Fundamentals of Machining Lab prep

Fundamentals of Machining Lab prep - t1= feed cos(scea)...

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Fundamentals of Machining Lab Prep
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Machining Fundamentals (Chip) Lab Learning Objectives Appreciate the relations between process variables (independent variable) and design parameters (dependent variable) in manufacturing Appreciate the process of chip formation Rationale Important for the design of parts, processes and tools
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Steps for the chip lab Feed is the independent variable Create NC Code (vary feed) Cut Parts Vary feed Collect Chips Monitor Power – record power levels for idling and each feed Measure part diameters Measure Surface Texture – calculate Rt Measure Chips – calculate shear angle Lab Report plots (indicate variance) Surface Roughness (Rt), measured and theoretical v. feed Chip thickness v. feed Shear angle v. feed Power v. feed Specific energy for material removal (J/mm 3 ) v. feed (Radius error-Rt) *EI /l 3 versus feed
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Turning straight down view tool chuck not shown side cutting edge angle (scea) feed workpiece rotation tool rake face t1 uncut chip thickness
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Unformatted text preview: t1= feed cos(scea) cutting edge Shear angle Shear angle From Geometry: tan = r t cos / (1- r t sin ) Chip thickness ratio r t = t 1 /t 2 Uncut chip thickness or depth of cut in orthogonal machining Vc cutting velocity Rake angle Theoretical Peak to valley roughness for an Idealized Turned surface profile 4 2 2 2 2 2 f R RR R R t t + +-= 4 2 2 2 f R RR t t + = r Tool nose radius profile R t peak to valley roughness r f/2 feed 2 2 2 ) 2 ( ) ( f R r r t +-= r f R t 8 2 2245 Surface roughness as a function of feed r f R t 8 2 2245 2 2 2 2 f r r R t--= Common approximation since Rt^2 is small compared with f^2 expanding 4 2 2 2 2 2 f R rR r r t t + +-= 4 2 2 2 f R rR t t + = 1.408mm 1.408mm 1.056 mm turned turned steel steel 1.408mm 1.408mm 0.05217mm 0.05217mm Cantilever beam deflection http://www.me.metu.edu.tr/me206/DARENDELILER/Beam_Deflection_Formulae.pdf I area moment of inertia E elastic modulus 30,000,000 psi Aluminum...
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Fundamentals of Machining Lab prep - t1= feed cos(scea)...

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