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Common Machining Operations: Kalpakjian

This document discusses common machining operations and parameters. It describes different types of lathes including engine, turret, and CNC lathes. Cutting parameters like depth of cut, cutting speed, and RPM are defined. Models for cutting forces and chip formation are shown. Factors that influence chatter and methods to reduce it are provided. Information on heat generation during cutting, maximum temperatures, tool materials, coated inserts, and machining costs is also presented. References for the content include sources by DeGarmo, Kalpakjian, and others.

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Rodrigo Filho
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128 views

Common Machining Operations: Kalpakjian

This document discusses common machining operations and parameters. It describes different types of lathes including engine, turret, and CNC lathes. Cutting parameters like depth of cut, cutting speed, and RPM are defined. Models for cutting forces and chip formation are shown. Factors that influence chatter and methods to reduce it are provided. Information on heat generation during cutting, maximum temperatures, tool materials, coated inserts, and machining costs is also presented. References for the content include sources by DeGarmo, Kalpakjian, and others.

Uploaded by

Rodrigo Filho
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Common Machining Operations

Kalpakjian
Parts of an Engine Lathe

Kalpakjian
Watchmakers lathe Typical Engine Lathe

www.ticktockpro.com www.blazingtech.net

Turret Lathe Big Engine Lathe

www.liberatorcrew.com
www.bakerprovan.com.au
Really Big Engine Lathes

www.practicalmachinist.com

60 feet c-c
www.harrismachinetools.com
CNC Lathe: aka Turning Center

(carriage is mounted toward back, upside down)

www.machineryvalues.com
Machining
Parameters

DeGarmo
Machining: Turning
Depth of Cut = DOC = (Dbefore Dafter) / 2

Cutting Speed = Speed of metal moving towards cutting tip


Usually called Surface Feet per Minute, SFPM, SFM
Each cutting tool & workpiece material combo has a max SFM for decent tool wear.
HSS & alum: 800 SFM
HSS & 1020 steel: 110 SFM
HSS & 1090 steel: 80 SFM
HSS & hard 4140: 30 SFM
TC & 1020 steel: 1000 SFM
SFM = r*w
= D * RPM * (/12)
D * RPM / 4
RPMmax = 4 * SFM / D
(most useful machining formula)
E.g., find RPM for turning
2 dia. 1020 steel:
RPM 4*110/2 = 220
RPM may need to be less due to chatter!
Most relations are similar
for milling, but D=cutter dia. Kalpakjian
Cutting
Forces

DeGarmo
Orthoganal
Model
(2-force)

DeGarmo
Orthoganal
Model
(2-force)

DeGarmo
Chip formation: chip types

DeGarmo

Kalpakjian
Merchants Model
(Simplified 2-force)

DeGarmo
Chatter
Vibrational resonance of entire machining system, especially workpiece-cutter.
Causes poor surface finish, fast tool wear, noise
Factors: stiffnesses of workpiece, cutter, machine
cutting params: speed, feed, DOC
cutter geometry: rake, clearances
Solutions:
Change the cutting params
esp. speed
Increase stiffnesses

Kalpakjian
Heat rise in Cutting

Kalpakjian
Temperature of Cutting Tip

Kalpakjian/Vieregge
Temperature of Cutting Tip

Kalpakjian / Chao & Trigger


Max Temperatures of Cutting Materials

Kalpakjian
Machining Time of Cutting Materials

Kalpakjian/Sandvik
Coated Carbide Cutting Inserts:
The norm for production machining
Layers are 2-10 microns thick:
TiN: titanium nitride (low friction, gold appearance)
TiCN: titanium carbonitride (wear resistance)
Al2O3: Alumina (chemical stability, wear resistance)

Tungsten Carbide substrate (~shock and wear resistance) www.greenleafcorporation.com

www.moldmakingtechnology.com

Kalpakjian/Kennametal
Cutter Shape
and Geometry

Kalpakjian
Machining Costs

Kalpakjian
References

DeGarmo: E.P. DeGarmo et al, Materials and Processes in Manufacturing, Wiley, 2003.
Kalpakjian: http://www.nd.edu/~manufact/index3.htm

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