Chapter 23. Machining Processes Used to Produce Round Shapes: Turning and Hole Making

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1 Chapter 23 Machining Processes Used to Produce Round Shapes: Turning and Hole Making R. Jerz 1 2/24/2006

2 Processes Turning (outside surface) straight, taper, facing, contour, form, cut-off, threading, knurling Boring (internal holes) taper, form, drilling, threading, reaming Drilling (internal) Reaming (internal) R. Jerz 2 2/24/2006

3 Machining Surface Roughness R. Jerz 3 2/24/2006

4 Drilling Holes R. Jerz 4 2/24/2006

5 Drilling Operations Various types of drills and drilling and reaming operations. R. Jerz 5 2/24/2006

6 Drilling Video R. Jerz 6 2/24/2006

7 Drilling Machines Figure (a) Schematic illustration of the components of a vertical drill press. (b) A radial drilling machine. Source: (b) Courtesy of Willis Machinery and Tools. R. Jerz 7 2/24/2006

8 Various Types of Drills R. Jerz 8 2/24/2006

9 Drills R. Jerz 9 2/24/2006

10 Reamers Figure (a) Terminology for a helical reamer. (b) Inserted-blade adjustable reamer. R. Jerz 10 2/24/2006

11 General Capabilities of Drilling Feed, f Speed, V Depth of cut, d Diameter, D RPM, N R. Jerz 11 2/24/2006

12 Speeds and Feeds in Drilling R. Jerz 12 2/24/2006

13 Drilling Design Considerations Design for clamping Flat surfaces preferred Tolerances requirements Machinability of materials Allowance for tool Depth of hole (walking) Diameter of hole R. Jerz 13 2/24/2006

14 Boring Process Characteristics Single point tool Enlarges or straightens an existing hole Produces accurate holes (better tolerances than drilling) Able to produce large internal holes Can be performed on a lathe, boring mill, or jig bore machine tools R. Jerz 14 2/24/2006

15 Boring R. Jerz 15 2/24/2006

16 Boring and Boring Mill R. Jerz 16 2/24/2006

17 Boring Design Considerations Through holes, not blind holes Greater length to diameter more difficult Avoid intermittent cuts R. Jerz 17 2/24/2006

18 Turning Process Creates cylindrical external or internal shapes Creates flat surfaces on part ends (faces) Uses a single point tool Wide variety of shapes The machine tool is called a lathe R. Jerz 18 2/24/2006

19 Lathe CAD Video R. Jerz 19 2/24/2006

20 Video Lathe/Turning R. Jerz 20 2/24/2006

21 Lathe Cutting Operations Turning: produces straight, conical, curved, or grooved workpieces Facing: produces flat surfaces at the end of the part and perpendicular to its axis. Also used to produce grooves. R. Jerz 21 2/24/2006

22 Lathe Cutting Operations Parting or Cutting Off: cuts a piece from the end of a part Threading: produces external or internal threads Knurling: produces a regularly shaped roughness on cylindrical surfaces, as in making knobs R. Jerz 22 2/24/2006

23 Lathe Cutting Operations Form tool: produces axisymmetric parts Boring: enlarges a previous hole or to produce circular internal grooves Drilling: produces a hole R. Jerz 23 2/24/2006

24 Cutting Screw Threads R. Jerz 24 2/24/2006

25 Lathe Figure 23.2 General view of a typical lathe, showing various components. Source: Courtesy of Heidenreich & Harbeck. R. Jerz 25 2/24/2006

26 NC Lathe and Turret R. Jerz 26 2/24/2006

27 Parts Made on Lathes R. Jerz 27 2/24/2006

28 Turning Operation Figure 23.3 Schematic illustration of the basic turning operation, showing depth-ofcut, d; feed, f; and spindle rotational speed, N in rev/min. Cutting speed is the surface speed of the workpiece at the tool tip. R. Jerz 28 2/24/2006

29 Tool R. Jerz 29 2/24/2006

30 Turning Formulas R. Jerz 30 2/24/2006

31 Turning Parameters R. Jerz 31 2/24/2006

32 Turning Feeds & Speeds R. Jerz 32 2/24/2006

33 Feeds & Speeds for Tool Materials R. Jerz 33 2/24/2006

34 Cost Elements Equipment Tooling Setup time Load/unload time Direct labor Indirect labor Cycle time, idle time Overhead rate R. Jerz 34 2/24/2006

35 Safety Factors Rotating parts or tools Hot, sharp chips Eye and skin irritation from cutting fluids R. Jerz 35 2/24/2006

36 Example from Book A 6-in long, 0.5 in diameter 304 stainlesssteel rod is being reduced in diameter to 0.48 in by turning on a lathe. The spindle rotates at N=400 rpm, and the tool is traveling at an axial speed of 8 in/min. Calculate, the cutting speed, material removal rate, cutting time, and power. R. Jerz 36 2/24/2006

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