Machining.ppt

Machining INT 201 Eastern Kentucky University Metal Cutting Process Lecture References: Degarmo E.P., Black J.T., Kosher R. (2003). Materials and Processes in Manufacturing, 9th edition. Wiley Repp, V. (1994). Metalwork: Technology and Practice, 9th edition. McGraw-Hill Groover, M. (2004). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 2nd edition. Wiley Chen, C.S. (2001) ITEC 502: Advanced Design and Manufacturing [Course]. Iowa State University Lesson Objectives REVIEW: Fundamentals of Machining Identify the basic parameters associated with machining (milling) Understand how these basic parameters are used to create and remove chips Understand that machine parameters are directly related to type of material and the machine Machining Fundamentals REVIEW Machining is a process of removing unwanted material from a workpiece in the form of chips. Making and removing chips Importance of lubricants $60 billion spent annually on metal removal operations Machining Fundamentals Basic machine processes Milling Machines Machining Fundamentals SPINDLE KNEE BASE TABLE COLUMN VERTICALLY LONGITUDINALLY TRANSVERSELY Basic Machining Parameters Basic Machining Parameters Cutting Speed Spindle Speed (RPM) Feed Rate Metal Removal Rate Chip Load Machine Horse Power Machining variables such as cutting speed, RPM, table feed rates, metal removal rates, and depth of cut all depend on: Work material Tool material Specific process/equipment Basic Machining Parameters Cutting Speed (SFPM) Cutting speed is the distance a point on the circumference of the milling cutter travels in one minute Measured in Surface Feet per Minute (SFPM) Calculated at the outside diameter of the cutter Different cutting speeds should be used when machining different metals With cutting speeds too fast, cutter will overheat and dulls rapidly With cutting speeds too slow, time is wasted and production costs will increase Cutting Speed (SFPM) Cutting Speed (SFPM) Factors a