Lecture 1 CAD/CAM branch third class

Machining

Metal Cutting Asst.Lec Mostafa Adel 1

 Traditional Manufacturing Processes

Casting

Forming

Sheet metal processing

Powder- and Ceramics Processing

Plastics processing

Cutting

Joining

Surface treatment

Metal Cutting Asst.Lec Mostafa Adel 2

 Cutting

Processes that involve removal of material from solid workpiece

Sawing
Shaping (or planing),
Broaching, drilling,
Grinding,
Turning
Milling

Important concept: PROCESS PLANNING

Fixturing and Location
Operations sequencing
Setup planning
Operations planning

Metal Cutting Asst.Lec Mostafa Adel 3

 Sawing

A process to cut components, stock, etc.

Process character: Precision: [very low,, very high]; MRR: low

Metal Cutting Asst.Lec Mostafa Adel

4
 Sawing

Metal Cutting Asst.Lec Mostafa Adel 5

 Shaping

A process to plane the surface of a workpiece (or to reduce part thickness

Process character: High MRR, medium Surface finish, dimension control

tool-post rotates as
(a) (b) (c) slide returns;
workpiece shifted;
tool-post pivot next stroke
slide
chip
chip

Metal Cutting Asst.Lec Mostafa Adel 6

 Broaching

Precise process for mass-production of complex geometry parts

(complicated hole-shapes)

Process character: High MRR, Very good surface, dimension control, Expensive

Broaching machine

Broaching tools

Complex hole shapes cut by broaching

Metal Cutting Asst.Lec Mostafa Adel 7

 Drilling, Boring

Processes to make holes

Process character: High MRR, Cheap, Medium-high surface, dimension control

Metal Cutting Asst.Lec Mostafa Adel 8

 Drilling basics

- softer materials  small point angle; hard, brittle material: larger point angle

- Length/Diameter ratio is large  gun-drilling (L/D ratio ~ 300)

- Very small diameter holes (e.g. < 0.5 mm): can’t drill

- F drilled hole > F drill: vibrations, misalignments, …

Metal Cutting Asst.Lec Mostafa Adel 9

 Tapping

Processes to make threads in holes

Process character: low MRR, Cheap, good surface, dimension control

Automated tapping
Manual tap and die set

Metal Cutting Asst.Lec Mostafa Adel 10

 Grinding, Abrasive Machining

Processes to finish and smooth surfaces

Process character: very low MRR, very high surface, dimension control

Metal Cutting Asst.Lec Mostafa Adel 11

 Abrasive tools and Machines

abrasive wheels, paper, tools diamond grinding wheel for slicing silicon wafers diamond dicing wheel for silicon

Grinding wheels

 Grinding machine
Centerless grinding 

Metal Cutting Asst.Lec Mostafa Adel 12

 Turning

Processes to cut cylindrical stock into revolved shapes

Process character: high MRR, high surface, dimension control

spindle chuck tool-post tail-stock tail-stock wheel

depth of cut, d

feed, f

lead-screw
carriage wheel carriage cross-slide wheel

Metal Cutting Asst.Lec Mostafa Adel 13

 Turning operations
depth of cut, d

feed, f

turning taper profile cut groove cut cut-off thread cut

knurling
facing face groove boring, internal groove drilling

Metal Cutting Asst.Lec Mostafa Adel 14

 Fixturing parts for turning

steps

part in a 3-jaw chuck 4-jaw chuck holding a non-rotational part A long part held between live center (at spindle)
and dead center (at tailstock)

A collet type work-holder; collets are common in

automatic feeding lathes – the workpiece is a long
bar; each short part is machined and then cut-off;
the collet is released, enough bar is pushed out to
make the next part, and the collet is pulled back to
grip the bar; the next part is machined, and so on.

Metal Cutting Asst.Lec Mostafa Adel 15

 Milling
Versatile process to cut arbitrary 3D shapes
Process character: high MRR, high surface, dimension control

[source: www.hitachi-tool.com.jp]
[source: www.phorn.co.uk]

[source: Kalpakjian & Schmid ]

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 Common vertical milling cutters

Flat

Ballnose

Bullnose

Metal Cutting Asst.Lec Mostafa Adel 17

 Up and Down milling

(a) Conventional, or Up milling (b) Climb, or Down milling

- chip thickness goes UP; - chip thickness goes DOWN;
- cutting dynamics: smoother - cutting dynamics: bad for forged/cast
parts with brittle, hard scales on surface

Metal Cutting Asst.Lec Mostafa Adel 18

 Fixtures for Milling: Vise

V-slot vise jaws hold cylindrical parts horizontally/vertically

 Vise fixed to a milling table, holding rectangular part

Universal angle vise can index parts along any direction 

Vise on sine-bar to hold part at an angle

relative to the spindle

Metal Cutting Asst.Lec Mostafa Adel 19

 Fixtures for Milling: Clamps

Clamp support Workpiece

(clamp and support have teeth)

Strap clamp

Parallel bars raise the part Bolt (bolt-head is inserted into T-slot in table)
above table surface – allow
making through holes

Metal Cutting Asst.Lec Mostafa Adel 20

 Analysis: process parameters optimization

Model objective:
Find optimum feed, cutting speed to [maximize MRR]/[minimize cost]/…

Feed:
Higher feed  higher MRR

Finish cutting:

surface finish  feed

 Given surface finish, we can find maximum allowed feed rate

Metal Cutting Asst.Lec Mostafa Adel 21