Manufacturing Processes (2), Ie-352 Ahmed M El-Sherbeeny, PHD Spring 2018
Manufacturing Processes (2), Ie-352 Ahmed M El-Sherbeeny, PHD Spring 2018
Manufacturing Processes (2), Ie-352 Ahmed M El-Sherbeeny, PHD Spring 2018
1. Introduction
2. Milling and Milling Machines
3. Planing and Shaping
4. Broaching and Broaching Machines
5. Sawing
6. Gear Manufacturing by Machining
Introduction
3
Typical parts and shapes that can be produced with machining processes
described in this chapter. Can you guess how a) – f) are produced?
Peripheral
milling:
(a) slab milling
(b) slotting
(c) side milling
(d) straddle milling
(e) form milling
Milling and Milling Machines:
8
Peripheral Milling
Orthogonal vs. oblique cutting (milling)
Cutters have straight or helical teeth
result in orthogonal or oblique cutting
Helical teeth preferred since:
teeth partially engaged with workpiece
lower and torque on cutter
smoother operation, reduced chatter
in slab milling:
Varies along its length (due to relative longitudinal motion
between cutter and workpiece)
As ↑ ↑
For straight-tooth cutter, approx. undeformed (chip depth of
cut):
Milling and Milling Machines:
13
Peripheral Milling
Milling
Parameters
: distance workpiece travels per tooth of cutter:
𝒎𝒎 /𝒓𝒆𝒗
𝜋 𝐷𝑁
Milling and Milling Machines:
16
Peripheral Milling
EXAMPLE 24.1
Material-removal Rate, Power, Torque, and Cutting
Time in Slab Milling
A slab-milling operation is being carried out on a 300-mm-
long, 100-mm-wide annealed mild-steel block at a feed f
0.25 mm/tooth and a depth of cut d 3.0 mm. The cutter is
D=50 mm in diameter, has 20 straight teeth, rotates at
100rpm and, by definition, is wider than the block to be
machined. Calculate the material-removal rate, estimate
the power and torque required for this operation, and
calculate the cutting time.
Torque
Power
7500 60 716 Nm
Rotational Speed 100 2
The cutting time is
Dimensions in face milling
Conventional milling (note, width of cut, , is not
necessarily the same as
cutter radius, )
Note,
can be approximated using:
Climb milling ratio should be no less than (typical face milling)
Milling and Milling Machines:
21
Face Milling
Relative motion between cutter teeth and workpiece
feed marks on machined surface (↓)
Note, these marks are similar to those left by turning
Roughness of workpiece depends on: corner geometry and
Feed marks due to
various insert shapes
Milling and Milling Machines:
22
Face Milling
Face-milling cutter: terminology and various angles:
2 cutting angles (side/corner and end)
2 rake angles (axial and radial)
2 relief angles (axial and radial)
Terminology of a
face-milling cutter
Milling and Milling Machines:
23
Face Milling
Lead angle: of insert in face milling
Has direct influence on the undeformed chip thickness,
As lead angle ↑
↓ ( chip thickness ↓)
but length of contact ( width of chip): ↑
but cross-sectional area of remains constant
Lead angles usually:
Note, insert must be large to accommodate ↑ in contact length
Milling and Milling Machines:
24
Face Milling
Relation between cutter and workpiece (↓):
This determines angle at which insert enters & exits workpiece
Tip of insert makes First contact is at an Insert exits workpiece Insert exits
first contact ( angle, away from at an angle ( force on workpiece
possible for cutting insert tip ( lower insert reduces to zero at suddenly
edge to chip off) tendency of insert to a slow rate) (undesirable
fail) for tool life)
Milling and Milling Machines:
25
Face Milling
EXAMPLE 24.2
Material-removal Rate, Power Required, and Cutting
Time in Face Milling
Assume that D = 150 mm, w = 60 mm, l = 500 mm, d = 3
mm, v = 0.6 m/min and N = 100 rpm. The cutter has 10
inserts, and the workpiece material is a high-strength
aluminum alloy. Calculate the material-removal rate,
cutting time, and feed per tooth, and estimate the power
required.
Milling and Milling Machines:
26
Face Milling
Solution
Material-removal Rate, Power Required, and Cutting
Time in Face Milling
The material-removal rate is
MMR 180 600 108,000 mm 3 / min
Straddle milling:
Two or more cutters: mounted on an arbor
Used to machine 2 surfaces on workpiece
Form milling:
Produces curved profiles
Uses cutters with specially shaped teeth
Also used for cutting gear teeth
Milling and Milling Machines:
Other Milling Operations and Milling Cutters
30
Slotting & Slitting operations:
Performed with circular cutters
Slitting saws: thin (usu. < )
T-slot cutters:
Used to mill T-slots
Application: machine-tool worktables
for clamping workpieces
Step 1: slot is milled with end mill
Step 2: cutter machines profile
of T-slot in one pass
Milling and Milling Machines:
Milling Process Capabilities
31
Table 24.2 shows (for milling), conventional ranges of:
Speeds (vary widely: )
Feed per tooth (typically: )
Depths of cut (usually: )
Note, large range of values shown is due to variance in:
Workpiece material
Workpiece condition
Cutting-tool material
Process parameters
Note, cutting fluid recommendations:
Same as those used with turning/hole making operations
32
Milling and Milling Machines:
Design and Operating Guidelines for Milling
33
Fig. 24.15
Milling and Milling Machines:
37
Milling Machines
Bed-type Milling Machines
Worktable replaces knee
Can move only longitudinally