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Machining Processes Used To Produce Round Shapes: Turning and Hole Making
Machining Processes Used To Produce Round Shapes: Turning and Hole Making
Figure 23.4 Designations for a right-hand cutting tool. Right-hand means the tool
travels form right to left, as shown in Fig. 23.3.
THE TURNING PROCESS
Tool Geometry
General Recommendations for Tool Angles in
Turning
THE TURNING PROCESS
Tool Geometry
Table 23.2: General Recommendations for Turning Tool Angles
Rake angles are important in controlling both direction of chip flow and
strength of tool tip
Positive rake angles improve cutting operation by reducing forces and
temperatures. However, positive angles result in a small included angle of
tool tip
Relief angles control interference and rubbing at tool workpiece interface
If relief angle is too large, tool tip may chip off. If it is too small, flank
wear may be excessive
Cutting-edge angle affect chip formation, tool strength, and cutting forces
to various degrees
The nose radius affects surface finish and tool-tip strength
The smaller the nose radius, the rougher the surface finish of the
workpiece and the lower the strength of the tool. Large nose radii can lead
to tool chatter.
THE TURNING PROCESS
Material Removal Rate (MRR)
THE TURNING PROCESS
Material Removal Rate (MRR)
THE TURNING PROCESS
Forces in Turning
Figure 23.5 Forces acting on a cuttin tool in turning, Fc is the cutting force, Ft is the thrust of
feed force (in the direction of feed), and Fr is the radial force that tends to push the tool away
from the workpiece being machined.
THE TURNING PROCESS
Summary of Turning Parameters and Formulas
N = Rotational speed of workpiece, rpm
= Feed, mm/rev or in/rev
= Feed rate, or linear speed of tool along workpiece length, mm/min or
in/min = N
V = Surface speed of workpiece, m/min or ft/min = DoN (for max
speed)= DavgN (for average speed)
l = Length of cut, mm or in
Do = Original diameter of workpiece, mm or in
D = Final diameter of workpiece, mm or in
Davg = Average diameter of workpiece, mm or in = (Do + D)/2
d = Depth of cut, mm or in = (Do - D)/2
t = Cutting time, s or min = L/N
MRR = mm3/min or in.3/min = Davg d N
Torque = N. m or lb.ft = (Fc) (Davg/2)
Power = k W or hp = (Torque) (), where = 2 N radians/min
Summary of
Turning
Parameters
and Formulas
THE TURNING PROCESS
Summary of Turning Parameters and Formulas
Figure 23.7 (a) and (b) Schematic illustrations of a draw-in type collet. The
workpiece is placed in the collet hole, and the conical surfaces of the collet are forced
inwards by pulling it with a draw bar into the sleeve. (c) A push-out type collet. (d)
Workholding of a workpiece on a face plate.
Mandrels to Hold Workpieces for Turning
Figure 23.8 Various types of mandrels to hold workpieces for turning. These mandrels
usually are mounted between centers on a lathe. Note that in (a), both the cylindrical
and the end faces of the workpiece can be machined, whereas in (b) and (c), only the
cylindrical surfaces can be machined.
LATHES AND LATHE OPERATIONS
Lathe Operations
Long and slender parts must be supported by a steady rest and
follow rest placed on the bed otherwise the part will deflect under the
cutting forces.
These rests usually are equipped with three adjustable fingers or
rollers that support the workpiece while allowing it to rotate freely
Steady rests are clamped directly on the ways of the lathe, whereas
follow rests are clamped on the carriage and travel with it.
A right-hand tool travels toward the headstock, and a left-hand tool
travels toward the tailstock.
Form tools are used to produce various shapes on solid, round
workpieces by moving the tool radially inward while the part is
rotating.
Form cutting is not suitable for deep and narrow grooves or sharp
corners, because vibration and chatter may result and cause poor
surface finish.
Steady rests and Follow rests
LATHES AND LATHE OPERATIONS
Lathe Operations
Boring on a lathe is similar to turning. It is performed inside hollow
workpieces or in a hole made previously by drilling or other means.
Out-of-shape holes can be straightened by boring.
Drilling The workpiece is clamped in a work holder on the headstock,
and the drill bit is advanced by rotating the handwheel of the tailstock.
Holes drilled in this manner may not be sufficiently concentric
because of the tendency for the drill to drift radially. The concentricity
of the hole can be improved by subsequently boring the drilled hole.
Drilled holes may be reamed (Section 23.6) on lathes in a manner
similar to drilling, thus improving hole dimensional tolerances and
surface finish.
The tools for parting, grooving, threading, and various other
operations are specially shaped for their particular purpose or are
available as inserts. Knurling is performed on a lathe with hardened
rolls
LATHES AND LATHE OPERATIONS
Types of Lathes
Bench Lathes.
Special-purpose Lathes.
Special applications (such as railroad wheels, gun barrels, and rolling-mill
rolls) with workpiece sizes as large as 1.7 m in diameter by 8 m in length and
capacities of 450 kW
Tracer Lathes
With attachments capable of turning parts with various contours
have been replaced largely by numerical-control lathes.
Automatic Lathes
medium to high volume production, parts are fed and removed
automatically, Lathes that do not have tailstocks are called chucking machines
or chuckers. They are either single- or multiple-spindle types.
Automatic Bar Machines (Screw Machines): high production rate of screws
LATHES AND LATHE OPERATIONS
Types of Lathes
Turret Lathes
multiple cutting operations [turning, boring, drilling, thread cutting,
and facing]
several cutting tools are mounted on the hexagonal main turret which
is rotated for each specific operation
Vertical turret lathes also are available; they are more suitable for
short, heavy workpieces with diameters as large as 1.2 m.
ram-type turret lathe-one in which the ram slides in a separate base
on the saddle.
The short stroke of the turret slide limits this machine to relatively
short workpieces and light cuts in both small- and medium-quantity
production.
In the saddle type, the main turret is installed directly on the saddle,
which slides along the bed.
Turret Lathe
Figure 23.9 Schematic illustration of the components of a turret lathe. Note the two
turrets: square and hexagonal (main).
LATHES AND LATHE OPERATIONS
Types of Lathes
CNC Lathe
They are equipped with automatic
tool changers (ATCs)
Pump shaft
Tubular part with internal
threads
Crankshaft
Example 23.3: Machining of Complex Shapes
Figure 23.12 Examples of more complex shapes that can be produced on a CNC lathe.
LATHES AND LATHE OPERATIONS
Turning Process Capabilities
Table 23.8 shows typical prod rates for various cutting operations.
Surface finish and dimensional accuracy in various operations
depend on (see figs 22.14 & 22.15):
1. characteristics and condition of the machine tool
2. stiffness
3. vibration and chatter
4. process parameters
5. tool geometry and wear
6. cutting fluids
7. machinability of workpiece material
8. operator skill
Typical
Production
Rates for
Various
Machining
Operations
Range of
Surface
Roughnesses in
Machining
Processes
Figure 23.13 The range of
surface roughnesses
obtained in various machining
processes. Note the wide
range within each group,
especially in turning and
boring.
Range of
Dimensional
Tolerances in
Machining as a
Function of
Workpiece Size
(d) (c)
Cutting
Screw
Threads
Figure 23.15 (a) Cutting screw threads on a lathe with a single-point cutting tool. (b) Cutting screw threads with a single-
point tool in several passes, normally utilized for large threads. The small arrows in the figures show the direction of the
feed, and the broken lines show the position of the cutting tool as time progresses. Note that in radial cutting, the tool is fed
directly into the workpiece. In flank cutting, the tool is fed inot the piece along the right face of the thread. In incremental
cutting, the tool is first fed directly into the piece at the center of the thread, then at its sides, and finally into the root. (c) A
typical coated-carbide insert in the process of cutting screw threads on a round shaft. (d) Cutting internal screw threads
with a carbide insert. Source: (c): Courtesy of Iscar Metals Inc.
Chasers and Die for Thread Cutting
Figure 23.19 Two common types of drills: (a) Chisel-point drill. The function of the pair of margins is to provide a
bearing surface for the drill against walls of the hole as it penetrates into the workpiece. Drills with four margins (double-
margin) are available for improved drill guidance and accuracy. Drills with chip-breaker features also are available. (b)
Crankshaft drills. These drills have good centering ability, and because chips tend to break up easily, these drills are
suitable for producing deep holes.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
General Capabilities of Drilling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Types of Drills
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Gun Drill
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Trepanning
Figure 23.23 (a) Trepanning tool. (b) Trepanning with a drill-mounted single cutter.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
General Recommendations for Speeds and Feeds
in Drilling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Troubleshooting Guide for Drilling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Vertical Drill Press and Radial Drilling Machine
Figure 23.24 (a) Schematic illustration of the components of a vertical drill press. (b) A radial
drilling machine. Source: (b) Courtesy of Willis Machinery and Tools.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Three-Axis Computer Numerical-Control Drilling
Machine
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Helical Reamer and Inserted-Blade Adjustable Reamer
Figure 23.27 (a) Terminology for a tap. (b) Tapping of steel nuts in production.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
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