IE 204 Manufacturing Processes

1
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MACHINING PROCESSES FOR PROCESSING VARIOUS SHAPES
Atilim University / Dept. of Industrial
Engineering
2
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MILLING

• Slab Milling
• Face Milling
• End Milling

Atilim University / Dept. of Industrial
Engineering
3
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
SLAB MILLING (PERIPHERAL MILLING)
The axis of cutter rotation is parallel to the
surface of the workpiece. The cutter has a number
of teeth (straight or helical) along its
circumference, each of which is acting like a
single-point cutting tool called a plain mill
Atilim University / Dept. of Industrial
Engineering
4
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Conventional Milling (Up Milling) Maximum chip
thickness is at the end of the cut
Atilim University / Dept. of Industrial
Engineering
5
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Conventional Milling (Up Milling) Cutting
starts with the chip at its thickest location
Atilim University / Dept. of Industrial
Engineering
6
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Cutting speed in milling (V) V ?.D.N D
cutter diameter N rotational speed of the
cutter Undeformed chip thickness (chip depth of
cut) Tc 2.f. (d/D)1/2 f feed per tooth of
the cutter (mm/tooth) d depth of cut
Atilim University / Dept. of Industrial
Engineering
7
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
f v / N.n v linear speed (feed rae) of the
workpiece n number of teeth on the cutter
periphery Cutting time (t) t (l lC) / v
Atilim University / Dept. of Industrial
Engineering
8
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Assuming that lC ltlt l Material Removal Rate
(MRR) MRR l.w.d / t w width of the cut
Atilim University / Dept. of Industrial
Engineering
9
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Example
A slab-milling operation is being carried out on
a 12-in. long, 4-in. wide annealed mild-steel
block at a feed of 0.01 in./tooth and depth of
cut d1/8 in. The cutter is 2 in. in diameter,
has 20 straight teeth, rotates at N100 rpm, and
is wider than the block to be machined. Calculate
the material removal rate, estimate the power and
torque required for this operation and calculate
the cutting time.
Atilim University / Dept. of Industrial
Engineering
10
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
FACE MILLING
The cutter is mounted on a spindle having an axis
of rotation perpendicular to the workpiece
surface.
Atilim University / Dept. of Industrial
Engineering
11
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
12
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Example
Assume that for a face milling operation, D150
mm, w60 mm l500 mm, d3 mm, v0.6 m/min. and
N100 rpm. The cutter has 10 inserts and the
workpiece material is a high-strength aluminum
alloy. Calculate the MRR, cutting time and feed
per tooth and estimate the power required.
Atilim University / Dept. of Industrial
Engineering
13
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
END MILLING
The cutter in end milling can rotate on an
axis perpendicular to the workpiece or it can be
tilted to machine tapered surfaces. The cutter
has either straight or tapered shanks for smaller
and larger cutter sizes.
Atilim University / Dept. of Industrial
Engineering
14
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Flat surfaces, curves surfaces, various
profiles, Cavities End mills ? high-speed
steels, carbide inserts
Atilim University / Dept. of Industrial
Engineering
15
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
OTHER MILLING OPERATIONS AND CUTTERS
Atilim University / Dept. of Industrial
Engineering
16
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
17
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
18
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
MILLING MACHINES - Column and knee type
Atilim University / Dept. of Industrial
Engineering
19
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
20
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Bed type
Atilim University / Dept. of Industrial
Engineering
21
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
PLANING AND SHAPING

• A simple cutting process by which flat surfaces
  and
• various cross-sections with grooves and notches
  are
• produced along the length of the workpiece.
• Large workpieces ? 25 m x 15 m
• Machining along a straight path
• Reciprocating motion noncutting during return
  stroke
• Not very economical, except for low-quantity
• production

Atilim University / Dept. of Industrial
Engineering
22
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
23
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
BROACHING
Broaching is used to machine internal and
external surfaces (holes of circular, square or
irregular section, keyways etc.) with a
multitooth cutting tool called broach. Broach ?
successively deeper cuts
Atilim University / Dept. of Industrial
Engineering
24
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
25
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
SAWING
Atilim University / Dept. of Industrial
Engineering