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Manufacturing Methods
Technology II – Jan Tomíček
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Machining operations
• Machined parts
– Rotational – cylindrical (shafts) or disk-like
– Nonrotational(Prismatic) – block-like or plate-like
• Elementary shapes
– Rotational,
– planes,
– contoured.
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Examples
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Machining operations:
creating a shape
• generating – by the feed trajectory of the tool
• forming – by the geometry of the tool
• combination – of both processes
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Machining – generating
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Machining – forming
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Machining – combination of forming
and generating
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Material removal processes
Conventional machining
Turning and related ops.
Drilling and related ops.
Milling and related ops.
Broaching, Shaping,
Other machining ops.
Abrassiveprocesses
Grinding
Other abrasive processes
Non-traditional machining
Mechanical energy processes
Electrochemical machining
Thermal energy processes
Chemical machining
Material forming processes
Classification of manufacturing methods
• Material removal processes
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A CUTTING TOOL
• single-point tool (a)
• multiple cutting edge tool (b)
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CUTTING EDGE• face - rake angle RA α
• flank - relief angle ERA γ
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Manufacturing Methods
Turning, Milling, Drilling
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Turning
Main movement – rotational – workpiece
Feed movement – linear – tool
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Lathe operations
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Turning tools - examples
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Turning machine - lathe
• Very long history (Egypt, Greece)
• 1300 BC
• Manually powered
• Water, steam
• Transmisions, gearbox
• Electric power, electronic control
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A lathe – workholding methods
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PART QUALITY CHARACTERISTICS
The quality of functional surfaces of a part –
4 main parameters (in a part drawing):
• dimension accuracy (a tolerance) –
a grade of fit (marked IT)
• shape accuracy
• relative location parameters
• surface roughness Ra
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Turning – work time x IT relation
0
50
100
150
200
250
300
350
400
IT 7 IT 8 IT 9 IT 10 IT 11 IT 12
400
280
180
10090
65
%
Work time
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Turning – work time x Ra relation
0
20
40
60
80
100
120
140
160
180
1.6 3.2 6.3 12.5
170
135
120
100%
Ra
Work time
Work time
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Turning – tolerances and surface finish
Type of cut IT Ra
roughing 11 - 14 12,5 - 100
finishing 9 - 11 1,6 - 12,5
NC machines finishing 6 – 9 1,6 - 6,3
fine finishing (sintered
carbide)6 – 8 0,4 - 1,6
fine finishing (diamond) 5 – 6 0,2 - 0,8
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DRILLING
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Operations related to drilling
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Drilling and whatnext?
• Drill(twist)
• Reamer drill – 3-4 twisted flutes and edges
• Reamer – 4-18 linear edges
• Dimensions?
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Twist drill Reamer drill Reamer
28,5 29,75 30H7
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Drilling machine – drill
• Hand drill
• Table drill
• Stand drill
• Radial drill
+CNC machines
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Drilling – tolerances and surface finish
Process/tool IT Ra
drilling (twist drill) 11 – 13 3,2 –
12,5
rough reaming
(reamer drill)9 – 10 1,6 – 6,3
reaming (reamer) 6 – 8 0,4 – 1,6
counterboring 7 – 10 1,6 – 6,3
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MILLING• plain (peripheral) milling – the axis of the tool is
parallel to the surface being machined
• face milling – the axis of the cutter is perpendicular to the surface being milled
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Face milling - examples
►facing ► end milling(a milling head) (an end mill)
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End milling
• Variation of tool shapes
• Generative process
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Milling machine
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Milling – tolerances and surface finish
Type of cut IT Ra
roughing 10 – 13 6,3 – 25
finishing 8 – 10 1,6 – 6,3
fine finishing 7 – 8 0,8 – 1,6
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Manufacturing Methods
BROACHING
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BROACHING• a multiple tooth cutting tool• the forming tool moves linearly relative to the
workpiece in the direction of the tool axis• Movement through or along the part
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Broaching tool
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External broaching tool
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Broaching process
• on a press – the tool is pushed
• on a broaching machine – the tool is pulled
• Using special machine – stationary broach
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Broaching machines• vertical ►
• horizontal ▼
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Broached shapes
• Internal – holes and other round shapes, keyways, profiles, gears
– Need leading hole to place the pilot
• External – faces, T-shape, co-planar surfaces, gears
• Holes calibration – Broach diameter slightly bigger than the hole.
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Keyway broaches
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Rotary broaching
• internal
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Rotary broaching - limitations
Broach lengthSpiraling
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Broaching limitions
• Machined volume
– Limited by chip thickness long broach
• Speed
– No wear demands low temperature, forces
• Tool costs
– Expensive production long tool life
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Broaching – tolerances and surface finish
Type of cut IT Ra
surface roughing 7 – 9 0,8 – 3,2
surface finishing 5 – 7 0,1 – 0,8
hole roughing 7 – 8 0,8 – 3,2
hole finishing 5 – 7 0,1 – 0,8
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Video links
• Turninghttps://youtu.be/8EsAxOnzEms
• Millinghttp://www.youtube.com/watch?v=U99asuDT97Ihttp://www.youtube.com/watch?v=RIbdYmmhPDIhttp://www.youtube.com/watch?v=hMK7g_PpCv8http://www.youtube.com/watch?v=J1VtofzVG24http://www.youtube.com/watch?v=r7-eEj_qq5Mhttp://www.youtube.com/watch?v=IPWGV_EGAHwhttp://www.youtube.com/watch?v=9OsNUi_o6C4http://www.youtube.com/watch?v=HfIaISnqHOkhttp://www.youtube.com/watch?v=om6GQKfoS1g
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Video links
• Broaching
http://www.youtube.com/watch?v=e26kCaPjX8E
http://www.youtube.com/watch?v=0Qe4ZGlhnhQ
http://www.youtube.com/watch?v=-ksHvyeIb-U
• Rotary
http://www.youtube.com/watch?v=BhvNU2E_x_Y
• Making a broach
http://www.youtube.com/watch?v=WE9ZfnP2SX8