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Cutting Technology – chip removing – the largest class of manufacturing activities in engineering production – ~1.87 million machine tools – ~$168 billion - the total value of the machining operation – numerical control of machine tools – flexible manufacturing

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Page 1: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

Cutting Technology

– chip removing

– the largest class of manufacturing activities in engineering production

– ~1.87 million machine tools

– ~$168 billion - the total value of the machining operation

– numerical control of machine tools

– flexible manufacturing

Page 2: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Single point tool operations– turning, boring, planing, and shaping

Page 3: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– the peripheral speed of the workpiece - the cutting speed

– the mean value

– the depth of cut is

– the metal removal rate is

• b- chip width

• h- chip thickness

• fr - feed per revolution

ndndv 2211 π v π

2

π 21 ddnvm

2

21 ddd

vfravhbvAQ

Page 4: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 5: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Tool geometry - the side cutting edge angle

– the tool consists of a cutting insert and a tool holder

Page 6: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 7: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 8: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 9: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 10: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• The tools

Page 11: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• boring tools

Page 12: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• classical system

Page 13: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 14: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 15: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 16: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 17: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 18: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

•7 - turn a taper•8 - rough turn a tapered thread•9 - finish the thread•10 - drill a short hole•11 - bore the hole to a larger and more accurate diameter•12 - cut an internal groove•13 - cut a short thread in the end of the hole

Page 19: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 20: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 21: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Automated machine tools– lead, set, clamp, and change tools

– control the path of the tool relative to the workpiece

– carry out measurements

Page 22: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 23: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Drilling operations

Page 24: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 25: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 26: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 27: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 28: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– the metal removal rate:

• d - hole diameter

• fr - feed rate (feed per revolution)

• n - rotational speed

– the chip area for each edge:

• ft = fr/2 = feed per tooth

– the tangential force in the direction of the cutting speed v is:

– the torque is:

– the power is:

• Ks - specific force

frnA

dQ

2

2

dftA

A

frdKs

ftdKsFt

2

)Nm(100082

2

frdKsd

FtT

QKsnfrdKs

nTTwP

4000

22

Page 29: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

Drilling Machines

Page 30: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– the positioning of the spindle relative to the workpiece for the proper location of the hole

– if the location is specified to a close tolerance, this cannot be accomplished manually without additional aids

Page 31: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– jig boring machines

• accurately positioned x, y coordinate motions to drill and bore holes in jigs with precise positions

• economical for medium size series of workpieces

• small-lot production on NC drilling machines

• mass production - use multispindle drilling machines as a part of a transfer line

Page 32: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Multipoint tool operations

Page 33: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 34: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 35: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 36: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– the tooth period:

– the mean metal removal rate is:

– ar - the radial depth of cut

– aa - the axial depth of cut

– f - feed rate

– the mean power is:

nmTt

1

faaQMRR arm

QKsP

Page 37: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 38: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 39: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 40: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 41: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Ways of clamping milling cutters

Page 42: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 43: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 44: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 45: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

• Broaching– motion: rectilinear

– no feed motion

– the teeth on the tool are so arranged that they increase in height

– the operation is carried out in one pass

– suited to mass production of surfaces that are straight in at lease one direction

– for machining internal and external surfaces

– gears

Page 46: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 47: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 48: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion
Page 49: Cutting Technology –chip removing –the largest class of manufacturing activities in engineering production –~1.87 million machine tools –~$168 billion

– the geometry of the broach completely determines the whole operation

– the machine supplies one linear cutting motion

– pull

– push type machine

– specialized (workpiece moves while the tool is stationary)


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