EME50: Week 1
EME50: Week 1 EME50
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This 5 page Class Notes was uploaded by Mae Underwood on Monday October 5, 2015. The Class Notes belongs to EME50 at University of California - Davis taught by Rida Farouki in Summer 2015. Since its upload, it has received 53 views. For similar materials see Manufacturing Processes in Mechanical Engineering at University of California - Davis.
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Date Created: 10/05/15
10515 EME50 Fall 2015 EME50 Week 1 11 12 13 14 15 16 17 Boring Turning operation enlarges an existing hole in a workpiece Broaching Cutting a contour of speci c shape using a tool with progressively larger teeth Chuck Clamping device that centers and holds collet in lathe 3 4 jaws Collet Tapered device with longitudinal splits used to grip workpiece for turning Deburring Removal of sharp pieces from machined cast or forged parts to improve handling safety fatigue life quality of t etc performed manually with le or through a variety of automated processes Drilling Cutting a cylindrical hole in a stationary workpiece End milling Cutting where the tool rotates about an axis perpendicular to part surface Evolving Aspects of Manufacturing Prototyping DFM Design for manufacturability Tolerances and assembly of components Computer controls and process automation FMS Flexible manufacturing systems Computerintegrated manufacturing CIM Quality control Testing and veri cation Economic ergonomic stylistic considerations Ecological issues Novel materials and processes Facing Producing a at surface on a workpiece Fixturing System of vices clamps etc that holds a workpiece in a milling machine Grinding Finishing operation using an abrasive wheel to obtain nal dimension and smooth parts surface occasionally used as bulk material removal process Headstock Part of lathe that supports the rotating spindle Knurling Producing a regular textured nish using a patterned indentation tool eg For better grip Milling Cutting into general shapes by feeding the workpiece along multiple axes into a spinning multiedge uted tool Parting Cutting off a portion from a workpiece Peening Shooting at a part surface with a high velocity to produce compressive residual stresses by surface indentation This improves fatigue life of parts by limiting the progression of surface cracks Polishing buf ng or burnishing Application of an extremely ne abrasive using a felt or fabric wheel to produce a mirrorlike nish 10515 18 19 20 21 22 23 24 25 26 27 28 EME50 Fall 2015 Reaming Finishing operation after drilling to achieve an accurate hole diameter with improved surface nish Slab milling Cutting where the tool rotates about an axis parallel to the part surface Tailstock Device to support other end of lathe workpiece to minimize exure when turning long parts drills reamers etc can also be mounted on tailstock Tapping Producing an internal screw thread in an existing hole Threading Producing an external screw thread using a lathe die etc Turning Cutting by feeding a single edge tool into a spinning workpiece Ways to Manipulate Mechanical Properties of Workpiece Material eg alloys Cold working of metals Heat treatment of metals Surface treatment processes Embedded components Fiber layout in composites Part geometry Ways to Shape Workpiece Additive processes Subtractive processes Mechanical deformation Material solidi cation Joining subcomponents 45 axis CNC mill This adds a rotary axis to the table allowing various workpiece orientations relative to the tool can reduce re xturing Climb milling Draws the part into the cutter and absorbs any backlash in the table CNC computer numerical control Uses digital controllers The computer compares the actual machine location with the inputted position at a sampling frequency of 1 kHz and applies a compensating voltage to make adjustments Maintains accuracy despite disturbances eg machining force variations thermal expansion 10515 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 EME50 Fall 2015 CNC lathe Workpiece mounted on a rotary axis and the single edge tool moves radially and longitudinally relative to workpiece Cuts parts with rotational or helical symmetry CNC mill Tool is attached to a stationary spindle workpiece is mounted on a table and moves in X Y and Z directions relative to tool three axis machine cuts only convex parts Common operations on an engine lathe Turning cylindrical surfaces Facing at surfaces Drilling and boring holes Cutting internal or external threads Cons of machining Slow and expensive for largecomplicalted parts Raw material waste unless chips are recycled Major investment in capital equipment machines wear down amp need regular replacement Conventional milling Workpiece is fed in the opposite direction of the cutter s rotation Counterbores Cylindrically enlarging a part of the hole Countersinks Conically enlarging the top of a hole forming a recess below the surface Cutting speed in a lathe is determined by The workpiece rpm Depth of cut Thickness of material chip removed by the cutting tool Drill machine or drill press function To dri or enlarge a cylindrical hole Drill press operations Driing Reaming Countersinking Counterboring Tapping Feed rate Linear speed at which tool is driven into workpiece Five major components of the milling machine Bass and column knee saddle table and head Four major groups of assemblies of the drill press The head table column and bass How are Mills classi ed If they have a vertical or horizontal spindle operation Amount of horsepower that the mill applies to the cutter Hybrid lathes Cross between the standard manually operated lathe and the computer operated lathe or CNC Lathe With a rotating workpiece around it s Zaxis and a xed cutting tool the tool is fed into the workpiece Lathes are classi ed according to Their maximum diameter aka swing 10515 47 48 49 50 51 52 53 54 55 56 57 58 EME50 Fall 2015 The maximum length of the workpiece that can be handled by the lathe Maximum horsepower that can be supplied to rotate the workpiece Controls manual CNC hybrid Machining is best suited for Finished machining of precision parts Prototyping and small production runs Complex geometries Machining performance measures Geometrical part accuracy and machine surface quality Tool integrity wear breakage chatter Material removal rate and tool machine time Machining forces and power requirements Avoidance of excessive heat generation Machining process parameters Cutting speed Depth of cut Feed rate Tool geometry material condition Cutting uid for lubrication cooling and chip removal Path planning xturing etc Dynamic adjustment Adjustment is made while the motor is turned on Milling machine A multitooth rotating cutter where the xed workpiece is fed into the cutter Milling machine operations Side and face milling y cutting precision boring drilling reaming etc Oblique machining Cutting edge is at an inclination angle i to the tool s motion Orthogonal machining Direction of tool motion is perpendicular to the cutting edge The plug tap Used to cut threads after the taper tap has been used and removed Preliminary operations of milling machine Cleaning set up tooling machine controls Pros of machining Excellent part accuracy and surface nish Great exibility in part geometry High structured integrity of parts Integration with CADCAM software tools CNC machines allow for manufacturing automation and minimization of part variations Rake angle The angle at which the cutting tool is applied to the material relative to the positive Y axis 10515 EME50 Fall 2015 59 Reamers A precision cutting tool intended to nish a hole to a speci c diameter 60 Speed in a milling machine is determined by tool RPM 61 The starting or tapered tap Used to start threads 62 63 64 65 66 67 68 Static adjustment Adjustment is made while the motor is turned off Tapping Used to cut internal threads in a cylindrical hole Twist drills Pointed cutting tool used for making cylindrical holes Composed of a shank body and point What is the dominant mode of material failure due to machining Shear stress What is the shape of a chip due to oblique machining Helical chip they are less likely to become entangled with the tool What is the shape of a chip due to orthogonal machining Spiral chip Merchant Model of Orthogonal Cutting Chip thiekhees g lie Velee itr V Rake Angle Chip l1 depth ef39eut 39 511ian Angle A b gt V ACllE39 l EE Aug Werkpieee From httpwwwslidesharenetmanoj18bietmechanicsof metalcutting
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