IE243MANUFACTURINGPROCESSES-IE101.pptVIP

EY fall08 EY fall08 * IE 243MANUFACTURING PROCESSES Material Removal Processes * Definition of Material Removal Processes Material removal processes are shaping operations. The common feature is removal of material from a starting workpart so the remaining part has the desired shape. Variety of work materials can be machined. Most frequently applied to metals. Variety of part shapes and special geometry features possible, such as: Screw threads, accurate round holes, very straight edges and surfaces. Good dimensional accuracy and surface finish is possible. However material removal processes are time consuming and wasteful of material. * Definition of Material Removal Processes There are three categories: Machining Abrasive operations Nontraditional operations * Material Removal ProcessesClassification Machining: Material removed from the surface of the workpart by means of sharp cutting tools. Examples are turning, milling, drilling, etc. turning milling drilling * Material Removal ProcessesClassification Abrasive operations: Material removed from the surface of the workpart by means of hard abrasive particles. e.g. grinding grinding * Material Removal ProcessesClassification Nontraditional operations: Various energy forms other than sharp cutting tool to remove material e.g. electro-discharge machining, water jet cutting etc. Electro-discharge machining * Material Removal ProcessesMachining Relative motion between the cutting tool and the workpiece develops a cutting action. Cutting action involves shear deformation of work material to form a chip. As chip is removed, a new surface is exposed. * Material Removal ProcessesMachining Chip formation due to shear * Material Removal ProcessesMachining Some terms and definitions in machining There is relative motion between the workpiece and the cutting tool. Primary motion: Cutting motion (defined by cutting speed) Secondary motion: Feed motion (defined by the feed rate) Depth of cut (defines the amou