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L13-machining - Machining Milling turning drilling VM250...

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Machining: Milling, turning, drilling VM250, Design and Manufacturing I Mechanical Engineering 1 Primary source: John Hart. Includes material from D. Dutta and K. Saitou
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Machining: definition Machining = removal of material from a workpiece Three broad categories of machining: Metal cutting using single-point or multi-point tools Abrasive processes such as grinding Non-traditional processes that use chemical, electrical, or hydrodynamic methods
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Metal cutting: definition Metal cutting = a material removal process in which a sharp metal cutting tool is used to mechanically remove material so that a desired part geometry remains Most common application is to shape metal parts This is the most versatile of all manufacturing process in its capability to produce part geometries and features with high precision and accuracy
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Casting and forging can also produce a variety of shapes, but they lack the precision and accuracy of machining For service life need replacement parts For replacement need interchangeable parts For interchangeability need dimensional accuracy For dimensional accuracy use machining
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Classifications of machined parts a. Rotational (axisymmetric) b. Non-rotational - Prismatic (mostly flat surfaces) - Freeform (spline surfaces)
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Classifications of machined parts b. Non-rotational - Freeform (spline surfaces) Die surfaces are typically freeform
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Creating geometry by machining Machining creates a part geometry by two main mechanisms: 1. Generating : the part geometry is determined by the trajectory of the cutting tool 2. Forming : the part geometry is determined by the shape of the cutting tool
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(a) straight turning, (b) taper turning, (c) contour turning, (d) plane milling, (e) profile milling. Generating: motion defines shape
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Forming: tool defines shape (a) form turning, (b) drilling, (c) broaching
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Generating + forming: shape by tool geometry and motion
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Chip Formation in Machining
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Chip formation and cut surfaces Kalpakjian and Schmid.
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Factors influencing cutting processes Kalpakjian and Schmid.
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1.6 1.6 Roughness Waviness Standard finish as specified in note
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