Machining: MIT 2.008x

2.
008x
Machining
MIT 2.008x
Prof. John Hart

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Machine shop in the DC printing office (1909)

National Photo Company Collection v ia wikimedia. This
work is in the public domain.
A present-day CNC machine shop

“KIM_6446.” Kim Becker (CC BY 2.0) v ia Flickr
CNC Tools
“Drill bit s et” v ia Pixabay.
This work is in the public domain.
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What is the highest

volume CNC machined
part in history?
Manufacturing the Macbook ‘unibody’
(+ iPhone etc) 2.008x
Excerpt from: http://www.youtube.com/watch?v=sxbiIpXZfG8

about J ony Ive (Apple VP of Design): http://www.newyorker.com/magazine/2015/02/23/shape-things-come
12” Macbook (released 2015)
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Terraced CNC housing to hold 30% more battery v olume;; s ingle PCB
2.03 pounds, 0.51” thick (max), 9hrs using wifi at 75% brightness
http://www.apple.com/macbook/design/
What is machining?
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§ … “a general term describing a group of

processes that consist of the removal of
material and modification of the surfaces
of a workpiece after it has been produced
by various methods.” (Kalpakjian and Schmid)
§ Traditional machining: a rotating cutter

containing several 'teeth' that removes
material from a local region of the part.
§ Other machining processes that use

different removal mechanisms and/or
energy sources include electron discharge
machining (EDM), laser machining, and
water jet cutting.
Kalpalkian and Schmid, Manufacturing Engineering and Technology

Machined parts: from small to large
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iPhone 5 and 6
housings
Watch m echanism
https://pixabay.com/en/watch-
time-gears-clock-time-clock-
932693/
Boeing 777 panel

outboard
Brass fittings
Image from Pixabay. This work is in the public domain.
Machining is good at flat and curved surfaces,
threads;; tolerances ~0.001” 2.008x
Brass fittings
Image from Pixabay. This work is
in the public domain.
0.5 m m
Diagram from Kalpalkian and Schmid, Manufacturing Engineering and Technology.

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2 mm
Agenda:
Machining 2.008x
§ Tool-material interaction
§ Cutting mechanics
§ Geometry and motion
§ Forces
§ Energy and power
§ Demonstration experiments!
§ Cutting forces
§ Tools, finish, and wear
§ Milling (+iPhone housing)

§ Design for machining
§ Conclusion
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Machining:
2. Basics of
tool-material
interaction
A lathe
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Kalpakjian and Schmid, Manufacturing Engineering and Technology

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CNC turning a chess rook (2X speed)
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Cutoff
(with saw)
Boring
(internal turning)
Turning Contour turning Facing
Video excerpt from: https://www.youtube.com/watch?v=lcGHtI9Lql4

Diagrams adopted from Kalpakjian and Schmid, Manufacturing Engineering and Technology
Basic cutting (turning) nomenclature
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à The cutting tool is set to a

certain depth of cut and travels
to the left with a certain
velocity as the workpiece
rotates (spindle speed)
§ Feed: axial distance tool moves per

spindle revolution
§ Depth of cut: amount of material
removed perpendicular to workpiece
§ Spindle speed: rotation speed of
workpiece [RPM]

Example: cutting speed and MRR
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A 304 stainless steel rod is being turned on a lathe.

§ The rod is initially 2.0 cm diameter, and becomes 1.9 cm in a single cut.
§ The spindle rotates at N=300 rpm, and the tool is traveling at an axial speed of 20
cm/min.
§ The specific cutting energy is 4.0 W-s/mm3.
à What is the initial cutting speed? (tangential velocity)
à What is the initial material removal rate (MRR)?

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à What is the initial cutting speed? (tangential

velocity)
Vc = πDo N = 0.31 m/s = 18.8 m/min

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MRR = πD1 Nfd = Vc fd
Va
f = = 0.067 cm/rev
N
Do − D f
d= = 0.05 cm
2
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MRR = πD1 Nfd = Vc fd
Va
f = = 0.067 cm/rev
N
Do − D f
d= = 0.05 cm
2
MRR = Vc fd = 1----
0.3 cm 3 /min
correct:
6.3 cm3/min
Material removal = controlled failure
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Material is removed (and a chip is produced) at the

head of the tool by plastically deforming and
continuously shearing the material
Excerpt from: https://www.youtube.com/watch?v=mRuSYQ5Npek
What do the tool and material experience
during cutting? 2.008x
§ Force
§ Motion (sliding, vibration)
§ Heating
à These lead to deformation

of the workpiece and wear
of the tool
à All of these are coupled

and influence part quality!
How we’ll understand cutting mechanics
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Step I:
Motion &
Deformation
Step II:
Forces
Step III:
Energy &
Power
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Machining:
3. Tool motion and

material deformation
We assume a 2D (orthogonal) z
cutting path 2.008x
z
x
y
x
Oblique (3D)
Realistic, yet difficult to analyze
y
Orthogonal (2D)
Provides insight for understanding
2D model: angles and assumptions
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Three important angles:

§ Rake angle α
Chip
§ Shear angle φ
- +
§ Relief angle ε
α
Tool
φ Assumptions:
ε § The tool is perfectly sharp
Workpiece § The tool moves at a
constant V and t0
§ A continuous chip is
Shear plane produced
What type of deformation do you see?
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α
φ ε
Excerpt from: https://www.youtube.com/watch?v=mRuSYQ5Npek

Shear model of
orthogonal cutting 2.008x
tc
Chip
tc
Tool
t0
Workpiece
In reality the ‘pages’ are very thin and

related to the microstructure of the
material being cut: ~0.001-0.01 mm
(10-3-10-4 in)
Analysis of shear
strain 2.008x
Δx bc + cd
γ= =
A ac
γ = cot (φ ) + tan (φ − α )
Analysis of shear strain
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γ = cot (φ ) + tan (φ − α ) Chip
- +
Shear plane α
Tool
What do we learn?
φ
§ φ ↓ = γ ↑ or α ↓ = γ ↑ ε
§ γ ∼2-4 (very large!) Workpiece
à Think of the material

‘turning the corner’
(Tesla video)
Mapping shear strains during cutting
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Here, digital image c orrelation (DIC) is used to map the s train field
NIST high s peed v ideos of tool/chip/material interaction: http://www.nist.gov/el/isd/sbm/hsds-machining-videos.cfm
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Machining:
4. Cutting forces
Why do we study
cutting forces? 2.008x
§ Forces are related to the

material and cut geometry
§ Forces cause the tool and
workpiece to deform
§ Forces (and speed)
determine the power
required for cutting
à The coupling of motion

and force at the cutting
interface influences quality,
tool life, and productivity!
Cutting force (FC)
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Chip
- +
α
FC
φ
Workpiece
Demo #1: Measuring cutting force
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Measuring cutting force
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Cutting force data from
Chip
video 2.008x
- +
α
Tool
φ
ε
Workpiece
Cut Feedrate Spindle Rake angle Depth of cut Diameter Force

[in/rev] [RPM] [deg] [in] [in] [lb]
1 0.0042 140 60 0.03 2 0.43
2 0.0147 140 60 0.03 2 0.90
3 0.0147 140 0 0.03 2 1.83
4 0.0147 330 0 0.03 2 2.03
5 0.0147 330 0 0.06 2 3.87
6 0.0147 330 0 0.06 1 3.38
!
Cutting force data for aluminum (AA2014)
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à Here too, cutting force depends strongly on feed (f) but not on speed (Vc)
Gokkaya, “The Effects of Machining Parameters on Cutting Forces,Surface Roughness, Built-Up Edge (BUE) and Built-Up Layer
(BUL) During Machining AA2014 (T4) Alloy”, J ournal of Mechanical Engineering 56(2010)9, 584-593
Merchant’s relationship: relating the angles
(reference slides to be posted) 2.008x
π β α [radians]
φ= − +
4 2 2 β = friction angle (µ = tan β)
is derived assuming that the shear angle (φ) self-adjusts to
minimize the required cutting energy
à if rake angle ↓ or friction angle ↑: shear angle ↓
à consequences of smaller shear angle: Chip

§ chip thickness ↑ -
α+
§ energy dissipation via shear ↑
Tool
§ heat generation ↑
§ temperature ↑ φ ε
Workpiece
Validating Merchant’s equation
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π β α
φ= − +
4 2 2
φ ε
Key assumptions:
§ Slow, orthogonal cutting
§ Constant material properties
with temperature
Chart adapted from: Metal Cutting Theory and Practice, § Simple sliding friction
Stephenson and Agapiou
§ No strain hardening
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Machining:
5. Field trip to IMTS

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Regular CNC machines
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Haas DT1 drill-tap c enter

https://www.haascnc.com/mt_spec1.asp?id=DT-1&webID=DRILL_TAP_VMC#gsc.tab=0
Giant machines (25 ton table capacity)
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Lots of tools
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Lots of tools
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And tool mascots!
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And chip management systems
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And chip management systems
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Machining:
6. Tools, finish, and

wear
Cutting tools
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Monolithic tool (e.g., HSS or Carbide)
Tooling with inserts
Diagrams from Kalpalkian and Schmid, Manufacturing Engineering and Technology

Demo #2: Tools, finish, and wear
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Demo #2: Data
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Tool Speed Depth of cut Feed MRR

Material [RPM] [in] [in/rev] [in3/min]
90 0.05 0.007 0.40
HSS 140 0.05 0.007 0.62
330 0.05 0.007 1.45
330 0.05 0.014 2.90
Carbide 385 0.05 0.014 3.29
585 0.05 0.014 5.15

Tool hardness, temperature rise
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speed V and feed f;; a
a b and b are constants
Tmean ∝V f that depend on the tool
and part
max
Kalpalkian and Schmid, Manufacturing Engineering and Technology

on
Tool wear
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Crater
Crater wear wear
Flank wear
Flank
wear
Crater Wear W
Thermal
on the Rake t
Cracking
Face
Wear on Deposition
the Flank causing a
Face “Built Up
Edge”
Depth of cut
Images from Figure 23.2 Fundamentals of Modern Manufacturing (4th Edition) by Groover. (c) Wiley (2010).
Wear schematics from: http://www.sandvik.coromant.com/en-us/knowledge/milling/troubleshooting/tool_wear
Chips from demo: carbide tool, 385 RPM
à Examine both sides 2.008x
Crater
wear
Flank
wear
Chip types (selected)
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Continuous chip (narrow primary shear zone)
§ Ductile materials @ high speed
§ Entanglement bad (use chip breakers)
Continuous chip with built up edge (BUE)

§ Bad for surface finish and tool wear
Discontinuous chip (good)

§ Brittle materials;; very low or very high cutting
speeds
Discontinuous
Continuous with BUE
Continuous chip
Kalpalkian and Schmid, Manufacturing Engineering and Technology.
What determines surface roughness of
machined parts? 2.008x
Surface
roughness 2.008x
Figure 7.44 from "Product Design for Manufacture and Assembly (2nd Edition)" by
Marinescu, Boothroyd. © Marcel Dekker Publishing (2002)
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Taken using Zygo profilometer

Improved tool materials à higher cutting speed
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Rate = 200x faster in

100 years
à ~5% increase per
year, (1.05)100
à Machine
requirements?
Layers: 2-20 μm thick

TiN: low friction
TiCN: wear resistance
Al2O3: high thermal
stability
Carbide: hardness and
fracture toughness Kalpakjian and Schmid, Manufacturing Engineering and Technology.
Figure 21-8 from DeGarmo's Materials & Processes in Manufacturing (10th Edition) by Black and Kohser, © Wiley (2008).
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Machining:
7. Cutting energy and

power
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Step I:
Motion &
Deformation
Step II:
Forces
Step III:
Energy &
Power
A simple estimate of cutting force
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b = depth of cut (d in turning)

FC ~b t0 S t0 = feed (f in turning)
Chip
S = strength
- +
α
FC
Material UTS* (MPa) φ
Wax 0.86
Workpiece
Aluminum 110
Aluminum 6061-T6 310
Steel (high strength alloy) 760
ASTM A-514
Titanium alloys 900
*UTS = Ultimate Tensile Strength
Shear strength ~0.5*UTS
What other forces are present?
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§ Thrust: Ft
Ff
§ Cutting: Fc
Fs N § Friction: Ff (µ = Ff/N)
§ Tool normal: N
Fn § Shear: Fs
R Ft
§ Chip Normal: Fn
Fc
Estimating the cutting power
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Power input = Power out + Power dissipated
Power input:
§ Machine: Pc = Fc * V
Plastically Fc
Power dissipation: Deformed Chip
§ Shear: Ps = Fs * Vs
§ Friction: Pf = Ff * Vc - +
α
Not deformed Vc
NOTE
φ
Vc = velocity of chip
V = cutting velocity
Fc
(denoted VC earlier) Fs
Vs V
Contributions to cutting energy Plastically
Deformed Chip
Fc
à specific energy = power/MRR - +

α
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Not deformed Vc
φ
Fc
Fs
Vs V
Shear + Friction + Others = TOTAL
*Kalpakjian
neglects Units =
Power/(volume/time)
[W*s/mm3]
Let’s estimate the cutting power and force
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§ A SS rod is initially 2.0 cm diameter, and
becomes 1.9 cm in a single cut (full rotation).
§ The spindle rotates at N=400 rpm, and the tool
is traveling at an axial speed of 20 cm/min.
à How much power is required?

MRR = Vfd = π D1 Nfd
à
p
d
Kalpakjian and Schmid, Manufacturing Engineering and Technology C
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à How much power is required?
Pspindle = ut MRR MRR = Vfd = π D1 Nfd

Pspindle ut MRR
Pinput = =
η drive η drive
P = 0.6 kW
with efficiency = 0.7
à
p
d
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à What is the approximate cutting force?

MRR = Vfd = π D1 Nfd
Pspindle = FcV = ut MRR
ut MRR utVfd
Fc = = = ut fd
V V
F = 1 kN
à
p
d
Material-dependent cutting energies
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à Also see ‘machinability rating’

What did we learn so far? (summary)
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§ Cutting removes material from a workpiece by (severe) plastic

deformation.
§ Using a 2D approximation (applied to turning) we can relate the
geometry and motion of the tool to the cutting force and power
required.
§ Tool-material interaction is dominated by shear and friction,
causing deformation and heating.
§ Commercial machine tools easily exert many kN of force at
many kW of power.
§ Recommended cutting parameters are stated based on
material and tool limits.
à Now let’s talk about milling.

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Machining:
8. Milling
How are milling and turning different?
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Excerpt from Ingersoll

https://www.youtube.com/watch?v=IUBQN1JfY80
Feed per tooth (f)

v = velocity of tool or workpiece
N = rotational speed
n = number of teeth (‘flutes’)

3-axis milling machine
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Climb milling versus 6061-T6 Aluminum with ¼” endmill
Spindle Speed: 4000rpm
Conventional milling Feed: 20.0ipm 2.008x
Depth of cut: .400”
Width of cut: .070”

Common milling operations
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Diagram from Kalpalkian and Schmid, Manufacturing Engineering and Technology.

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Fly$cutter$ Face$mill
(single$point$for$making$
smooth$surfaces)
End$mill
iPhone 6 teardown
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Logic board
Front-facing
camera
Housing
Battery
Type of joint Number
Camera
Bolted 44
Adhesive 5
Screen
(flipped) ClipiPhone 6 chassis assembly
8
Faceplate Threaded inserts 46
Counted from teardown s equence
Modified f rom: https://d3nevzfk7ii3be.cloudfront.net/igi/DSCkX6EfcARJYOHa.hug

iPhone 6 housing: What do we notice?
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‘Straight’
tool path T-slot
endmill
Press-fit
threaded
insert
‘Curved’
tool path
Plastic insert
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Feature sizes
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0.5 mm
0.5 mm
6 mm
2 mm
Tool paths
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Zig-zag tool path
Contour-parallel tool path
https://en.wikipedia.or g/wiki /CNC _po

cket_milling
How the toolpath for each area is designed
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Evaluate the shape of material to be removed
Contours of drilled holes and features such
as bosses
Boundary contours pf the pocket
Generate the pocket cutting paths

Contour-parallel tool path Direction-parallel tool path
Begin with offset elements Select reference line and mill along
of the contour to generate parallel lines
cutting paths
Zig milling: Feed along spindle
Step inwards or outwards direction
for subsequent passes
Zig-zag: Both directions (includes
significantly fewer tool retractions)
Add finishing passes

where needed Finishing pass around features
Contour parallel path
Diagrams from M. Held, O n the Computational G eometry of Pocket Machining;; Lecture Notes in Computer Science;; Springer Berlin Heidelberg: Berlin,
Heidelberg, 1991;; Vol. 500.
Optimization for
cost or time? 2.008x
Cost of machining =

§ Machine use ($/time)
§ Tool cost
Taylor’s equation
V*(Tool_life)n = Constant
§ Tool change cost ($/time)
§ Nonproductive cost ($ for
load/unload operations
etc)
Time (1/rate) of machining =

§ Machining time
§ Tool change time
§ Nonproductive time
(load/unload etc)

iPhone housing: 4 à 5 à 6
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§ Materials?
§ Advantages / disadvantages of each design?
§ Other notable differences?
4/5/6 back
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5-axis machining
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3-axis 5-axis
Photo from https://www.youtube.com/watch?v=CqePrbeAQoM

Diagrams fromhttp://www.awea.com/awea_en/milling/5-axes/fmv/overview.htm
5-axis machining
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Video excerpt from https://www.youtube.com/watch?v=mudofisRCjA

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Machining:
9. Design guidelines
for Machining
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Design for
Manufacturing (DFM):
The process of designing

parts/products to enable
easier* and more robust**
manufacturing.
*fewer steps, lower cost
**more reliable, better quality

Design for Machining
Don’t Do 2.008x
D = 0.627” D = 0.625”
Don’t Difficult to

fixture
Use s tandard dimensions

Avoid long, narrow holes
Do
Don’t Do
Easier to
hold
Design parts that are easy to
fixture
Provide access for tools Don’t Do
Avoid long, thin sections that Impossible

Impossible
Use ¼ - ½”
cause v ibration Radius s maller radius
than ¼”
Design for reasonable internal

pockets radii
From Otto and Wood, Product Design: Techniques in Reverse Engineering and New Product Development
DFM: what’s wrong with this part?
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§ Sharp internal corners are

impossible!
§ Avoid thin sections à
(deformation, poor surface
finish).
also
§ Minimize the number of tool changes, while considering overall
machining time (e.g., rough removal versus fine finishing).
§ Know the limits of tooling available (e.g. minimum size, maximum depth)!
§ Consider fixturing (how you will hold the part, and reference it if re-
fixtured)
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Machining:
10. Conclusion
How is machining
advancing now? 2.008x
§ Higher speed machining, largely

driven by tool materials/coatings
à lower cost and higher
throughput!
§ Growing demand for machining

of advanced materials, e.g.,
titanium, composites, etc.
§ Networked machines enabling

remote process monitoring and
optimization à toolpath, cutting
speed, tool life, surface quality,
etc.
High-speed machining: chip carries the heat away
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Total heat generated

100%
% to
workpiece
% to
Heat generated
tool
50% % to
chip
0
Excerpt from: https://www.youtube.com/watch?v=8Lh600hVyt8 Low High
Cutting speed
Figure adopted from 20.31, Degarmo, Materials and Processes in Manufacturing
Conclusion: performance of machining
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Machining
Rate Low-Medium
Quality Good!
Cost Wide range, depends on design, material,

production volume
Flexibility High (within machine

constraints)
References
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1 Introduction
Photo of CNC Mill by Roland Josch on Pixabay. This work is in the public domain.
Photo of Machine Shop in DC Printing Office by National Photo Company from U.S. Library of
Congress. This work is in the public domain.
Photo of CNC Machine Shop by Kim Becker v ia Flickr (CC BY) 2.0
Photo of Drill Bit Set by Michael Schwarzenberger on Pixabay. This work is in the public domain.
Video of MacBook Pro Manufacturing © Apple Inc.
Image of MacBook Pro Exploded View © 2016 Apple Inc.
Machining Processes: Figure 1.5e "Manufacturing Engineering & Technology (6th Edition)" by
Kalpakjian, Schmid. © Upper Saddle River;; Pearson Publishing (2010).
Photo of Mechanical Watch Mechanism by User: tookapic on Pixabay. This work is in the public
domain.
Photo of Brass Fittings by Ingbert Merz on Pixabay. This work is in the public domain.
Machined Part: Figure IV.3 from "Manufacturing Engineering & Technology (7th Edition)" by
References
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2 Basics of Tool-Material-Interaction
Lathe Picture: Figure 23.2 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Schmid. © Upper Saddle River;; Pearson Publishing (2014).
Video of Rook Machining © 2016 Glacern Machine Tools
Lathe Cutting Operations: Figure 23.1 from "Manufacturing Engineering & Technology (6th Edition)"
by Kalpakjian, Schmid. © Upper Saddle River;; Pearson Publishing (2009).
Turning Schematic: Figure 21.2 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Videos of Iscar Chip Formation © Rick Steinard.
3 Tool Motion and Material Interaction
Video of Iscar Chip Formation © Rick Steinard.
Video of Titanium machining example, by NIST of the U.S. Dept. of Commerce 2009.
Photo of CNC Mill by Roland Josch on Pixabay. This work is in the public domain.
References
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4 Cutting Forces
Graphs by Gokkaya, “The Effects of Machining Parameters on Cutting Forces, Surface Roughness, Built-Up
Edge (BUE) and Built-Up Layer (BUL) During Machining AA2014 (T4) Alloy”, Journal of Mechanical
Engineering 56(2010)9, 584-593
Shear Angle Chart adapted from: Metal Cutting Theory and Practice, Stephenson and Agapiou
6 Tools and Wear
Lathe Cutting Tool: Figure 21.10 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Tooling with Insert: Figure 22.3 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Temperature Distribution: Figure 21.12 from "Manufacturing Engineering & Technology (7th Edition)" by
Hardness Chart: Figure 22.1 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
References
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Crater Wear: Figure 23.2 from "Fundamentals of Modern Manufacturing (4th Edition)" by Groover. © John
Wiley & Sons Inc. (2010)
Wear schematics images © 2000 Sandvik AB
Chip Types: Figures 21.5 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Machining Time: Figure 22.6 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Coating Cross-Section: Figure 22.8 from "Manufacturing Engineering & Technology (7th Edition)" by
Insert: Figure 21-8 from "DeGarmo's Materials & Processes in Manufacturing (10th Edition)" by Black and
Kohser, © John Wiley & Sons, Inc. (2008).
7 Cutting Energy and Power
Turning Schematic: Figure 21.2 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Cutting Energies: Table 21.2 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
References
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8 Milling
Video of Face Milling Slow-Motion © Ingersoll Cutting Tool Company
Parts Produced by Milling: Figure 24.1 from "Manufacturing Engineering & Technology (7th Edition)" by
Milling Operation Parameters: Figure 24.3 b) from "Manufacturing Engineering & Technology (7th Edition)"
by Kalpakjian, Schmid. © Upper Saddle River;; Pearson Publishing (2014).
Conventional vs. Climbing: Figure 24.3 a) from "Manufacturing Engineering & Technology (7th Edition)" by
Milling Operations: Figure 24.2 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Image of iPhone 6 © 2000-2016 GSMArena.com
Image of iPhone 6 Exploded View © 2016 iFixit
Image of T-Slot End Mill Cutter © 2003 Bewise Inc. All Rights Reserved
Image of Tool Paths by Kangkan iitd on Wikimedia. (CC BY-SA) 3.0
Pocket Machining: Figure 1.3 from "On the Conceptual Geometry of Pocket Machining" by Held © Springer-
Verlag (1991).
References
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Toolpaths: Figure 1.4 from "On the Conceptual Geometry of Pocket Machining" by Held © Springer-Verlag
(1991).
Cost Optimization: Figure 25.17 from "Manufacturing Engineering & Technology (7th Edition)" by Kalpakjian,
Diagrams of Advantages of 5-Axis Milling Machines © AWEA Mechatronic Co. LTD. 2016. All Rights
Reserved.
Image of 5-Axis Vertical Machining Center © Okuma America Corporation.
Video of Mazak Variaxis i700 © John Hart Pty Ltd.
9 Design for Manufacturing
DFM Practice Diagram: Figure 14.10 from "Product Design: Techniques in Reverse Engineering and New
Product Development" by Otto and Wood, © Upper Saddle River;; Pearson Publishing (2001)
10 Conclusion
Image of Datron M8Cube © 2016 DATRON Dynamics, Inc.
Heat vs. Speed Diagram: Figure 20-31 from "DeGarmo's Materials & Processes in Manufacturing (10th
Edition)" by Black and Kohser, © John Wiley & Sons, Inc. (2008).

Machining: MIT 2.008x

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Machining: MIT 2.008x

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2.

Prof. John Hart

Machine shop in the DC printing office (1909)

A present-­day CNC machine shop

What is the highest

Excerpt from: http://www.youtube.com/watch?v=sxbiIpXZfG8

§ … “a general term describing a group of

§ Traditional machining: a rotating cutter

§ Other machining processes that use

Kalpalkian and Schmid, Manufacturing Engineering and Technology

Boeing 777 panel

Diagram from Kalpalkian and Schmid, Manufacturing Engineering and Technology.

§ Milling (+iPhone housing)

Kalpakjian and Schmid, Manufacturing Engineering and Technology

Turning Contour turning Facing

Video excerpt from: https://www.youtube.com/watch?v=lcGHtI9Lql4

à The cutting tool is set to a

§ Feed: axial distance tool moves per

Kalpakjian and Schmid, Manufacturing Engineering and Technology

A 304 stainless steel rod is being turned on a lathe.

à What is the initial cutting speed? (tangential velocity)

à What is the initial material removal rate (MRR)?

à What is the initial cutting speed? (tangential

Vc = πDo N = 0.31 m/s = 18.8 m/min

à What is the initial material removal rate (MRR)?

MRR = πD1 Nfd = Vc fd

à What is the initial material removal rate (MRR)?

MRR = πD1 Nfd = Vc fd

Material is removed (and a chip is produced) at the

à These lead to deformation

à All of these are coupled

3. Tool motion and

Three important angles:

Excerpt from: https://www.youtube.com/watch?v=mRuSYQ5Npek

In reality the ‘pages’ are very thin and

γ = cot (φ ) + tan (φ − α ) Chip

à Think of the material

§ Forces are related to the

à The coupling of motion

Cut Feedrate Spindle Rake angle Depth of cut Diameter Force

à if rake angle ↓ or friction angle ↑: shear angle ↓

à consequences of smaller shear angle: Chip

5. Field trip to IMTS

Haas DT1 drill-­tap c enter

6. Tools, finish, and

Tooling with inserts

Diagrams from Kalpalkian and Schmid, Manufacturing Engineering and Technology

Tool Speed Depth of cut Feed MRR

90 0.05 0.007 0.40

HSS 140 0.05 0.007 0.62

330 0.05 0.007 1.45

330 0.05 0.014 2.90

Carbide 385 0.05 0.014 3.29

585 0.05 0.014 5.15

Kalpalkian and Schmid, Manufacturing Engineering and Technology

Continuous chip with built up edge (BUE)

Discontinuous chip (good)

Taken using Zygo profilometer

Rate = 200x faster in

Layers: 2-­20 μm thick

7. Cutting energy and

b = depth of cut (d in turning)

à specific energy = power/MRR -­ +

A present-day CNC machine shop

Haas DT1 drill-tap c enter

Layers: 2-20 μm thick

à specific energy = power/MRR - +

Zig-zag tool path

Contour-parallel tool path

Video of Face Milling Slow-Motion © Ingersoll Cutting Tool Company

Image of iPhone 6 © 2000-2016 GSMArena.com

Image of 5-Axis Vertical Machining Center © Okuma America Corporation.