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8 - Machining Processes

The document covers various machining processes including turning, drilling, and milling, detailing parameters such as cutting speed, feed rate, and material removal rate. It discusses the benefits of cryogenic turning for biomedical components, and compares climb milling and conventional milling techniques. Additionally, it provides formulas for calculating cutting time and material removal rates for different machining operations.

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Pedro Rodrigues
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13 views20 pages

8 - Machining Processes

The document covers various machining processes including turning, drilling, and milling, detailing parameters such as cutting speed, feed rate, and material removal rate. It discusses the benefits of cryogenic turning for biomedical components, and compares climb milling and conventional milling techniques. Additionally, it provides formulas for calculating cutting time and material removal rates for different machining operations.

Uploaded by

Pedro Rodrigues
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MACHINING PROCESSES

Chapter 8
Turning operations

Roughing
Finishing
Turning parameters

CUTTING SPEED vt: relative speed between the tool


and the workpiece [m/min]

FEED RATE va: speed at which the tool travels along the
feed direction [mm/min]

FEED f: distance travelled by the tool on the feed direction for


each turn of the workpiece [mm/giro]

DEPTH OF CUT d: amount of metal to be removed,


measured perpendicularly to the feed direction [mm]

DN D0 − Df
N [round/min] D [mm]
vt = d=
10 3 2
v a = Nf
Material removal rate MRR
Volume of material machined in
the time unit [mm3/min]

Volume machined for each workpiece turn

p Davg fd
D0 + Df
Davg =
2

MRR = Davg fdN


Turning time
l
t= l distance travelled by the tool

fN NOTE: the formula does not include the time


needed for the tool engage and disengage
Cutting speed in turning
Cutting speed in turning
Cryogenic turning of biomedical components
Benefits:
→ Increase of the tool life
→ Increase of the machined surface integrity
Cryogenic turning of biomedical components
EBM Ti6Al4V pin Benefits:
→ Increase of the tribo-corrosion resistance

Vc=50 m/min Vc=50 m/min


f=0.1 mm/rev f=0.2 mm/rev
Wrought CoCrMo flat plate DRY DRY

CRYO CRYO

• Worn cryogenic machined pins increased in weight due to the


adhered flat plate material due to their higher initial hardness
Drilling

▪ Utensile generalmente dotato sia del moto di


taglio (rotatorio intorno all’asse dell’utensile)
che del moto di avanzamento (rettilineo in
direzione dell’asse medesimo)
▪ Utensile: generalmente una punta elicoidale
Drilling parameters

CUTTING SPEED vt: the tool speed at its external p DN


diameter D [m/min] vt =
10 3
where D [mm], N [rev/min]

FEED f: the distance travelled by the tool for each turn [mm/rev]

MATERIAL REMOVAL RATE


[mm3/min]

D 2
CUTTING TIME [min] MRR = fN
4
L L
t= =
v a nf
L = e + l + la
where e is the initial extra-distance travelled by the
tool to engage the piece (2-3 mm), l is the length of
the hole to be drilled, and la is the length of the
conical final part of the driller
Cutting speed and feed in drilling
Drilling of dental implants
n
Vibration Assisted Drilling VAD refers to the
superimposition of ultrasonic vibration
Drill bit

US vibration

Near-net-shape Post-processing
AM product machining Finishing
Workpiece

R
f = 0.005 mm/tooth f = 0.015 mm/tooth f = 0.020 mm/tooth

VAD VAD
CD CD VAD
CD
Slab/peripheral milling
The axis of the tool is parallel to the surface to be milled

Climb milling Conventional


milling
Peripheral milling parameters
Cutting speed = cutter tangential speed [m/min] (evaluated
at the cutter diameter D)

DN N= cutter rotational speed [round/min]


V=
10 3 D= cutter diameter [mm]

If the feed is straight, f [mm/rev] is the distance travelled


by the workpiece for each turn of the cutter
d [mm] is the depth of cut

Feed for each tooth of the cutter


v
fZ =
v= linear speed of the workpiece

Nn n= number of teeth of the cutter


Peripheral milling parameters

Cutting time

t=
(l + lc )
l= length of the workpiece
lc= extent of the cutter’s first
contact with the workpiece
v
v= linear speed of the workpiece

Material removal rate MRR [mm3/min]


lwd w= width of the cut
MRR = = wdv
t d= depth of cut
Conventional milling
• the shape of the chip is like a comma, with a
thickness equal to zero when the tooth comes in
contact with the workpiece to the maximum thickness
when it leaves the contact
• every tooth rubs on the previously machined surface
before starting cutting and this leads to material
hardening and cutter wear
• the cutter works on virgin material: possible surface
oxidation does not influence the cutter; therefore, this
kind of operation is preferable for finishing operations
• the force R resultant of the cutting force T and normal
force N has a vertical component V (which can cause
the workpiece to lift from the its fixtures, which makes
the fixturing very important) and a horizontal
component O (which acts opposite to the feeding
direction)
• the cutting force T acting on each tooth varies during
the operation: it is equal to zero when the tooth comes
in contact with the workpiece and becomes maximum
when the tooth leaves the contact; this causes high
vibrations.
Climb milling

• the tooth begins to cut with an impact when the


thickness of the chip is maximum: hard surfaces can
cause the tool chipping
• rubbing phenomena are absent, we have less wear of
the tools, less vibrations
• the vertical component V of the force resultant R
tends to compress the workpiece on its (more easy
fixturing) whereas the horizontal component O is along
the feed direction
• very high forces arise at the tooth impact with the
surface: a very rigid set-up is needed
• used especially for clean surfaces; not suitable for
oxidized surfaces
Face milling
The axis of the tool is perpendicular to the surface to be milled

Better milled surface, almost constant thickness of the chip, higher number of engaged
teeth, possibility to use inserts

Climb milling
Conventional milling
Cutting speed in milling

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