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    GhoshAandAKMallikMachini 116 PDF

    Uploaded by

    Barinder Singh

    Copyright:

    © All Rights Reserved
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    of 102
    MANUFACTURING SCIENCE’ A. GHOSH, 8 Eng, M Eng, PhD. Professor of Mechanical Engineering and A. K, MALLIK, B Eng, M Eng , PhD. Professor of Mechanical Engineering both of Indian Institute of Technology, Kanpur ELLIS HORWOOD LIMITED Publishers - Chichester Halsted Press: a division of JOHN WILEY & SONS [New York Chichester Brisbane - Toronto First published in India by Affilated East-West Press Private Limited ‘This Edition published in 1986 by ELLIS HORWOOD LIMITED Market Cross House, Cooper Street, Chichester, West Sussex, POI9 1EB, England The publishe'scolophon is reproduced from James Gillson’s drawing ofthe ancient Market Bee hithenee Phen & Product I Distributors: Australia and New Zealand: Tacaranda-Wiley Ltd. Jacaranda Press, JOHN WILEY & SONS INC ‘GPO Box 859, Brisbane, Queensland 4001, Australia Canada. JOHN WILEY & SONS CANADA LIMITED 22 Worcester Road, Rexdale, Ontario, Canada Europe and Africa: JOHN WILEY & SONS LIMITED Baffins Lane, Chichester, West Sussex, England North and South America and the rest of the world (except in India) Halsted Press: a division of JOHN WILEY & SONS 60 Third Avenue, New York, NY 10158, USA. © samated Fast-West Pres Private Limited 1986 British Library Cataloguing in Publication Data Ghosh, A. “Manufacturing scence. — (Elis Horwood series in mechanical engineering) 1. Production engineering Ete Malle, AK 67042 T3176 ISBN 0-7458-0059-9 (Elis Horwood Limited — Library Edn ) ISBN 0-7456-0075-4 (Elis Horwood Limited — Student Edn) ISBN 0-470-20312-9 (Halsted Press) Printed in Great Britain by Butler & Tanner, Frome Somerset ‘COPYRIGHT NOTICE AA Riahis Reserved. No pat ofthis publication may be reproduced, stoted in a tettieval SYstem, of trnsmited, in Sny orm or by any means, eleetonte, mechanical, ng, teeording or otherwise, without the petmiion of Elis Horwood Limited, Market Cross House, Cooper Steet, Chichester, West Sussex, England 4 Machining Processes 4,1 INTRODUCTION In Chapters 2 and 3, we discussed two methods, viz., casting and forming, for obtaining the desired shape, size, and finish. Both these methods require a suitable movement of the material particles either in the liquid or in the solid state, However, both the methods have limitations and, in a very large number of situations, neither is suitable. Casting imposes severe problems from the point of view of material properties and accuracy, whereas forming becomes impractical when the job is either very large (requiring very large forming forces and huge machines) or the material is not suitable for the forming operation, Apart from these, the geometric complexity of the final job may be such that these methods, again, are of no use. ‘The foregoing problems can be overcome if the method used is such that the desired shape, size, and finish are obtained through the removal of excess material (From the original workpiece of a suitable size and shape) in the form of small chips. In most cases, a large scale removal is not possible either for geometric reasons or for the size involved. This process is termed as machining, and is perhaps the most versatile manufacturing process. The body which removes the excess material through a direct mechanical contact is called the cutting tool and the machine which provides the necessary relative motions between the work and the tool is commonly known as the machine tool. ‘Since the removal of material takes place only in the form of small chips, the machining of a finite area requires a continuous feeding of the uncut portion at a suitable rate, The relative motion (between the tool and the work) responsible for the cutting action is known as the primary or cutting motion, and that responsible for gradually feeding the uncut portion is termed as the secondary or feed motion. Depending on the nature of the two relative motions, various types of surfaces can be produced. To explain this in more detail, let us consider a point P (Fig. 41) where the material is being cut at a particular instant. Now, if the cutting motion is rectilinear and the feed (provided after the comple- tion of each cutting stroke) is also rectilinear (Fig. 4.1a), the machined surface will be plain (Fig. 4.1). The line generated by the cutting motion js called the generatrix and the line from the feed motion is termed as the directrix (Fig. 4.1e). So, various geometries can be obtained depending on the shapes of the generatrix and the directrix and their relative directions. To understand why the relative directions are important, let us consider MACHINING PROCESSES 187 Cutting jeneratcin ‘motion Z > Feed Direetrix (a) Motions of (b) Production of (6) Generatrix and cutting point surface directrix Fig. 4.1 Concept of generatrix and directrix. the two situations in Fig. 4.2. Figure 4.2a shows a case with the generatrix as acircle and the directrix as a straight line perpendicular to the plane of the generatrix. It is seen that the surface obtained is cylindrical, If the same circular generatrix and the rectilinear directrix lie in the same plane, two straight lines are generated, as explained in Fig, 4.2b. So, a series of such generatrix-directrix combinations, placed side by ‘direction per- pendicular to the plane of the generatrix, result in a plain surface. In Fig. 4.2a, the surface is generated by a direct tracing of the generatrix, and Generatrix Cylindrical surface Directrin produced L (a) Directrix perpendicular to plane of generatrix Lines &) @y~ Generatrix (b) Directrix in the plane of generattix Fig. 42 Cases with circular generatrix and straight directrix, in Fig. 4.2b, the final surface geometry is given by the envelope of the generatrices, and the process is known as generation, Table 4.1. gives ‘common examples of surface generation. In practice, cutting is really never done at a point but along a cutting edge. Thus, several generatrices and directrices are involved end generation yields not a line but a surface. 188 MANUFACTURING SCIENCE Table 4.1 Generation of various surfaces Number Generatrix _Directrix. © Process-—Surface obtained 1 Straight ine Straight line Tracing Plain 2 Cirewlar Straight line Tracing Cylindrical 3 Plaincurve Circular Tracing Surface of revolution 4 Cireutar Straight line Generation Straight line (plain surface in practice) We shall now give brief descriptions of the common machining processes. i) Shaping and planing In shaping and planing, the surface obtained is plain (Number 1 in Table 4.1). In shaping, the cutting tool is given a reciprocating motion, and after every cutting stroke, the work is fed (Fig. 43) perpendicularly (during the return stroke, the work is advanced by a small distance) in order to provide a layer of the uncut material to the tool. Since here the cutting is not continuous, the machining is known as an intermittent cutting operatio For a long job, it becomes inconvenient to provide long cutting strokes with the mechanism used in a shaping machine. In such a case, the work is provided with the cutting motion, whereas the feed is given to the tool; this operation is known as planing. The basic geometry of the machining operation is the same as that of shaping. ee Teal surtice Cutting pay produced — motion. Surface generated Surface fencrated Gaal Feea(stoke Work Feed motion Fig. 4.3 Shaping operation. Fig.44 Turning operation. (i) Turning This is 2 very basic operation and produces a cylindrical surface. Of course, by face turning, a flat surface can also be obtained. The machine tool used for this type of an operation is known as a lathe. Figure 4.4 shows a typical turning operation where a workpiece in the form MACHINING PROCESSES 189 of @ cylindrical bar is rotated about the axis of symmetry, The tool is provided with a feed motion parallel to the work axis. Thus, itis easy to see that with respect to the work the tool has a helical motion and always ‘encounters an uncut layer of the workpiece. Here, the machining operation is continuous. This operation results in a reduced work diameter and a new cylindrical surface. When the tool is fed in the radial direction along the face (Fig. 4.4), a flat surface is produced and the length of the workpiece gets reduced. Gii) Drilling This is used for making a hole in a solid body. Figure 4.5 shows the operation schematically. The cutting motion is provided to the Feed motion Cutting motion Fig. 4.5 Drilling operation, two cutting edges (lips) by rotating the drill, and the feeding is done by siving a rectilinear motion to the drill in the axial direction. The final surface obtained is an internal cylindrical surface. (iv) Milling A versatile machining operation, it can produce various types of surfaces. A plain slab milling operation is shown in Fig, 4.6a. The tool, normally known as a milling cutter, possesses a number of cutting ‘edges. It is provided with a rotary motion and the work is gradually fed Cutting motion Cuter Cutting Abrasive Mi motion ‘Chip—> oe " ‘Brains Work Work Feed motion Feed motion (@) Scheme of miling operation Cee Fig. 4.6 Machining with multipoint tools, 190 MANUFACTURING SCIENCE ‘Small chips ate removed by each cutting edge during revolution, and finally a flat surface is produced. (v) Grinding In grinding, the cutting tools are the sharp edges of the abrasive grains of the grinding wheel. These grains are very Jarge in number and have a random orientation and distribution. However, if a particular grain is observed, its action would be as shown in Fig. 4.6. OF course, the size of the chips removed by a grain is exceedingly small. 4.2 MECHANICS OF BASIC MACHINING OPERATION Before we start our discussion on the mechanics of the machining opera~ tion, it is advisable that we study the basic similarity in the nature of ‘material removal during the different types of machining operations (Fig. 4.7). The sectional view XX of the actual cutting zone in Figs. 4.7a, (a) Shaping (©) Drilling (@) Milling Fig. 4.7 Simulation of actual machining processes. 4.7b, and 4,7e and an enlarged view of the cutting zone in Fig. 4.74 show that ‘the basie nature of material removal in each of these operations is similar and can be represented as in Fig. 4.8. The important parameters involved are (i) the thickness of the uncut layer (1), (ii) the thickness of the chips produced (2), (if) the inclination of the chip-tool interface with MACHINING PROCESSES 191

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