Chip-Type Machining Processes

General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

Chip-Type Machining Processes Class 1

Machining - Removing unwanted material from a workpiece in the form of chips US industries spend $60 billion a year on metal removal processes Most products require some type of machining
Direct
Add value = drill hole, mill pocket, etc. Rough (cleanup sand castings) to high precision (.0001)

Indirect
molds, dies, jigs, fixtures
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Why Machining Process vs. Other Manufacturing Processes

Accuracy is not obtainable by other methods Repeatability - interchangeable manufacturing Design requirements
Tolerance, surface finish, mechanical strength requirements

Low order quantity Manufacturing firms capabilities

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Process Basics

Machine Tool
A piece of equipment designed to accomplish a specific process.
Example - a milling machine, injection molding machine, lathe, etc.

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Process Basics
Conventional

Computer Numerical Control

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Process Basics

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Process Basics
Conventional

Computer Numerical Control

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Process Basics

Combination Conventional / CNC

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Process Basics

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Process Basics

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Process Basics

Machining Process
Changes the value and quality of the raw material. A process typically involves a series of steps or operations and utilizes a machine tool.
Examples include turning, milling, drilling, etc.

Operation
A distinct action being performed to produce a desired effect.
Material handling, packaging, inspection, drilling, threading
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Process Basics

Tools
Refers to devices used to cut or deform the metal.
Cutting tools - examples include end mills, carbide inserts, drills, grinding wheels, shell mills, etc.

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Process Basics

Tooling
Refers to holding devices
Examples include- vises, fixtures, jigs...etc.

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Process Basics

Cutting fluid
Act as a coolant and lubricant Reduce friction between chip and tool face Extend tool life Help to remove chips from cutting area

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Seven Basic Chip Formation Processes

Shaping Turning Milling Drilling Sawing Broaching Abrasive Machining

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Seven Basic Chip Formation Processes

Turning

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Seven Basic Chip Formation Processes

Milling

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Seven Basic Chip Formation Processes

Drilling

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Seven Basic Chip Formation Processes

Sawing

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Seven Basic Chip Formation Processes

Broaching

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Seven Basic Chip Formation Processes

Abrasive Machining

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Metal Removal Related Calculations

To efficiently use these components, different input parameters have to be calculated. They include:
RPM of cutter
Milling or drilling operation = Rpm for cutter Turning operation = Rpm for part Basically the rotating component

Feed
The distance in inches, feet, or millimeters per minute that the work advances into the cutter. Rensselaer Polytechnic Institute
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Metal Removal Related Calculations

Input parameters (cont)

Cutting speed(CS)-the surface feet per minute or meters per minute, at which a metal can be machined efficiently. This variable has a direct relationship to the diameter of the cutter, in a milling or drilling operation, or the diameter of the work piece in a lathe operation.
Example - When machining(using a milling machine) a medium grade steel, the cutter must achieve a surface speed of about 90 ft/min. The diameter of the cutter will have a direct relationship to the rpm calculation. Rensselaer Polytechnic Institute
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Metal Removal Related Calculations

Input parameters (cont)

Depth of cut - Amount of material being removed. Horsepower required for cut Material removal rate (MRR) - volume of material being removed per unit of time In a milling operation, you also have to take into account the thickness of the chip each tooth will remover per revolution as it advances into the work. This value is expressed in feed per tooth.
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Metal Removal Problem

1. Cutting Tools 4.

2.
3.
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Metal Removal Problem

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Factors Effecting Calculations

Set-up conditions Machine conditions Tooling conditions Material conditions Cutting fluid

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