Material Removal Processes for Round Shapes ATILIM VERS TES

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Material Removal Processes for Round Shapes ATILIM VERS TES Powered By Docstoc
					IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




MATERIAL REMOVAL PROCESSES
      AND MACHINES




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




            MACHINING PROCESSES
                    FOR
          PROCESSING ROUND SHAPES




Atılım University / Dept. of Industrial Engineering
  IE 204 Manufacturing Processes                            Dr. Zühal ERDEN



         TURNING
The workpiece is rotating, while it is being machined.

Turning  to produce straight, conical, curved or grooved
workpieces

Facing  to produce a flat surface at the end of the workpiece

Boring  to enlarge a hole or to produce internal grooves

Drilling  to produce a hole

Parting  to cut a piece from the end of a part

Threading  to produce external or internal threads in a workpiece

Knurling  to produce a regularly shaped roughness on cylindrical
           surfaces
   Atılım University / Dept. of Industrial Engineering
 IE 204 Manufacturing Processes                         Dr. Zühal ERDEN




Material Removal Rate (MRR)




  Atılım University / Dept. of Industrial Engineering
Material Removal Rate (MRR)

Volume of material removed per unit time (mm3/min)

A = f.d

A: cross-sectional of the ring-shaped layer
f: feed (the distance that the tool travels per revolution)
d: depth of cut
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN




Average circumference of the ring = .Davg

Davg = (D0 + Df) / 2

MRR per revolution = (.Davg).f.d

For N revolutions per unit time (per minute);

MRR = (.Davg).f.d.N




 Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN




Cutting time, t;

t = l / f.N
l: length of the w/p

Feed rate = f.N = (mm/rev).(rev/min)= (mm/min)




 Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN



 Lathes and Lathe Operations




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




     Turret Lathes




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




     Computer-Controlled Lathes




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                                      Dr. Zühal ERDEN




BORING AND BORING MACHINES

Producing circular internal profiles in hollow workpieces
or on a hole made by drilling or another process.

Boring Mills for large workpieces

Boring Mills  Turning, facing, grooving, chamfering

                                      Boring Mills



        Vertical                                       Horizontal


 Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN




DRILLING AND DRILLS

Drilling is a holemaking operation. Holes are used either
for assembly with fasteners or to provide access inside
a part.

Drills

 High length-to diameter ratio, produces deep holes

 Flexible

 Chip disposal


 Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                               Dr. Zühal ERDEN

  MRR in Drilling

  Volume of material removed by the drill per unit time.

  For a drill with diameter D, the cross-sectional area of
  the drilled hole is;

  D2/4

  The velocity of the drill perpendicular to the workpiece

  V = f.N

  where, N : rotational speed
         f= feed (the distance the drill penetrates per revolution)

 N = V / D
 MRR =    (D2/4)(f)(N) in mm3/min

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                            Dr. Zühal ERDEN



    Drilling Machines

    Used for drilling holes, tapping, reaming and other
    small diameter boring operations.




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




REAMING AND REAMERS

Reaming is an operation used to make an existing hole
dimensionally more accurate.

Centering
Drilling
Boring
Reaming




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN




Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN



TAPPING AND TAPS

Production of internal threads. Tapping can be done by
hand or in drilling machines, lathes or automatic screw
machines.




 Atılım University / Dept. of Industrial Engineering