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48 views16 pages

1 Introduction Machining & Machinability R

Uploaded by

6qky9xk46q
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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WELCOME TOMENG

434

Material Removal Processes


INTRODUCTION
TO
Material Removal
Processes
Text Book
Principles of Modern Manufacturing,
Mikell P. Groover, 5th Edition, 2015 John
Wiley & Sons Inc.

Lecture Notes
Regular Laboratory
1) Turning
2) Measurements of cutting forces
3) Measurement of surface roughness
4) Types of chip
5) Milling
6) Drilling
COURSE ASSESSMENT
GRADING

Homework and Lab 30


Two Exams 30
Final Exam 40
SYLLABU
S
Fundamentals of cutting: Machining and machinability,
mechanics of chip formation,
Cutting forces and power
Effect of temperature on cutting process, tool life and metal
removal rate.
Cutting tool materials and fluids.
Machining processes: turning, thread cutting, boring, drilling,
reaming, milling, shaping and planing, broaching,
Gear cutting processes.
Abrasives (grinding wheels, grinding processes).
Super finishing process, Lapping, honing. blasting and peening.
Non-conventional machining.
Numerical control of machine tools.
Chapte
r1
INTRODUCTION TO
MATERIAL REMOVAL PROCESSES

Classification of Material Removal


Processes
Machining, Machinability, and Machinable
Materials
Theory of Chip Formation in Metal
Machining
Force Relationships and the Merchant
Equation
Power and Energy Relationships in
Machining
Classification
of material
removal
processes
Machini
ng process in which a sharp
Machining is a manufacturing
cutting tool is used to cut away material to leave the desired
part shape.
Machining system consists of the work-piece, the tool, and the
equipment.
The predominant cutting action in machining involves
shear deformation of the work material to form a chip; as the
chip is removed, a new surface is exposed.
An example of machining process is ‘turning operation’ (see
Figure).
Machining operations generally
performed after other
manufacturing processes, such
as casting, forging, and bar
drawing
Machining provides the final
shape, dimensions, finish, and
special geometric details that
other processes cannot create
Why Machining is
Important?
Variety of work materials can be machined
Variety of part shapes and special geometric features possible,
such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good dimensional accuracy
Good surface finish
Disadvantages with Machining

Wasteful of material
Chips generated in machining are wasted material.
Although these chips can usually be recycled, in terms of
the unit operation, the material that is removed is waste.
Time consuming
A machining operation generally takes more time to
shape a given part than alternative shaping processes,
such as casting, powder metallurgy, or forming
Machinabi
lity
Machinability is a system property that indicates how easily a
material can be machined at low cost.

Quantitative measures of machinability:


Tool life: service time in minutes or seconds to total failure by
chipping or cracking of the tool at certain cutting speed, or the
volume of material removed before total failure.
Surface finish produced at standardized cutting speeds and
feeds.
Other measures are based on:
cutting force,
power,
temperature, and
chip formation.

Good machinabililty may mean one or more of the following:


Minimum cutting forces and energy.
Minimum tool wear (longer tool life).
Good surface finish.
Machinable
Materials
Good machinable materials should have the
following properties:

Ductility directly affects the type of chip produced which, in turn,


affects surface finish.
Medium ductility is desirable for good machinability, because:
Less ductile (brittle) materials may cause tool damage
Very ductile materials produce continuous chip that are difficult to
control
Low strain-hardening exponent (n), low fracture toughness.
Low shear strength.
Inclusions that soften at high temperatures are beneficial.
High thermal conductivity is helpful.
Low metallurgical bond (adhesion) between tool and workpiece.
Avoid the embedded very hard compounds, such as some oxides,
all carbides, and silicon, that accelerate tool wear.
Is material ductility important for machinability? Explain.
Factors Influencing Machining Operations
Roughing vs.
Finishing
In production, several roughing cuts are usually
taken on the part, followed by one or two finishing
cuts

Roughing
Removes large amounts of material from
starting workpart
Creates shape close to desired geometry, but leaves
some material for finish cutting
High feeds and depths, low speeds

Finishing
Completes part geometry (Final dimensions, tolerances,
and finish)
Low feeds and depths, high cutting speeds
Questio
ns
1. Differentiate between machining and machinability
2. Why machining is Important?
3. List the disadvantages of machining operations.
4. List the parameters used in quantitative measures of
machinability
5. List the properties of good machinable materials
6. Explain why the material ductility is important for
machinability?

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