IE 204 Manufacturing Processes

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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MATERIAL REMOVAL PROCESSES AND MACHINES
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MACHINING PROCESSES FOR PROCESSING ROUND SHAPES
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
TURNING
The workpiece is rotating, while it is being
machined. Turning ? to produce straight,
conical, curved or grooved workpieces Facing ?
to produce a flat surface at the end of the
workpiece Boring ? to enlarge a hole or to
produce internal grooves Drilling ? to produce a
hole Parting ? to cut a piece from the end of a
part Threading ? to produce external or internal
threads in a workpiece Knurling ? to produce a
regularly shaped roughness on cylindrical
surfaces
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Material Removal Rate (MRR)
Atilim University / Dept. of Industrial
Engineering
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Material Removal Rate (MRR) Volume of material
removed per unit time (mm3/min) A f.d A
cross-sectional of the ring-shaped layer f feed
(the distance that the tool travels per
revolution) d depth of cut
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Average circumference of the ring ?.Davg Davg
(D0 Df) / 2 MRR per revolution
(?.Davg).f.d For N revolutions per unit time
(per minute) MRR (?.Davg).f.d.N
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Cutting time, t t l / f.N l length of the
w/p Feed rate f.N (mm/rev).(rev/min)
(mm/min)
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Lathes and Lathe Operations
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Turret Lathes
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Computer-Controlled Lathes
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
BORING AND BORING MACHINES Producing circular
internal profiles in hollow workpieces or on a
hole made by drilling or another process. Boring
Mills for large workpieces Boring Mills ?
Turning, facing, grooving, chamfering
Boring Mills
Horizontal
Vertical
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• DRILLING AND DRILLS
• Drilling is a holemaking operation. Holes are
  used either
• for assembly with fasteners or to provide access
  inside
• a part.
• Drills
• High length-to diameter ratio, produces deep
  holes
• Flexible
• Chip disposal

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MRR in Drilling Volume of material removed by
the drill per unit time. For a drill with
diameter D, the cross-sectional area of the
drilled hole is ?D2/4 The velocity of the
drill perpendicular to the workpiece V
f.N where, N rotational speed f feed (the
distance the drill penetrates per revolution) N
V / ?D
(?D2/4)(f)(N) in mm3/min
MRR
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Drilling Machines Used for drilling holes,
tapping, reaming and other small diameter boring
operations.
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
REAMING AND REAMERS Reaming is an operation used
to make an existing hole dimensionally more
accurate. Centering Drilling Boring Reaming
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
TAPPING AND TAPS Production of internal threads.
Tapping can be done by hand or in drilling
machines, lathes or automatic screw machines.
Atilim University / Dept. of Industrial
Engineering