ME 143 - WORKSHOP TECHNOLOGY

Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

ME 143 WORKSHOP PRACTICE II

SPRING 2010 Lecture 1: Introduction
Instructor
Asst. Prof. Rizwan Arshad Department of Mechanical & Aerospace Engineering Institute of Avionics & Aeronautics (IAA) AIR University, E-9 Islamabad

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ME 143 - WORKSHOP TECHNOLOGY

Introduction
Metal cutting operations are carried out in a machine shop using machine tools Leading manufacturing industries (aerospace, automobiles Metal Cutting etc) use state of the art machine tools to manufacture their products A machine tool is a metal cutting machine. Conventional Lathe Machine machine tools are, Lathe machine Drilling Shaper Machine Planer Slotter Milling Machine Drill press Milling machine Shaper Grinding machine etc.
Introduction

[A typical machine shop]

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ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

In metal cutting on a machine tool, relative motion b/w cutting tool and job changes the size and shape of the workpiece Due to the interaction between workpiece and cutting tool, material is removed in the form of shaving or swarf commonly known as chip On the basis of tool orientation, cutting operation can be classified into two Orthogonal cutting Oblique cutting

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ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Motions of tool & workpiece]

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ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Motions of tool & workpiece]

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ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Metal cutting operation] 6

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Metal Cutting
CUTTING TOOL
Introduction

Body having teeth or cutting edges on it e.g. lathe, shaper, planner & boring tool

Metal Cutting Single point cutting tool has only one cutting edge Lathe Machine Drilling Machine Milling Machine Shaper

Multi-point cutting tool has a number of teeth or cutting edges on its periphery e.g. milling cutter, drill, reamer and broach

[Single point cutting tool]

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[Multiple point cutting tool. A drill bit] 7

ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
SINGLE POINT CUTTING TOOL
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

A typical geometry of single point cutting tool comprises of nose, rake face, flank, heel and shank

[Geometry of a single point cutting tool]

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Metal Cutting
TYPES OF SINGLE POINT CUTTING TOOL Solid type of single point cutting tool (made of HSS) Tipped type single point cutting tool (HSS, cemented carbide) Metal Cutting Index able insert type single point cutting tool
Lathe Machine Drilling Machine Milling Machine Shaper
(a) (b) (c)

Introduction

[(a) Solid type of single point cutting tool (b) Tipped type single point cutting tool (c) Index able insert type single point cutting tool]
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ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction Back rake angle (Positive or Negative) Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

Angle between the face of the tool and a line parallel with base of the tool measured in a perpendicular plane through the side cutting edge Helps to remove chips away from the work piece
Side View

Side View
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[Back Rake Angle] 10

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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

Back rake angle (Positive or Negative)

Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[http://www.mmsonline.com/cdn/cms/Fig.%204%20-%20Chip%20formation.gif]
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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

Side rake angle Provides clearance between work piece and tool so as to prevent the rubbing of work- piece with end flake of tool
End View

Metal Cutting Angle by which the face of tool is inclined side ways. Lathe Machine Drilling Machine Milling Machine Shaper

End View
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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

End relief angle the cutting edge and a line perpendicular to the base of the tool, measured at right angles to the flank

Metal Cutting Angle between the portion of the end flank immediately below Lathe Machine Drilling Machine Milling Machine Shaper

Allows the tool to cut without rubbing on the work- piece

Side View

Side View
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[End relief angle] 13

ME 143 - WORKSHOP TECHNOLOGY

Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

Side relief angle the side edge and a line perpendicular to the base of the tool measured at right angles to the side

Metal Cutting Angle between the portion of the side flank immediately below Lathe Machine Drilling Machine Milling Machine Shaper

Prevents the interference as the tool enters the material

End View

End View
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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

End cutting edge angle to the shank of the tool Provides clearance between tool cutting edge and work piece
Top View Top View

Metal Cutting Angle between the end cutting edge and a line perpendicular Lathe Machine Drilling Machine Milling Machine Shaper

[End Cutting Edge Angle]

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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction

Side cutting edge angle the side of the shank. It is also known as lead angle Responsible for turning the chip away from the finished surface
Top View Top View

Metal Cutting Angle between straight cutting edge on the side of tool and Lathe Machine Drilling Machine Milling Machine Shaper

[Side Cutting Edge Angle]

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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL Nose radius Connects the side cutting edge & end cutting edge Metal Cutting Responsible for generating surface finish on the work-piece
Lathe Machine Drilling Machine Milling Machine Shaper
Top View Top View

Introduction

[Nose Radius]
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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Elements of tool signature or nomenclature of single point tool]

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Metal Cutting
NOMENCLATURE SINGLE POINT CUTTING TOOL
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Elements of tool signature or nomenclature of single point tool]

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Metal Cutting
TOOL SIGNATURE SINGLE POINT CUTTING TOOL Angles that a tool utilizes during the cut. It specifies the active angles of the tool normal to the cutting edge Metal Cutting Valid as long as the tool shank is mounted at right angles to the work-piece axis.
Lathe Machine Drilling Machine Milling Machine Shaper Introduction

The seven elements that comprise the signature are, Tool signature 0-7-6-8-15-16-0.8 1. Back rake angle (0) 2. Side rake angle (7) 3. End relief angle (6) 4. Side relief angle (8) 5. End cutting edge angle (15) 6. Side cutting edge angle (16) 7. Nose radius (0.8 mm)
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Metal Cutting
MECHANICS Workpiece is clamped in machine tool vice A wedge shaped cutting tool is set to move against the Metal Cutting workpiece with certain depth of cut By moving the tool against the workpiece, the surface Lathe metal is compressed and split from the workpiece Machine Unwanted metal is removed by sliding the sheared metal against the cutting tool Drilling Removed metal takes the form of chips Machine
Milling Machine Shaper Introduction

[Metal cutting operation]

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Metal Cutting
MECHANICS-ORTHOGONAL CUTTING
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Schematic illustration of a two-dimensional cutting process, also called orthogonal cutting]

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Metal Cutting
MECHANICS-ORTHOGONAL CUTTING
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper
-Cutting force , Fc -Thrust force , Ft -Normal force , N -Friction force , F -Resultant force , R -Shear force , Fs, at the shear plane -Normal force , Fn, at the shear plane

[Forces acting on a cutting tool in two-dimensional cutting. Note that the resultant force, R, must be colinear to balance the forces.]
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Metal Cutting
MECHANICS OBLIQUE CUTTING
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

[Schematic illustration of cutting with an oblique tool. (b) Top view showing the inclination angle, i. (c) Types of chips produced with different inclination]
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Metal Cutting
TYPES OF CHIPS Metal Cutting
Lathe Machine Introduction

Continuous Built up edge Serrated or segmented Discontinuous

Drilling Machine Milling Machine Shaper

[Continuous chips, Discontinuous Chips, BUE]

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Metal Cutting
TYPES OF CHIPS
Introduction

Continuous Chip Formation A good surface finish is generally produced Not always desirable, particularly get tangled around the tool Need to be remove during the cutting operation

Metal Cutting Usually formed at high rake angles and/or high cutting speeds Lathe Machine Drilling Machine Milling Machine Shaper

[Continuous Chip Formation Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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Metal Cutting
TYPES OF CHIPS
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

Continuous Chip Formation

[Continuous Chip Formation. Secondary shear zone Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]
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Metal Cutting
TYPES OF CHIPS
Introduction Built Up Edges (BUE) Metal Cutting layers of material are deposited over from the workpiece on Lathe Machine Drilling Machine Milling Machine Shaper

the tool. Unstable and therefore breaks BUE material is carried away on the tool side of the chip Rest is deposited randomly on the workpiece surface. Results in poor surface finish Reduced by increasing the rake angle & therefore decreasing the depth of cut

[BUE. Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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Metal Cutting
TYPES OF CHIPS
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

Built Up Edges

[BUE. Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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Metal Cutting
TYPES OF CHIPS
Introduction

Segmented or Serrated Chips Low thermal conductivity and strength metals exhibit this behavior

Metal Cutting Semi continuous chips with zones of low and high shear strain Lathe Machine Drilling Machine Milling Machine Shaper

[Segmented chips. Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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Metal Cutting
TYPES OF CHIPS
Introduction

Discontinuous loosely attached to each other These chips occur when machining hard brittle materials such as cast iron. Brittle failure takes place along the shear plane before any tangible plastic flow occurs Discontinuous chips will form in brittle materials at low rake angles (large depths of cut).

Metal Cutting Discontinuous chips consist of segments that may be firmly or Lathe Machine Drilling Machine Milling Machine Shaper

[Discontinuous chips. Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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Metal Cutting
TYPES OF CHIPS
Introduction Metal Cutting Lathe Machine Drilling Machine Milling Machine Shaper

Discontinuous

[Discontinuous chips Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.]

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