Machining Overview & Basics of Chip Formation Mechanics

Machining Overview &
Basics of Chip Formation

Mechanics
Old Machine
Shop
Edisons lab
ver. 1
ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton
Machining = Chip formation by a tool

Prof. J.S. Colton
Discontinuous chips

Prof. J.S. Colton

Prof. J.S. Colton
Big lathe with big chips

Prof. J.S. Colton
Continuous chips

Prof. J.S. Colton
Idealized Chip-formation Process
Overview
Machine tools and processes
Basics of cutting mechanics
chip
shear zone
Orthogonal
cutting tool
Definitions
Cutting velocities
Shear strain
Card Model
workpiece

Prof. J.S. Colton
Machine Tools and Processes
Turning
Boring
Milling
Planing
Shaping
Broaching
Drilling

Prof. J.S. Colton
Lathe (for turning)
Filing
Sawing
Grinding
Reaming
Tapping
Honing

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Lathe Parts

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10
Typical Insert Cutting Tool

insert
holder

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11

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12
Old Lathe

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15
Old Planer

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16
Old Boring
Machine
Boring

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Shaper
17

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18
Trepanning
Drilling
(a)

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Milling

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20
Face Milling
21

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Old Horizontal Mill
Horizontal Mill

Prof. J.S. Colton

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Milling Types
Vertical Mill

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25
Broach

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26
Reamers
27

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28
Why Machine (1)?
Honing
Very accurate highest of all manufacturing

processes
small amounts of materials removed
precise tools, dies, molds can be
made
mirrors can be cut to 1/2 wavelength
of light
Prof. J.S. Colton
29

Prof. J.S. Colton
30
Why Machine (2)?
Why Machine (3)?
Highly Flexible
Low cost tooling
shape is programmed
many different parts can be made
on one machine
any arbitrary shape can be
machined

Prof. J.S. Colton
contour is generated by path of

tool, rather than its shape, in most
cases
cutting tools are mass-produced in
standardized shapes
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Prof. J.S. Colton
Why Machine (4)?
32
Why Machine (5)?
Trade-off
Highly wasteful
low cost tool vs. machine tools

operating costs
high production rates and low tool
life

Prof. J.S. Colton
chips are scrap $ billions/year
33

Prof. J.S. Colton
Machinability
34
Nomenclature
Material Removal Rate (MRR) (turning)
= speed x feed x depth of cut = sfd
Power requirements
specific cutting energy
Tool life
abrasiveness, compatibility
Surface finish
burr formation, tool size (radius)
Precision
v (sfpm)
d
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35
chip
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Cutting Conditions
Nomenclature
Cutting speed (s)

ranges from <1 to 2000 sfpm
(5 mm/s to 10 m/s)
can be up to 10,000 sfpm (50 m/s)
typical 10 - 600 sfpm (50 mm/s to
3 m/s)
sxf used for optimization of cutting

d fixed by initial and final dimensions
limited by cutting tool
Feed (f)
0.0005 - 0.1 inch (per revolution)
13 m to 2.5 mm (per revolution)

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37

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38
Idealized Chip-formation Process

Orthogonal Cutting
Cutting Conditions
Depth of cut (d)
up to 1 inch (25.4 mm)
chip
shear zone
Volume of material removed per

time (MRR)
cutting tool
> 100 in3/min (28 cm3/s) possible

typical 5 - 10 in3/min (1.3 - 2.8 cm3/s)
workpiece

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39
Orthogonal Cutting Assumptions (1)

Process adequately represented
by two-dimensional geometry.
Tool is perfectly sharp.
Tool only contacts workpiece on
its front (rake) face.
Primary deformation occurs in a
very thin zone adjacent to the
shear plane.
Prof. J.S. Colton

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40
Orthogonal Cutting Assumptions (2)

Cutting edge is perpendicular to
cutting direction.
The chip does not flow to the side.
41

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42
Chip-formation Geometry
chip
primary shear zone
tc
B
to
Geometric Definitions
tool
V (cutting velocity)
to = depth of cut (d) = undeformed chip

thickness
tc = chip thickness
= rake angle
= shear angle
= clearance angle
workpiece
43

Prof. J.S. Colton
Dependency of Variables
Rake Angle ()
Independent variables
to, , , V
sharper cutting
reduces shear place size
lower strain than negative rake
lower cutting force
lower power consumption
45

Prof. J.S. Colton
46

Prof. J.S. Colton
Chip Thickness Ratio (r)
Negative Rake Angle ()

Stronger edge
Increases shear plane size
r = to/tc
more deformation
chip
to tc
B
to
r=
negative - 8 edges
positive - 4 edges
Prof. J.S. Colton
Positive
Dependent variables
, tc
Can be turned over,

yielding twice as many
edges
44

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to
AB sin
=
tc AB cos( )
tc
tool
A
workpiece

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48
Shear Angle ()
r cos
tan =
1 r sin
Shear Strain ()
Geometric shear strain ()
= cot() + tan(-)
for = 0
10
5 .8 4
20
3 .1 2
30
2 .3
49

Prof. J.S. Colton
50

Prof. J.S. Colton
Shear Strain
Cutting Mechanics
> 1 (as tc > to)
& =0
In general:
V (cutting speed)
=0
& =0
shear zone & >>0
51

Prof. J.S. Colton
Cutting Velocities
52

Prof. J.S. Colton
Velocity Relationships
Cutting Speed (V)

tool relative to workpiece
Vs
Vc
Shear Velocity (Vs)
Vc
sin
=
V cos( )
Vs
cos
=
V cos( )
chip relative to workpiece
Chip Velocity (Vc)

chip relative to tool

Prof. J.S. Colton
Vc t o
=
=r
V tc
53
Vs
Vc
V

Prof. J.S. Colton
54
Shear Zone Shear Strain Rate

Approximation
d
& =
Shear Zone
dt
1<<6
2 < < 4: typical
for a shear zone thickness = 0.001

(25 m), s = 500 sfpm (2.54 m/s)
& =
104/s <
1
= 105 / s
shear zone thickness
speed
& <106/s: typical
high strain rate, localized deformation

Prof. J.S. Colton
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56

Prof. J.S. Colton
Card Model Analysis Geometrical Shear Strain
Card Model of Chip Formation
chip
d
cutting tool
shear zone
B
=
d
A
workpiece

Prof. J.S. Colton
x
24
d
57

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Summary
Introduced machining processes
Reviewed basics mechanics of
orthogonal cutting

Prof. J.S. Colton
10

Machining Overview & Basics of Chip Formation Mechanics

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Machining Overview &

Basics of Chip Formation

ME 6222: Manufacturing Processes and Systems

Machining = Chip formation by a tool

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Big lathe with big chips

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Idealized Chip-formation Process

ME 6222: Manufacturing Processes and Systems

Machine Tools and Processes

ME 6222: Manufacturing Processes and Systems

Lathe (for turning)

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Typical Insert Cutting Tool

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Old Horizontal Mill

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Why Machine (1)?

Very accurate highest of all manufacturing

ME 6222: Manufacturing Processes and Systems

Why Machine (2)?

Why Machine (3)?

Low cost tooling

ME 6222: Manufacturing Processes and Systems

contour is generated by path of

ME 6222: Manufacturing Processes and Systems

Why Machine (4)?

Why Machine (5)?

low cost tool vs. machine tools

ME 6222: Manufacturing Processes and Systems

chips are scrap $ billions/year

ME 6222: Manufacturing Processes and Systems

Cutting speed (s)

sxf used for optimization of cutting

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Idealized Chip-formation Process

Volume of material removed per