Fundamentals Of Machining/Orthogonal Machining
Fundamentals ofMachining/Orthogonal MachiningChapter 20ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.1 IntroductionME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-1 Thefundamental inputs andoutputs to machiningprocesses.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.2 FundementalsME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-2 Theseven basicmachiningprocesses used inchip formation.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-3 Turning acylindrical workpiece on alathe requires you toselect the cutting speed,feed, and depth of cut.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-4 Examples of a table for selection of speed and feed for turning. (Source: Metcut’sMachinability Data Handbook.)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-4 Examples of a table for selection of speed and feed for turning. (Source: Metcut’sMachinability Data Handbook.)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-5 Relationship ofspeed, feed, and depth of cut inturning, boring, facing, andcutoff operations typically doneon a lathe.ME-215 Engineering Materials and ProcessesVeljko Samardzic
ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-6 Basicsof milling processes(slab, face, and endmilling) includingequations for cuttingtime and metalremoval rate (MRR).ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-7 Basics of the drilling (hole-making)processes, including equations for cutting time andmetal removal rate (MRR).ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-8 Process basics ofbroaching. Equations for cuttingtime and metal removal rate(MRR) are developed inChapter 26ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-9 (a) Basics of theshaping process, includingequations for cutting time (Tm ) andmetal removal rate(MRR). (b) The relationship of thecrank rpm Ns to the cutting velocityV.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-10 Operations and machines used for machining cylindrical surfaces.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-10 Operations and machines used for machining cylindrical surfaces.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-11 Operationsand machines used togenerate flat surfaces.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.3 Energy and Power inMachiningME-215 Engineering Materials and ProcessesVeljko Samardzic
ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-12 Obliquemachining has three measurablecomponents of forces acting onthe tool. The forces vary withspeed, depth of cut, and feed.ME-215 Engineering Materials and ProcessesVeljko Samardzic
ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-13 Three ways to performorthogonal machining. (a) Orthogonal platemachining on a horizontal milling machine, goodfor low-speed cutting. (b) Orthogonal tube turningon a lathe; high-speed cutting (see Figure 20-16).(c) Orthogonal disk machining on a lathe;very high-speed machining with tool feeding (ipr)in the facing directionME-215 Engineering Materials and ProcessesVeljko Samardzic
20.4 Orthogonal Machining (TwoForces)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-14 Schematics ofthe orthogonal plate machiningsetups. (a) End view of table,quick-stop device (QSD), andplate being machined for OPM.(b) Front view of horizontalmilling machine. (c) Orthogonalplate machining with fixed tool,moving plate. The feedmechanism of the mill is used toproduce low cutting speeds. Thefeed of the tool is t and the DOCis w, the width of the plate.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-15 Orthogonaltube turning (OTT) produces atwo-force cutting operation atspeeds equivalent to those usedin most oblique machiningoperations. The slight differencein cutting speed between theinside and outside edge of thechip can be neglected.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-16Videographmade from theorthogonal platemachining process.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-17 Schematicrepresentation of the materialflow, that is, the chip-formingshear process. f defines theonset of shear or lower boundary.c defines the direction of slipdue to dislocation movement.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-18 Three characteristic types of chips.(Left to right) Discontinuous, continuous, andcontinuous with built-up edge. Chip samples producedby quick-stop technique. (Courtesy of Eugene Merchant(deceased) at Cincinnati Milacron, Inc., Ohio.)ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.5 Merchant’s ModelME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-19 Velocitydiagram associated withMerchant’s orthogonalmachining model.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.6 Mechanics of Machining(Statics)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-20 Free-body diagram of orthogonal chipformation process, showing equilibrium conditionbetween resultant forces R and R.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-21 Merchant’s circular force diagram usedto derive equations for Fs , Fr , Ft , and N as functionsof Fc, Fr , f, a, and b.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.7 Shear Strain and Shear FrontAngleME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-22 Shearstress ts variation withthe Brinell hardnessnumber for a group ofsteels and aerospacealloys. Data of someselected fcc metals arealso included. (Adaptedwith permission from S.Ramalingham and K. J.Trigger, Advances inMachine Tool Design andResearch, 1971,Pergamon Press.)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-23 The Black–Huang “stack-of-cards”model for calculating shear strain in metalcutting is based on Merchant’s bubble model for chipformation, shown on the left.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.8 Mechanics of Machining(Dynamics)ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-24 Machiningdynamics is a closed-loopinteractive process that createsa force-displacement response.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-25There are threetypes of vibrationin machining.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-26 Someexamples of chatter that arevisible on the surfaces of theworkpiece.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-27 When theoverlapping cuts get out ofphase with each other, a variablechip thickness is produced,resulting in a change in Fc on thetool or workpiece.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-28 Regenerativechatter in turning and millingproduced by variable uncut chipthickness.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-29 Milling and boring operations can be made more stable by correct selection of insert geometry.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-30 Dynamicanalysis of the cutting processproduces a stability lobediagram, which defines speedsthat produce stable and unstablecutting conditions.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-31 Distribution ofheat generated in machining tothe chip, tool, and workpiece.Heat going to the environmentis not shown. Figure based onthe work of A. O. Schmidt.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-32 There are three main sources of heat in metal cutting. (1) Primary shear zone. (2)Secondary shear zone tool–chip (T–C) interface. (3) Tool flank. The peak temperature occurs at thecenter of the interface, in the shaded region.ME-215 Engineering Materials and ProcessesVeljko Samardzic
FIGURE 20-33 The typical relationship of temperature at the tool–chip interface to cuttingspeed shows a rapid increase. Correspondingly, the tool wears at the interface rapidly withincreased temperature, often created by increased speed.ME-215 Engineering Materials and ProcessesVeljko Samardzic
20.9 SummaryME-215 Engineering Materials and ProcessesVeljko Samardzic
the orthogonal plate machining setups. (a) End view of table, quick-stop device (QSD), and plate being machined for OPM. (b) Front view of horizontal milling machine. (c) Orthogonal plate machining with fixed tool, moving plate. The feed mechanism of the mill is used to produce low cutting speeds. The feed of the tool is t and the DOC
Creating Orthogonal Array. As we will explain shortly, the technique proposed in this paper usually requires dif-ferent orthogonal arrays for di erent problems. e con-struction of orthogonal array is not a trivial task since we do not know whether an orthogonal array of given size exists. Many
6-Pair Orthogonal right angle header connector solution. The connectors enable efficient implementation of Direct-Mate orthogonal and midplane orthogonal architectures. Orthogonal architecture solutions eliminate long, complex traces, via stub effects, simplify signal links and reduce backplane layer count.
There are different types of machining process used for sapphire material. The fig. 1 shows a graphical representation of sapphire machining processes i.e. laser machining process, grinding process, polishing process, lapping process, new developed machining process, compound machining process and electro discharge machining process. Fig.1.
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
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Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
where the use of 5-axis simultaneous machining brings unequalled surface quality. Moreover, it is targeted at prototype machining, 5-axis trimming and special machining where full 5-axis machining is the requirement for quick and accurate manufacturing. Multi-Axis Surface Machining is also an add-on product to Prismatic Machining and Lathe .
ANSI A300 standards are the accepted industry standards for tree care practices. ANSI A300 Standards are divided into multiple parts, each focusing on a specific aspect of woody plant management. Tree Selection and Planting Recommendations Evaluation of the Site The specific planting site should be evaluated closely as it is essential to understand how the chemical, biological and physical .
