Professional Documents
Culture Documents
Production Technology Ch23
Production Technology Ch23
2001 Prentice-Hall
Page 23-1
Figure 23.1 Typical parts and shapes produced with the machining processes described in this chapter.
2001 Prentice-Hall
Page 23-2
2001 Prentice-Hall
Page 23-3
2001 Prentice-Hall
Page 23-4
2001 Prentice-Hall
Page 23-5
Face Milling
Figure 23.5 Face-milling operation showing (a) action of an insert in face milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling. The width of cut, w, is not necessarily the same as the cutter radius. Source: Ingersoll Cutting Tool Company.
Figure 23.6 A face-milling cutter with indexable inserts. Source: Courtesy of Ingersoll Cutting Tool Company.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 23-7
Figure 23.7 Schematic illustration of the effect of insert shape on feed marks on a face-milled surface: (a) small corner radius, (b) corner flat on insert, and (c) wiper, consisting of a small radius followed by a large radius which leaves smoother feed marks. Source: Kennametal Inc. (d) Feed marks due to various insert shapes.
Kalpakjian Schmid Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 23-8
Face-Milling Cutter
2001 Prentice-Hall
Page 23-9
2001 Prentice-Hall
Page 23-10
2001 Prentice-Hall
Page 23-11
2001 Prentice-Hall
Page 23-12
2001 Prentice-Hall
Page 23-13
Arbors
Figure 23.13 Mounting a milling cutter on an arbor for use on a horizontal milling machine.
2001 Prentice-Hall
Page 23-14
100 0.9 MN
1.7
2001 Prentice-Hall
Page 23-15
TABLE 23.4
General-purpose starting conditions Speed Feed m/min mm/tooth (ft/min) (in./tooth)
0.130.20 (0.0050.008) 120180 (400600)
Workpiece material
Low-C and freemachining steels Alloy steels Soft
Cutting tool
Uncoated carbide, coated carbide, cermets Uncoated, coated, cermets Cermets, PCBN
Hard Cast iron, gray Soft Hard Stainless steel, austenitic High-temperature alloys, nickel base Titanium alloys Aluminum alloys Free machining High silicon Copper alloys Thermoplastics and thermosets
0.100.18 (0.0040.007) 0.100.15 (0.0040.006) 0.1010.20 (0.0040.008) 0.100.20 (0.0040.008) 0.130.18 (0.0050.007) 0.100.18 (0.0040.007) 0.130.15 (0.0050.006) 0.130.23 (0.0050.009) 0.13 (0.005) 0.130.23 (0.0050.009) 0.130.23 (0.0050.009)
90170 (300550) 180210 (600700) 120760 (4002500) 120210 (400700) 120370 (4001200) 30370 (1001200) 5060 (175200) 610900 (20003000) 610 (2000) 300760 (10002500) 270460 (9001500)
0.080.30 (0.0030.012) 0.080.25 (0.0030.010) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.38 (0.0030.015) 0.080.46 (0.0030.018) 0.080.38 (0.0030015) 0.080.46 (0.0030.018) 0.080.46 (0.0030.018)
60370 (2001200) 75460 (2501500) 901370 (3004500) 90460 (3001500) 90500 (3001800) 30550 (901800) 40140 (125450) 3003000 (100010,000) 370910 (12003000) 901070 (3003500) 901370 (3004500)
Uncoated, coated, cermets, SiN Cermets, SiN, PCBN Uncoated, coated, cermets Uncoated, coated, cermets, SiN, PCBN Uncoated, coated, cermets Uncoated, coated, PCD PCD Uncoated, coated, PCD Uncoated, coated, PCD
Source: Based on data from Kennametal Inc. Note: Depths of cut, d , usually are in the range of 18 mm (0.040.3 in.). PCBN: polycrystalline cubic boron nitride ; PCD: polycrystalline diamond. Note: See also Table 22.2 for range of cutting speeds within tool material groups.
2001 Prentice-Hall
Page 23-17
2001 Prentice-Hall
Page 23-18
Figure 23.14 Surface features and corner defects in face milling operations; see also Fig. 23.7. For troubleshooting, see Table 23.5. Source: Kennametal Inc.
Kalpakjian Schmid Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 23-19
Figure 23.16 Schematic illustration of a vertical-spindle column-and-knee type milling machine (also called a knee miller). Source: G. Boothroyd.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 23-20
2001 Prentice-Hall
Page 23-21
Figure 23.19 Schematic illustration of a five-axis profile milling machine. Note that there are three principal linear and two angular movements of machine components
2001 Prentice-Hall
Page 23-22
Figure 23.21 (a) Typical parts made by internal broaching. (b) Parts made by surface broaching. Heavy lines indicate broached surfaces. Source: General Broach and Engineering Company.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 23-23
Broaches
Figure 23.22 (a) Cutting action of a broach, showing various features. (b) Terminology for a broach.
2001 Prentice-Hall
Page 23-24
(b)
2001 Prentice-Hall
Page 23-25
Figure 23.24 Terminology for a pull-type internal broach used for enlarging long holes. Figure 23.25 Turn broaching of a crankshaft. The crankshaft rotates while the broaches pass tangentially across the crankshafts bearing surfaces. Source: Courtesy of Ingersoll Cutting Tool Company.
2001 Prentice-Hall
Page 23-26
Figure 23.26
2001 Prentice-Hall
Page 23-27
Sawing Operations
Figure 23.27 Examples of various sawing operations. Source: DoALL Company.
2001 Prentice-Hall
Page 23-28
Figure 23.28 (a) Terminology for saw teeth. (b) Types of tooth set on saw teeth, staggered to provide clearance for the saw blade to prevent binding during sawing.
2001 Prentice-Hall
Page 23-29
2001 Prentice-Hall
Page 23-30
Spur Gear
Figure 23.31 Nomenclature for an involute spur gear.
2001 Prentice-Hall
Page 23-31
Gear Generating
Figure 23.32 (a) Producing gear teeth on a blank by from cutting. (b) Schematic illustration of gear generating with a pinionshaped gear cutter. (c) Schematic illustration of gear generating in a gear shaper using a pinionshaped cutter. Note that the cutter reciprocates vertically. (d) Gear generating with rackshaped cutter.
2001 Prentice-Hall
Page 23-32
2001 Prentice-Hall
Page 23-33
Figure 23.34 (a) Cutting a straight bevel-gear blank with two cutters. (b) Cutting a spiral bevel gear with a single cutter. Source: ASM International.
2001 Prentice-Hall
Page 23-34
Gear Grinding
Figure 23.25 Finishing gears by grinding: (a) form grinding with shaped grinding wheels; (b) grinding by generating with two wheels.
2001 Prentice-Hall
Page 23-35
2001 Prentice-Hall
Page 23-36