Chapters 23 & 24 Machining ProcessesIntroduction23.1 Introduction23.2 The Turning Process23.2 The Turning Process Cont.Slide 623.3 Lathes and Lathe Operations23.3.1 Lathe Components23.3.1 Lathe Components Cont.Slide 10Slide 11Slide 12Slide 1323.3.2 Workholding devices & Accessories23.3.3 Lathe Operations23.3.4 Types of Lathes23.3.5 Turning Process Capabilities23.3.4 Types of Lathes Cont.Slide 19Slide 20Slide 21Slide 22Slide 2323.3.6 Design Considerations & Guidelines for Turning Ops.23.3.7 Chip Collection System23.3.8 Cutting Screw ThreadsMachining ProcessesBoring and Boring MachinesWhat is BoringBoring MachinesHorizontal Boring MillVertical Boring MillJig Boring MachinesConsiderationsDrilling, Drills, and Drilling MachinesWhat are Holes used For?Drilling is a Common Process!!!PropertiesStandard-Point Twist DrillSlide 40Slide 41Other Types of DrillsSlide 43More Drill TypesGun DrillTrepanningMaterial-Removal RateGeneral TroubleshootingReaming and ReamersWhat is ReamingSlide 514 Steps to AccuracyTapping and TapsTappingTypes of TapsMachining Processes Used to Produce Various Shapes: Milling, Broaching, Sawing, and Filing; Gear ManufacturingIntroduction24.2 MillingMillingThe various types of surfaces generated in milling are shown below.Slide 61Peripheral millingConventional milling and climb millingWhich is preferred methodMilling parametersMilling ParametersSummary of Milling Parameters and FormulasFace MillingSlide 69End MillingSlide 71High-speed end millingMilling overviewSlide 74Other milling operations and milling cuttersOther milling cont’dOther milling optionsSlide 78T-slot millingToolholdersMilling processes capabilities (pg736)Design and operation guidelines for millingSlide 83Column-and-knee type machinesColumn-and-knee mills cont’dSlide 86Bed-type milling machinesOther types of millingOther types of milling machinesWork holding devices and accessoriesPlaningSlide 92ShapingBroachingSlide 95Broaching MachinesSawingTeeth setsHack sawsCircular saws (Cold saws)Band saws24.8 Gear Manufacturing by Machining24.8.1 Form Cutting24.8.2 Gear Generating1. Pinion Shaped Cutter2. Rack shaped cutterExamples of gear cutting with a rack shaped cutter3. Gear cutting HobExamples of gear hobbing:Multiaxis computer-controlled machines24.8.3 Cutting bevel gears24.8.4 Gear Finishing ProcessesSlide 113Slide 114Slide 11524.8.5 Design Considerations for Gear Machining24.8.6 Economics of Gear ProductionReferencesSlide 119Slide 120Chapters 23 & 24Chapters 23 & 24Machining ProcessesMachining ProcessesGroup #3Group #33/29/063/29/06Keith DagerKeith DagerJared MartinezJared MartinezDavid FullerDavid FullerAustin Weddington Austin Weddington Grant ThomasGrant ThomasIntroductionIntroductionChapter 23: Chapter 23: Processes capable Processes capable of producing round of producing round parts. Typically parts. Typically carried out on a carried out on a lathelatheChapter 24: Chapter 24: Processes capable Processes capable of producing of producing complex shapes. complex shapes.23.1 Introduction 23.1 Introduction TurningTurningFacingFacingCutting w/ form Cutting w/ form toolstoolsBoringBoringDrillingDrillingPartingPartingThreadingThreadingKnurlingKnurling23.2 The Turning Process23.2 The Turning ProcessThe majority of turning operations involve the The majority of turning operations involve the use of simple single point cutting toolsuse of simple single point cutting toolsThree principle forces act on the cutting toolThree principle forces act on the cutting tool23.2 The Turning Process 23.2 The Turning Process Cont.Cont.Rake Angle: Rake Angle: controls direction controls direction of chip flow & of chip flow & strength of tool tipstrength of tool tip–Side rake angleSide rake angle–Cutting-edge angleCutting-edge angle–Relief angleRelief angle–Nose radiusNose radius23.2 The Turning Process 23.2 The Turning Process Cont.Cont.Turning specifications Turning specifications depends on tool used depends on tool used (formulas on table 23.3)(formulas on table 23.3)Tools used depend on Tools used depend on material usedmaterial usedMaterial used is Material used is determined by determined by applicationapplicationRefer to table to Refer to table to decide which tool goes decide which tool goes with materials used with materials used (table 23.4)(table 23.4)23.3 Lathes and Lathe 23.3 Lathes and Lathe OperationsOperationsLathes are Lathes are considered to be the considered to be the oldest machine toolsoldest machine toolsRange from $2000 Range from $2000 to $100,000to $100,000Require skilled Require skilled machinist because machinist because all controls are all controls are manipulated by manipulated by handhand23.3.1 Lathe Components23.3.1 Lathe ComponentsBed Bed CarriageCarriageHeadstockHeadstockTailstockTailstockFeed Rod & lead screwFeed Rod & lead screwLathe SpecificationsLathe Specifications–SwingSwing–Dist. Head to Tail StockDist. Head to Tail Stock–Length of BedLength of Bed23.3.1 Lathe Components 23.3.1 Lathe Components Cont.Cont.BedBed–Supports all major Supports all major components of the components of the lathelathe–Usually cast ironUsually cast iron–Has two Has two waysways23.3.1 Lathe Components 23.3.1 Lathe Components Cont.Cont.CarriageCarriage–Slides along Slides along ways ways –Consists of an Consists of an assemble of:assemble of:Cross-slideCross-slideTool postTool postApronApron23.3.1 Lathe Components 23.3.1 Lathe Components Cont.Cont.HeadstockHeadstock–Fixed to the bed Fixed to the bed and equipped with and equipped with motors, pulleys, motors, pulleys, and v-belts that and v-belts that supply power to a supply power to a spindle at various spindle at various speedsspeeds23.3.1 Lathe Components 23.3.1 Lathe Components Cont.Cont.TailstockTailstock–Slides along waysSlides along ways–Supports the other Supports the other end of the work end of the work piecepiece–Or used to drill Or used to drill holes in the work holes in the work peicepeice23.3.1 Lathe Components 23.3.1 Lathe Components Cont.Cont.Feed Rod & Lead Feed Rod & Lead ScrewScrew–Powered by a set of Powered by a set of gears through the gears through the headstockheadstock–Provide movement Provide movement to the carriageto the carriage–Example use is Example use is cutting threads cutting threads accuratelyaccurately23.3.2 Workholding devices 23.3.2 Workholding devices & Accessories&