Professional Documents
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MACHINING
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Material Removal Processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
The family tree
of material
removal
processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Machining
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Why Machining is Important
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Disadvantages of Machining
Wasteful of material
Chips generated in machining are wasted material
At least in the unit operation
Time consuming
A machining operation generally takes longer to
shape a given part than alternative shaping
processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Machining in the Manufacturing
Sequence
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Machining Operations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Turning
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Drilling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Milling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Tool Classification
1. Single-Point Tools
One dominant cutting edge
Point is usually rounded to form a nose radius
Turning uses single point tools
2. Multiple Cutting Edge Tools
More than one cutting edge
Motion relative to work achieved by rotating
Drilling and milling use rotating multiple cutting
edge tools
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Tools
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Conditions in Machining
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Conditions in Turning
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Roughing vs. Finishing Cuts
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Machine Tool
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Orthogonal Cutting Model
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Chip Thickness Ratio
to
r
tc
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Determining Shear Plane Angle
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shear Strain in Chip Formation
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shear Strain
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Actual Chip Formation
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Four Basic Types of Chip in
Machining
1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Discontinuous Chip
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Continuous Chip
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Continuous with BUE
Ductile materials
Low‑to‑medium cutting
speeds
Tool-chip friction causes
portions of chip to adhere to
rake face
BUE forms, then breaks off,
cyclically
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Serrated Chip
Semicontinuous - saw-tooth
appearance
Cyclical chip forms with
alternating high shear strain
then low shear strain
Associated with difficult-to-
machine metals at high
cutting speeds
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Forces Acting on Chip
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Resultant Forces
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Coefficient of Friction
tan
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shear Stress
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Force and Thrust Force
F, N, Fs, and Fn
cannot be directly
measured
Forces acting on
the tool that can be
measured: Cutting
force Fc and
Thrust force Ft
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Forces in Metal Cutting
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
The Merchant Equation
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
What the Merchant Equation
Tells Us
45
2 2
To increase shear plane angle
Increase the rake angle
Reduce the friction angle (or reduce the coefficient
of friction)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Effect of Higher Shear Plane
Angle
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Power and Energy Relationships
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Power and Energy Relationships
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Power and Energy Relationships
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Unit Power in Machining
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Specific Energy in Machining
Pc Fc v
U = Pu = =
RMR vtow
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Temperature
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Temperatures are
Important
High cutting temperatures result in the following:
Reduce tool life
Produce hot chips that pose safety hazards to the
machine operator
Can cause inaccuracies in part dimensions due to
thermal expansion of work material
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Temperature
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
https://youtu.be/mRuSYQ5Npek
https://youtu.be/8SbBC5UWeNI
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e