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Machining: 2.810 Fall 2009 T. Gutowski
Machining: 2.810 Fall 2009 T. Gutowski
Machining
2.810 Fall 2009 T. Gutowski
go to website below
http://electron.mit.edu/~gsteele/mirrors/www.nmis.org/EducationTraining/machineshop/mill/intro.html
Readings
Kalpakjian Ch 21-27
Simplified Time Estimation Booklet
for Basic Machining Operations
Outline
1. Basics 2. Machine Configurations 3. Production Configurations 4. Processing Planning 5. Environment
Machining processes
Turning
*
Grinding
V D Grinding wheel Grains
Workpiece
Milling
* Cutter Arbor Spindle Spindle Shank End mill
Arbor
Face milling
End milling
Machine Tools
* * Headstock
Spindle
Ways Cross slide Carriage Center Tailstock quill Tailstock
Head
Table
Saddle Knee
Basic Lathe
Vertical-Spindle Mill
Base * Source: Kalpakjian, Manufacturing Engineering and Technology
Power, Forces
Heat, Tool materials, Rate limits Temperature Surface finish
d(work) dt
work
work
V
Rake angle
specific energy u S
Tool
t0
Shear plane
Approximation us ~ H (Hardness)
Specific energy, uS
Power us X MRR
MRR is the Material Removal Rate or d(Vol)/dt Since Power is P=F*V and MRR can be written as, d(Vol)/dt = A * V Where A is the cross-sectional area of the undeformed chip, we can get an estimate for the cutting force as,
F us
Note that this approximation is the cutting force in the cutting direction.
Fp Fcn Fc
Fc ~ H
Ac
Fp
Fcn
Fc
v (m/s)
Side view
Consider the workpiece moving into the cutter at rate v. In travel time t the feed is v t. The time for one rotation is t = The travel for one tooth is 1/4 Hence the feed per tooth is f = v/4 . In general, a cutter may have N teeth, so the feed per tooth is The material removal rate (MRR) is,
f=v/N
MRR = v w d
where d is the depth of the tool into the workpiece.
N = 4 (number of teeth) D = 2 (cutter diameter) Let w = 1 (width of cut), d=0.1 (depth of cut) f = 0.007 (feed per tooth), vs = 2500 ft/min (surface speed; depends on cutting tool material; here, we must have a coated tool such as TiN or PCD)
d w
The rotational rate for the spindle is = vs / D = 4775 rpm Now, we can calculate vw, workpiece velocity, f = vw / N => vw= 134 [in/min]
Material removal rate, MRR = vw*w*d = 13.4 [in3/min] Power requirement, P = us*MRR = 5.36 [hp] Cutting force / tooth, F ~ us*d*f = 111 [lbf]
us from Table 21.2 (20.2 ed 4); Note 1 [hp min/in3] = 3.96*105 [psi]
Recommended feed = 0.006 (Table 23.4 (22.4)) Recommended surface speed = 1000 ft/min = 1000 ft/min = 3820 rpm 1 1ft/12
Let d = 0.1
Material removal rate, MRR = 0.1 0.006 1 3820) = 7.2 [in3/min] Power requirement, P = us*MRR = 1.9*7.2 = 13.7 [hp] Cutting force / tooth, F ~ us*d*f = (1.9*3.96*105)*(0.1*0.006) = 450 [lbf]
us from Table 21.2 (20.2 ed 4); Note 1 [hp min/in3] = 3.96*105 [psi]
Temperature ( F)
Year
Feed (in/rev)
m/min
HRC
1m X 1m area
* References: 1. Advanced Methods of Machining, J.A.McGeough, Chapman and Hall, 1988 2. Manufacturing Engineering and Technology, S. Kalpakjian, Addison-Wesley, 1992 3. Laser Machining, G. Chryssolouris, Springer-Verlag, 1991
MRR = f d * N
Cutter geometry
Form tool, cutter radius, inserts, tool changers
Software
flexibility, geometrical compensation, look ahead dynamics compensation
Head
Column
Base
New developments
Micro machines
Stewart Platform
Linear actuator
Tool
Schematics
* Source: http://macea.snu.ac.kr/eclipse/background/background.html
www.iwf.mavt.ethz.ch/
http://web.mit.edu/pmc/www/index.html
Machining Part 2
System Configurations
Part Holding / Fixturing
Process Planning
Environment
Primary Rotational
Primary Planar
Secondary
See video
Ref J T. Black
Job shop
Flow Shop
L L M D G A A
Receiving
Shipping
Transfer line
Machining Cell
HM VM Part movement VM Decoupler (Kanban square)
G
Worker path Final inspection Finished part cart
Worker position
Raw material cart
OUT
Vise Jaws / T-slot Bolt clamps / T-slot Direct bolt to plate / T-slot Special work holding jaws and clamps
Soft jaws, custom jaws, stops, mechanical clamps,
Production
Vise
Faceplate on lathe
Production
Modular Fixtures http://www.royalworkholding.com/RM3.html Hydraulic Pallet Fixture http://www.royalworkholding.com Collet Index Fixture http://www.cuttingtoolmall.com/catalog/standard.cfm?FamilyID=225205
SMED
Single-Minute-Exchange-Die
Shigeo Shingo, A Study of the Toyota
Production Systems
Stage1: Separating Internal and External Setup Stage2: Converting Internal to External Setup Stage3: Streamlining all aspects of the setup operation
Standardized Fixtures
Process planning
How would you machine this part?
Assumption: 1. We begin with a stock size of 2.5 X 2.25 X 12 2. This will be manufactured in a job shop for very low quantity
We will use: - A bandsaw to roughly cut the stock to size - A manual vertical mill to create the planar features and the holes - A belt sander to sand the radii ( assuming the tolerance is not very high)
Machine
Operation
Belt sender
* Source: http://www.jettools.com/Catalog/Metalworking/CatalogPages/HVBS56M.html
Machine
Horizontal band saw
Operation
Saw stock to ~4.125
Mill width to 2 Mill out 2X1.5X4 Drill hole 1 diameter Bore 1 radius
Belt sender
* Source: http://www.hemsaw.com/Videolinkpages/x-vVideopg.htm
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4
Mill width to 2
Mill out 2X1.5X4 Drill hole 1 diameter Bore 1 radius
Belt sender
* Source: http://www.hemsaw.com/Videolinkpages/x-vVideopg.htm
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2
Belt sender
* Source: http://www.hemsaw.com/Videolinkpages/x-vVideopg.htm
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2
Belt sender
* Source: http://www.hemsaw.com/Videolinkpages/x-vVideopg.htm
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2
Bore 1 radius
Belt sender Sand 0.5 radii
* Source: http://www.hemsaw.com/Videolinkpages/x-vVideopg.htm
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2
Belt sender
Process plan
Machine
Horizontal band saw
Operation
Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2
Belt sender
2.02 0.13R 0.75F 0.46R 0.67F 2.19R 0.93F 0.03 0.05 0.04 0.01 0.96R 0.01F
0.30D, 0.05I 0.63D, 0.05I, 0.13M 0.43D, 0.05I, 0.13M 0.50D, 0.05I 0.13M, 0.13M
2 2 2 2 2
0.20
0.20
Belt sender
0.08
0.20R 0.21F
Environmental issues
Waste material Energy
Dry machining
Data from US Energy Information Administration, DOE 2002 & Klee & Graedel
Ref. Toyota
30% 243 hours 70% 567 hours 149288 5471 6237 160996 Aluminum 3 20.0 cm /sec 3 40824000 cm 3 14.2 kJ/cm kWh kWh kWh kWh Steel 3 4.7 cm /sec 3 9593640 cm 3 60 kJ/cm
60% 351 hours 40% 234 hours 1038 1033 673 2744 Aluminum 3 5.0 cm /sec 3 4212000 cm 3 2.3 kJ/cm kWh kWh kWh kWh Steel 3 1.2 cm /sec 3 1010880 cm 3 10 kJ/cm
60% 351 hours 40% 234 hours 3033 1818 702 5553 Aluminum 3 5.0 cm /sec 3 4212000 cm 3 4.7 kJ/cm kWh kWh kWh kWh Steel 3 1.2 cm /sec 3 1010880 cm 3 20 kJ/cm
70% 221 hours 30% 94.5 hours 600 0 100 700 Aluminum 3 1.5 cm /sec 3 510300 cm 3 4.9 kJ/cm kWh kWh kWh kWh Steel 3 0.35 cm /sec 3 119070 cm 3 21 kJ/cm
30% 243 hours 70% 567 hours 149288 5471 6237 160996 Aluminum 3 20.0 cm /sec 3 40824000 cm 3 14.2 kJ/cm kWh kWh kWh kWh Steel 3 4.7 cm /sec 3 9593640 cm 3 60 kJ/cm
70% 221 hours 30% 94.5 hours 600 0 100 700 Aluminum 3 1.5 cm /sec 3 510300 cm 3 4.9 kJ/cm kWh kWh kWh kWh Steel 3 0.35 cm /sec 3 119070 cm 3 21 kJ/cm
Ref Smil
Sample calculation
1 kg part made from 2 kg of aluminum stock 2024 production machining 14.2 kJ/cm3 1000 g /2.7 g/cm3 = 370 cm3 (14.2 X 370 = 5.25 MJ) X 3 = 15.8 MJ material production (284.5 MJ/kg X 2 kg = 569 MJ)+15.8 = 585 MJ/ kg of part
C. Smith 2001
Home works
See webpage Re-do face milling of Al alloy example with uncoated tools estimate % of spindle power (7hp) used for tool break video