiftandJDBooker,p.98.
GATEWAY
ScallopHeightw/BallNosedEndMill
R
y
h
s
d
x
s 2
2
Thus h=R R 2
(if hd)
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#16
GATEWAY
ScallopHeightBallNoseonanIncline
Edge of cutter described by
x12 +y12 =R2
On previous pass it was
s 2 2
x2 +
+y2 =R2
cos(
)
s
x=
2cos(
)
h=R
x
R
h
s
(if hd)
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#17
s
y= R2
2cos(
)
2
s
2cos(
)
R2
GATEWAY
HorizontalMillingMachine
COMPONENTS
Base & Column
Knee
Saddle
Table
Spindle
Overarm & Arbor Support
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#18
Ref: Figure 8.68, Kalpakjian. Manufacturing Processes for Engineering Materials 2nd Ed, Addison-Wesley 1991.
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TypesHorizontalMillingOperations
Slab- Axis of cutter //
to workpiece surface
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#19
GATEWAY
Drilling
Any component requiring cylindrical holes.
Engine Blocks, Machine Components
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#20
Ref:ProcessSelection,KGSwiftandJDBooker,p.104.
GATEWAY
GrindingandAbrasiveProcesses
Abrasive Processes- Generally slower (more
expensive) than other traditional machining
processes. Used on very hard materials, and can
achieve HIGH (virtually unmatched) levels of
precision and finish.
Grinding
Deburring
Honing
Polishing
Lapping
Superfinishing
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#21
GATEWAY
GrindingMachines
Pedestal Grinder
Surface Grinder
Type I- Horizontal spindle w/ reciprocating table
Type II- Horizontal spindle w/ rotary table
Type III- Vertical spindle, table either reciprocates or rotates (blanchard)
Cylindrical Grinder
Center-type
Roll-type- workpiece in bearings rather than on centers
Centerless Grinder- workpiece supported on rest blade, grinding wheel
on one side, regulating wheel on the other
Internal Cylindrical Grinder
Tool Cutting Grinders
Specialty Grinders
Form Grinders and Generating Types
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#22
GATEWAY
SurfaceGrinders
Type I
Type II
Reciprocating
Table
Type III
Rotating
Table
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#23
Ref:
Figures N-1, N-3,N-4, & N-5, Kibbe ,et al. Machine Tool Practices 5th Ed, Prentice Hall,1995.
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CylindricalGrinders
Centerless Type
Center/Roll Type
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#24
Ref: Figures N-8, N-17, N-18, Kibbe ,et al. Machine Tool Practices 5th Ed, Prentice Hall,1995.
GATEWAY
SurfaceRoughness
Surface roughness is generally described with 1 of 2 methods
Ra- Arithmetic Mean Value- the average of the absolute values
of the deviations from the center line of the surface
(n
Ra= |a|+|b|+|c|+|d|+
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#25
GATEWAY
RoughnessUnits
Both generally given in micrometers (microns) or
microinches
1Micrometer=1m=1micron=106meters
1Microinch=1in=106inches
1in=0.025m
1m=40in
Humanhair~40m
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#26
GATEWAY
TypicalArithmeticAverageRoughness
Process
micrometers
microinches
Flame Cutting
Snagging (Coarse Grinding)
Sawing
Planing, Shaping
50
25
12.5
2000 1000 500
6.3
250
3.2
125
1.6
63
0.8
32
0.4
16
0.2
8
0.1
4
Average Application
Less Frequent Application
Drilling
Chemical Machining
Electrical-discharge Machining
Milling
Broaching
Reaming
Electron-beam Machining
Laser Machining
Electrochemical Machining
Turning, Boring
Barrel Finishing
Electrochemical Grinding
Roller Burnishing
Grinding
Honing
Electropolishing
Polishing
Lapping
Superfinishing
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#27
Ref: Fig. 8.35, Kalpakjian. Manufacturing Processes for Engineering Materials 2nd Ed, Addison-Wesley 1991.
GATEWAY
Summary
Fourtypesofmechanicalremoval
processes
Turning
Milling
Drilling
Grinding
Finishofworkpiece
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#28
GATEWAY
Credits
Thismoduleisintendedasasupplementtodesignclassesinmechanical
engineering.ItwasdevelopedatTheOhioStateUniversityundertheNSF
sponsoredGatewayCoalition(grantEEC9109794).Contributingmembers
include:
GaryKinzel..Projectsupervisor
ChrisHubertandAlanBonifas.....Primaryauthors
PhuongPhamandMattDetrick...Modulerevisions
L.Pham....Audiovoice
References:
Kalpakjian, Manufacturing Processes for Engineering Materials 2nd Ed,
Addison-Wesley 1991
Kibbe ,et al. Machine Tool Practices 5th Ed, Prentice Hall,1995
Swift,KGandJDBooker, ProcessSelection,Arnold/JohnWiley&SonsInc.,
NewYork,1997
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#29
GATEWAY
Disclaimer
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DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#30