Lecture 15. Chapter 23 Machining Processes Used to Produce Round Shapes. Turning
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1 Lecture 15 Chapter 23 Machining Processes Used to Produce Round Shapes Turning Turning part is rotating while it is being machined Typically performed on a lathe Turning produces straight, conical, curved, or grooved parts Facing produces flat surface perpendicular to turning axis Cutting with form tools produces axisymmetric shapes Boring enlarging cavities / producing internal grooves Drilling production of a hole Parting to cut a piece off from the end of a part Threading production of internal or external threads Knurling production of regularly shaped roughness 1
2 Turning Processes Lathe Components 2
3 Collets Mandrels 3
4 Turning Processes and Tolerances TABLE 22.1 General Characteristics of Machining Processes Described in Chapters 22 and 23 Process Characteristics Commercial tolerances(±mm) Turning Turning and facing operations on all types of materials; uses single-point or form tools; requires skilled labor; low production rate, but medium to high with turret lathes and automatic machines, requiring lessskilled labor. Fine: Rough: 0.13 Skiving: Boring Internal surfaces or profiles, with characteristics similar to turning; stiffness of boring bar important to avoid chatter. Drilling Round holes of various sizes and depths; requires boring and reaming for improved accuracy; high production rate; labor skill required depends on hole location and accuracy specified. Milling Variety of shapes involving contours, flat surfaces, and slots; wide variety of tooling; versatile; low to medium production rate; requires skilled labor. Planing Flat surfaces and straight contour profiles on large surfaces; suitable for low-quantity production; labor skill required depends on part shape. Shaping Flat surfaces and straight contour profiles on relatively small workpieces; suitable for low-quantity production; labor skill required depends on part shape. Broaching External and internal flat surfaces, slots, and contours with good surface finish; costly tooling; high production rate; labor skill required depends on part shape Sawing Straight and contour cuts on flat or structural shapes; not suitable for hard materials unless saw has carbide teeth or is coated with diamond; low production rate; requires only low labor skill. 0.8 Independent variables 1. Rotational speed (N) 2. Depths of Cut (d) 3. Feeds (f) 4. Material properties Work-piece Tool Dependent variables 1. Surface finish Turning Variables 2. Dimensional Accuracy 4
5 Designations for a Right Hand Cutting Tool Designations for a Right Hand Cutting Tool Rake Angles Side rake angle Back rake angle Controls flow of chip Positive rake angle Reduces forces and temperature Smaller included angle more apt to break Cutting edge angles Chip formation Tool strength Cutting forces 5
6 Designations for a Right Hand Cutting Tool Relief angle Controls interference / rubbing at the tool-work-piece Too big tool may chip off Too small flank wear Nose Radius Small radii (Sharp tool) rough surface finish Large radii - chatter Trends Tool Angles Compare Al Steel - Plastics TABLE 22.2 High-speed steel Carbide (inserts) Material Back rake Side rake End relief Side relief Side and end cutting edge Back rake Side rake End relief Side relief Side and end cutting edge Aluminum and magnesium alloys Copper alloys Steels Stainless steels High-temperature alloys Refractory alloys Titanium alloys Cast irons Thermoplastics Thermosets
7 Forces in Turning Three principle forces in turning Cutting force (F c ) Deflects tool tip downward Deflects work-piece upward Suggest a model? Thrust force (F t ) Acts longitudinally pushes the tool away from the chuck Radial force (F r ) Pushes the tool away from the work-piece Turning Parameters and Formulas TABLE 22.3 N = Rotational speed of the workpiece, rpm f = Feed, mm/rev or in/rev v = Feed rate, or linear speed of the tool along workpiece length, mm/min or in/min =fn V = Surface speed of workpiece, m/min or ft/min = π D o N (for maximum speed) = π D avg N (for average speed) l = Length of cut, mm or in. D o = Original diameter of workpiece, mm or in. D f = Final diameter of workpiece, mm or in. D avg = Average diameter of workpiece, mm or in. = (D o +D f ) /2 d = Depth of cut, mm or in. = ( D o +D f ) /2 t = Cutting time, s or min =l/f N MRR = mm 3 /min or in 3 /min = π D avg d fn Torque = Nm or lb ft = ( F c )( D avg /2 ) Power = kw or hp = (Torque) (w, where w=2π radians/min Note: The units given are those that are commonly used; however, appropriate units must be used and checked in the formulas. 7
8 Ranges for Cutting Speeds and Feed Rates for Different Tooling Materials Types of Cutting Fluids for Turning TABLE 22.5 Material Aluminum Beryllium Copper Magnesium Nickel Refractory Steels (carbon and low alloy) Steels (stainless) Titanium Zinc Zirconium Type of fluid D, MO, E, MO FO, CSN MC, E, CSN D, E, CSN, MO FO D, MO, MO FO MC, E, CSN MC, E, EP D, MO, E, CSN, EP D, MO, E, CSN CSN, EP, MO C, MC, E, CSN D, E, CSN Note: CSN, chemicals and synthetics; D, dry; E, emulsion; EP, extreme pressure; FO, fatty oil; and MO, mineral oil. 8
9 Turning Limitations TABLE 22.6 Machine tool Maximum dimension (m) Power (kw) Maximum rpm Lathes (swing/length) Bench 0.3/1 < Engine 3/ Turret 0.5/ Automatic screw 0.1/ ,000 Boring machines (work diameter/length) Vertical spindle 4/ Horizontal spindle 1.5/ Drilling machines Bench and column (drill diameter) ,000 Radial (column to spindle distance) 3 Numerical control (table travel) 4 Note: Larger capacities are available for special applications. 9
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