Enviar búsqueda
Cargar
Lecture2 (1)
•
1 recomendación
•
2,320 vistas
Self Employed
Seguir
Denunciar
Compartir
Denunciar
Compartir
1 de 35
Descargar ahora
Descargar para leer sin conexión
Recomendados
Lecture 2 (Manufacturing process-1)
Lecture 2 (Manufacturing process-1)
krupal3
Merchants circle-diagram
Merchants circle-diagram
cpandiv
Tool wear and tool Life
Tool wear and tool Life
Dr. Bolleddu Venkateshwarlu
METAL CUTTING
METAL CUTTING
Kunj Thummar
Unit 1 Metal Cutting
Unit 1 Metal Cutting
Mechbytes
Theory of Metal Cutting
Theory of Metal Cutting
Kunduru Srinivasulu Reddy
Theory of metal cutting
Theory of metal cutting
Muhammad Muddassir
Merchant's circle
Merchant's circle
Sumit Shrivastava
Recomendados
Lecture 2 (Manufacturing process-1)
Lecture 2 (Manufacturing process-1)
krupal3
Merchants circle-diagram
Merchants circle-diagram
cpandiv
Tool wear and tool Life
Tool wear and tool Life
Dr. Bolleddu Venkateshwarlu
METAL CUTTING
METAL CUTTING
Kunj Thummar
Unit 1 Metal Cutting
Unit 1 Metal Cutting
Mechbytes
Theory of Metal Cutting
Theory of Metal Cutting
Kunduru Srinivasulu Reddy
Theory of metal cutting
Theory of metal cutting
Muhammad Muddassir
Merchant's circle
Merchant's circle
Sumit Shrivastava
Production technology Metal Cutting introduction
Production technology Metal Cutting introduction
Ahmedabad Institute Of Technology
METAL MACHINING
METAL MACHINING
MOHD BILAL NAIM SHAIKH
Oblique Cutting
Oblique Cutting
Adil Malik
Ipec manu scunit1
Ipec manu scunit1
Manoj Yadav
Metal cutting and Machining tools
Metal cutting and Machining tools
SHIVAM AGRAWAL
Tool Geometry & It’s Signature.
Tool Geometry & It’s Signature.
Akash Patel
Theory of metal machining
Theory of metal machining
Pardeep Kumar
Metal cutting 2
Metal cutting 2
Naman Dave
Optimization of Turning Parameters Using Taguchi Method
Optimization of Turning Parameters Using Taguchi Method
IJMER
04 metal cutting(1)
04 metal cutting(1)
Thulasikanth Vaddi
azad alam alig
azad alam alig
azadalig
Lecture 3 theory of metal cutting
Lecture 3 theory of metal cutting
VJTI Production
Cutting tools
Cutting tools
University of engineering and technology taxila
TYPES OF CUTTING
TYPES OF CUTTING
Anil Asodariya
Merchant circle diagram
Merchant circle diagram
GATE / ESE teacher
non traditional machining
non traditional machining
Khalid Sheikh
Topic 2 machining 160214
Topic 2 machining 160214
Huai123
Theory of metal cutting
Theory of metal cutting
Sahebrao Deshmukh
Unit1
Unit1
naanmech123
machining and machine tool Unit 1&2
machining and machine tool Unit 1&2
alakshendra pratap singh
Iv report
Iv report
Self Employed
1theoryofmetalcutting 130917122754-phpapp02
1theoryofmetalcutting 130917122754-phpapp02
manojkumarg1990
Más contenido relacionado
La actualidad más candente
Production technology Metal Cutting introduction
Production technology Metal Cutting introduction
Ahmedabad Institute Of Technology
METAL MACHINING
METAL MACHINING
MOHD BILAL NAIM SHAIKH
Oblique Cutting
Oblique Cutting
Adil Malik
Ipec manu scunit1
Ipec manu scunit1
Manoj Yadav
Metal cutting and Machining tools
Metal cutting and Machining tools
SHIVAM AGRAWAL
Tool Geometry & It’s Signature.
Tool Geometry & It’s Signature.
Akash Patel
Theory of metal machining
Theory of metal machining
Pardeep Kumar
Metal cutting 2
Metal cutting 2
Naman Dave
Optimization of Turning Parameters Using Taguchi Method
Optimization of Turning Parameters Using Taguchi Method
IJMER
04 metal cutting(1)
04 metal cutting(1)
Thulasikanth Vaddi
azad alam alig
azad alam alig
azadalig
Lecture 3 theory of metal cutting
Lecture 3 theory of metal cutting
VJTI Production
Cutting tools
Cutting tools
University of engineering and technology taxila
TYPES OF CUTTING
TYPES OF CUTTING
Anil Asodariya
Merchant circle diagram
Merchant circle diagram
GATE / ESE teacher
non traditional machining
non traditional machining
Khalid Sheikh
Topic 2 machining 160214
Topic 2 machining 160214
Huai123
Theory of metal cutting
Theory of metal cutting
Sahebrao Deshmukh
Unit1
Unit1
naanmech123
machining and machine tool Unit 1&2
machining and machine tool Unit 1&2
alakshendra pratap singh
La actualidad más candente
(20)
Production technology Metal Cutting introduction
Production technology Metal Cutting introduction
METAL MACHINING
METAL MACHINING
Oblique Cutting
Oblique Cutting
Ipec manu scunit1
Ipec manu scunit1
Metal cutting and Machining tools
Metal cutting and Machining tools
Tool Geometry & It’s Signature.
Tool Geometry & It’s Signature.
Theory of metal machining
Theory of metal machining
Metal cutting 2
Metal cutting 2
Optimization of Turning Parameters Using Taguchi Method
Optimization of Turning Parameters Using Taguchi Method
04 metal cutting(1)
04 metal cutting(1)
azad alam alig
azad alam alig
Lecture 3 theory of metal cutting
Lecture 3 theory of metal cutting
Cutting tools
Cutting tools
TYPES OF CUTTING
TYPES OF CUTTING
Merchant circle diagram
Merchant circle diagram
non traditional machining
non traditional machining
Topic 2 machining 160214
Topic 2 machining 160214
Theory of metal cutting
Theory of metal cutting
Unit1
Unit1
machining and machine tool Unit 1&2
machining and machine tool Unit 1&2
Destacado
Iv report
Iv report
Self Employed
1theoryofmetalcutting 130917122754-phpapp02
1theoryofmetalcutting 130917122754-phpapp02
manojkumarg1990
Heat in metal cutting
Heat in metal cutting
Karan Prajapati
Ch1 mp1
Ch1 mp1
jigarmech
Cutting operations
Cutting operations
Gulfam Hussain
Thermal metal removal processes by chandrakanth
Thermal metal removal processes by chandrakanth
Chandrakanth Bhajantri
Amitabh bachchan
Amitabh bachchan
Himanshu Shekhar
Ch10 math
Ch10 math
klivsie
NC Programming
NC Programming
Vishnuvardhan Reddy S
Ch17
Ch17
klivsie
Ch27 1
Ch27 1
klivsie
Ch12
Ch12
klivsie
Mechanics of metal cutting
Mechanics of metal cutting
manoj18biet
Food porn: the food that turns you on
Food porn: the food that turns you on
Raquel Herrera Ferrer
Abrasive Jet Machining
Abrasive Jet Machining
Melbin Mathew
Sexiest Women Of All Time Part One
Sexiest Women Of All Time Part One
fondas vakalis
Ch10
Ch10
klivsie
Ch19
Ch19
klivsie
Naked truth about porn on social media
Naked truth about porn on social media
Sotrender
Theory of-metal-cutting
Theory of-metal-cutting
Gaurav Gunjan
Destacado
(20)
Iv report
Iv report
1theoryofmetalcutting 130917122754-phpapp02
1theoryofmetalcutting 130917122754-phpapp02
Heat in metal cutting
Heat in metal cutting
Ch1 mp1
Ch1 mp1
Cutting operations
Cutting operations
Thermal metal removal processes by chandrakanth
Thermal metal removal processes by chandrakanth
Amitabh bachchan
Amitabh bachchan
Ch10 math
Ch10 math
NC Programming
NC Programming
Ch17
Ch17
Ch27 1
Ch27 1
Ch12
Ch12
Mechanics of metal cutting
Mechanics of metal cutting
Food porn: the food that turns you on
Food porn: the food that turns you on
Abrasive Jet Machining
Abrasive Jet Machining
Sexiest Women Of All Time Part One
Sexiest Women Of All Time Part One
Ch10
Ch10
Ch19
Ch19
Naked truth about porn on social media
Naked truth about porn on social media
Theory of-metal-cutting
Theory of-metal-cutting
Similar a Lecture2 (1)
MRP
MRP
Yogesh Mistry
Theory of metal machining
Theory of metal machining
Dr Ibrahim
sheet metal
sheet metal
Vivek Tyagi
Sheet metalworking
Sheet metalworking
Dr Ibrahim
Sheeet metal
Sheeet metal
Eajaz Khan
sheetmetalworking-220317091136.pptx
sheetmetalworking-220317091136.pptx
upendramaurya11
Ch21-MetalCuttingTheory-Wiley.pdf
Ch21-MetalCuttingTheory-Wiley.pdf
Dr. J S Sri Kantamurthy
THEORY OF METAL MACHINING.pptx
THEORY OF METAL MACHINING.pptx
Dr. J S Sri Kantamurthy
ppt on Sheet metal process
ppt on Sheet metal process
sumant99
Sheetmetal 150503052320-conversion-gate02
Sheetmetal 150503052320-conversion-gate02
divyesh bhanderi
Machining.pptx
Machining.pptx
FebrianJha
Machining .pdf
Machining .pdf
FebrianJha
MACHINING OPERATIONS AND MACHINE TOOLS.pptx
MACHINING OPERATIONS AND MACHINE TOOLS.pptx
JiaJunWang17
Chap-25-1.ppt
Chap-25-1.ppt
secondactivity
Chap-23-2.pdf
Chap-23-2.pdf
secondactivity
MT PPT.pptx
MT PPT.pptx
Vignesh864406
Metal working
Metal working
Eajaz Khan
9.Metalcutting.pdf
9.Metalcutting.pdf
SambathKumar88
9.Metalcutting.pdf
9.Metalcutting.pdf
SambathKumar88
Metal cutting by engr Rehan zeb khan Bajaur
Metal cutting by engr Rehan zeb khan Bajaur
PMAS-Arid Agriculture Universty Rawalpindi
Similar a Lecture2 (1)
(20)
MRP
MRP
Theory of metal machining
Theory of metal machining
sheet metal
sheet metal
Sheet metalworking
Sheet metalworking
Sheeet metal
Sheeet metal
sheetmetalworking-220317091136.pptx
sheetmetalworking-220317091136.pptx
Ch21-MetalCuttingTheory-Wiley.pdf
Ch21-MetalCuttingTheory-Wiley.pdf
THEORY OF METAL MACHINING.pptx
THEORY OF METAL MACHINING.pptx
ppt on Sheet metal process
ppt on Sheet metal process
Sheetmetal 150503052320-conversion-gate02
Sheetmetal 150503052320-conversion-gate02
Machining.pptx
Machining.pptx
Machining .pdf
Machining .pdf
MACHINING OPERATIONS AND MACHINE TOOLS.pptx
MACHINING OPERATIONS AND MACHINE TOOLS.pptx
Chap-25-1.ppt
Chap-25-1.ppt
Chap-23-2.pdf
Chap-23-2.pdf
MT PPT.pptx
MT PPT.pptx
Metal working
Metal working
9.Metalcutting.pdf
9.Metalcutting.pdf
9.Metalcutting.pdf
9.Metalcutting.pdf
Metal cutting by engr Rehan zeb khan Bajaur
Metal cutting by engr Rehan zeb khan Bajaur
Lecture2 (1)
1.
1.
Overview of Machining Technology 2. Theory of Chip Formation in Metal Machining 3. Force Relationships and the Merchant Equation 4. Power and Energy Relationships in Machining 5. Cutting Temperature ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2.
A family of
shaping operations, the common feature of which is removal of material from a starting workpart so the remaining part has the desired geometry Machining – material removal by a sharp cutting tool, e.g., turning, milling, drilling Abrasive processes – material removal by hard, abrasive particles, e.g., grinding Nontraditional processes - various energy forms other than sharp cutting tool to remove material ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
3.
Machining
Cutting action involves shear deformation of work material to form a chip As chip is removed, new surface is exposed (a) A cross-sectional view of the machining process, (b) tool with negative rake angle; compare with positive rake angle in (a). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
4.
Variety of work materials can be machined ◦ Most frequently used to cut metals Variety of part shapes and special geometric features possible, such as: ◦ Screw threads ◦ Accurate round holes ◦ Very straight edges and surfaces Good dimensional accuracy and surface finish Generally performed after other manufacturing processes, such as casting, forging, and bar drawing Disadvantages • Wasteful of material and time consuming ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
5.
Most important machining operations: ◦ Turning ◦ Drilling ◦ Milling Other machining operations: ◦ Shaping and planing ◦ Broaching ◦ Sawing ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
6.
Turning Single point cutting
tool removes material from a rotating workpiece to form a cylindrical shape ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
7.
Drilling Used to create
a round hole, usually by means of a rotating tool (drill bit) with two cutting edges ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
8.
Milling
Rotating multiple-cutting-edge tool is moved across work to cut a plane or straight surface Two forms: peripheral milling and face milling (c ) peripheral milling, and (d) face milling. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
9.
Cutting Tools (a)
A single-point tool showing rake face, flank, and tool point; and (b) a helical milling cutter, representative of tools with multiple cutting edges. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
10.
Three dimensions of a machining process: ◦ Cutting speed v – primary motion ◦ Feed f – secondary motion ◦ Depth of cut d – penetration of tool below original work surface For certain operations, material removal rate can be computed as MRR = v f d where v = cutting speed; f = feed; d = depth of cut ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
11.
Roughing - removes large amounts of material from starting workpart ◦ Creates shape close to desired geometry, but leaves some material for finish cutting ◦ High feeds and depths, low speeds Finishing - completes part geometry ◦ Final dimensions, tolerances, and finish ◦ Low feeds and depths, high cutting speeds ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
12.
A power-driven machine
that performs a machining operation, including grinding Functions in machining: ◦ Holds workpart ◦ Positions tool relative to work ◦ Provides power at speed, feed, and depth that have been set The term is also applied to machines that perform metal forming operations ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
13.
Orthogonal Cutting Model
Simplified 2-D model of machining that describes the mechanics of machining fairly accurately Orthogonal cutting: (a) as a three-dimensional process. to r = tc chip ratio always less than 1.0 Based on the geometric parameters of the orthogonal model, the shear plane angle φ can be determined as: r cos α tan φ = where r = chip ratio, & α = rake angle 1 − r sinα ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
14.
Shear Strain in
Chip Formation Shear strain during chip formation: (a) chip formation depicted as a series of parallel plates sliding relative to each other, (b) one of the plates isolated to show shear strain, and (c) shear strain triangle used to derive strain equation. γ = tan(φ - α) + cot φ where γ = shear strain, φ = shear plane angle, and α = rake angle of cutting tool ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
15.
Chip Formation More realistic
view of chip formation, showing shear zone rather than shear plane. Also shown is the secondary shear zone resulting from tool-chip friction. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
16.
1.
Discontinuous chip 2. Continuous chip 3. Continuous chip with Built-up Edge (BUE) 4. Serrated chip ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
17.
Discontinuous Chip Brittle workmaterials
Low cutting speeds Large feed and depth of cut High tool-chip friction Four types of chip formation in metal cutting: (a) discontinuous ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
18.
Continuous Chip
Ductile work materials High cutting speeds Small feeds and depths Sharp cutting edge Low tool-chip friction (b) continuous ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
19.
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 (c) continuous with built-up edge ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
20.
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 (d) serrated. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
21.
Forces Acting on
Chip Friction force F and Normal force to friction N Shear force Fs and Normal force to shear Fn Forces in metal cutting: (a) forces acting on the chip in orthogonal cutting ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
22.
Vector addition of F and N = resultant R Vector addition of Fs and Fn = resultant R' Forces acting on the chip must be in balance: ◦ R' must be equal in magnitude to R ◦ R’ must be opposite in direction to R ◦ R’ must be collinear with R ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
23.
Coefficient of friction
between tool and chip: F µ= N Friction angle related to coefficient of friction as follows: µ = tan β ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
24.
Shear stress acting
along the shear plane: Fs S= As where As = area of the shear plane t ow As = sin φ Shear stress = shear strength of work material during cutting ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
25.
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 Forces in metal cutting: (b) forces acting on the tool that can be measured ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
26.
Equations can be derived to relate the forces that cannot be measured to the forces that can be measured: F = Fc sinα + Ft cosα N = Fc cosα - Ft sinα Fs = Fc cosφ - Ft sinφ Fn = Fc sinφ + Ft cosφ Based on these calculated force, shear stress and coefficient of friction can be determined ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
27.
Of all the possible angles at which shear deformation can occur, the work material will select a shear plane angle φ that minimizes energy, given by α β φ = 45 + − 2 2 Derived by Eugene Merchant Based on orthogonal cutting, but validity extends to 3-D machining ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
28.
α
β φ = 45 + − 2 2 To increase shear plane angle ◦ Increase the rake angle ◦ Reduce the friction angle (or coefficient of friction) ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
29.
Effect of Higher
Shear Plane Angle Higher shear plane angle means smaller shear plane which means lower shear force, cutting forces, power, and temperature Effect of shear plane angle φ : (a) higher φ with a resulting lower shear plane area; (b) smaller φ with a corresponding larger shear plane area. Note that the rake angle is larger in (a), which tends to increase shear angle according to the Merchant equation ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
30.
A machining operation requires power The power to perform machining can be computed from: Pc = Fc v where Pc = cutting power; Fc = cutting force; and v = cutting speed ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
31.
Useful to convert power into power per unit volume rate of metal cut Called unit power, Pu Pc PU = MRR Unit power is also known as the specific energy U Pc Fc v U = Pu = = RMR vtow Units for specific energy are typically N-m/mm3 or J/mm3 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
32.
Approximately 98% of the energy in machining is converted into heat This can cause temperatures to be very high at the tool-chip The remaining energy (about 2%) is retained as elastic energy in the chip ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
33.
High cutting temperatures 1.
Reduce tool life 2. Produce hot chips that pose safety hazards to the machine operator 3. Can cause inaccuracies in part dimensions due to thermal expansion of work material ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
34.
Analytical method derived by Nathan Cook from dimensional analysis using experimental data for various work materials 0.333 0.4U vt o T = ρC K where T = temperature rise at tool-chip interface; U = specific energy; v = cutting speed; to = chip thickness before cut; ρC = volumetric specific heat of work material; K = thermal diffusivity of work material ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
35.
Experimental methods can be used to measure temperatures in machining ◦ Most frequently used technique is the tool-chip thermocouple Using this method, Ken Trigger determined the speed-temperature relationship to be of the form: T = K vm where T = measured tool-chip interface temperature, and v = cutting speed ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Descargar ahora