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Material Removal Principals: 1) What Are Types of Machining?

1) The document discusses material removal principles in machining like drilling, turning, milling and shaping. It explains that a wedge-shaped tool is common in these processes. 2) Experiments showed that a square tool does not cut effectively due to rubbing and chip compression. A clearance angle and then rake angle on the tool solved these issues by enabling shearing of chips along the shear plane. 3) A larger rake angle creates a shorter shear plane and less power consumption, but exceeding a certain value can damage the tool. The optimal rake angle depends on work material, tool material, and ranges from 10-15 degrees for mild steel with HSS tool.

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55 views6 pages

Material Removal Principals: 1) What Are Types of Machining?

1) The document discusses material removal principles in machining like drilling, turning, milling and shaping. It explains that a wedge-shaped tool is common in these processes. 2) Experiments showed that a square tool does not cut effectively due to rubbing and chip compression. A clearance angle and then rake angle on the tool solved these issues by enabling shearing of chips along the shear plane. 3) A larger rake angle creates a shorter shear plane and less power consumption, but exceeding a certain value can damage the tool. The optimal rake angle depends on work material, tool material, and ranges from 10-15 degrees for mild steel with HSS tool.

Uploaded by

غزالة مجدي
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Material Removal Principals

1) What are Types of Machining? :


1) Drilling: used to make holes, where the tool takes booth speed and feed. 2) Turning: used for making circular profiles, where the work piece takes the speed and the tool takes the feed. 3) Milling: used for generating flat surfaces, contours, slots and many other shapes. The tool takes the speed and the work piece takes the feed rate. 4) Shaping: used to machine surfaces. It can cut curves, angles, slots and many other shapes. It is a popular The common in all these machining processes is the presence of a wedge shape in its tools, whether it is single wedged or multi wedged tool.

2) Why a Wedge Shape?


The approach we will use to know why, is removing the wedge shape and observing the effect. Tests were conducted at the institute of technology in cranfield. (more information at their site
http://www.cranfield.ac.uk/index.html)

For that we shall use a square shaped tool on a planner machine.

Observation: 1) The chip doesnt flow naturally; it is being compressed and tends to break up.
2) The tool doesnt cut the full length. 3) Rubbing between the bottom of the tool and the work piece causing rough surface of the work piece and presence of traces of the work piece material on the bottom of the tool.

Solution: making what is called a clearance


angle between the bottom of the tool and the surface of the work piece using a grinder to make the bottom of the tool slopes away from the work piece. Now only the cutting edge touches the work piece.

Then we tested again after that modification.

Observation: 1) The tool cuts through the full


length of the work piece. 2) The chip still doesnt flow naturally and compressed.

Solution: making what is called the rake angle


using a grinder to change the angle of the tool face.

Then we tested once more.

Observation: the chip flows more naturally and shears along a line perpendicular to the tool
face; which we shall call the shear plane.

3) The Shear Action:


In the video the he said that the shear plane is perpendicular to the tool face which is wrong. If we go to merchants analysis we will find that the shear plane makes angle with the work piece and angle of 90 - + with the tool face which is bigger than 90 in case of positive rake.

Shear Length

Shear Width

Now we will observe the effect of different rake angles on the shear plane.

Observation:
When given a 5o rake angle the shear length was as shown

But when given a 15o rake angle it was like that

Conclusion:
From these observations we concluded that the larger the rake angle the shorter the shear plane length and the larger the shear angle .

But we shall ask ourselves what shall I gain or lose if the shear plane length gets longer or shorter. For that we shall test the effect of different rake angles on the power consumed during machining.

4) The Effect of Different Rake Angles on Power Consumption:


We shall use this time a lathe, where the speed, feed and clearance angle are constant, the only variable is the rake angle. We tested for rake angles of 10o, 20o, 30o and 40o. The results were as follows: Angles (degrees) Power (KW) 10 2.6 20 2.3 30 2.1 40 2

3 2.5 2 1.5 1 0.5 0

Power Consumed

Series1

Rake Angle
10 20 30 40

Conclusion: it is very clear that the larger the rake, the less power is used i.e. the shorter the
shear plane length and angle the less power is used.

Limitation: as we said the larger the rake, the less power is, but if the rake angle exceeds a
certain value it shall cause the tool to be damaged due to wear or thermal failure. For the mild steel they tested, they said the optimum value was between 10 and 20o. But its better to be between 10 and 15o. He also should have said that these values for using an HSS tool and that should change for different tool materials not only different work piece materials.

He ended his words with a question: would say 15o be the right angle for cutting any of those materials? Of course not, as he mentioned different materials which are mild steel, brass, nylon and aluminum. For an HSS tool each one shall have a different rake angle as shown: Material Brass Mild steel Aluminum Nylon Of course by changing tool material these values shall change. Rake Angle 0-5o 10-15o 20-25o 20-25o

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