Lecture 1& 2

Processes & Tooling

Overview to Computer Aided Manufacturing -

ENGR-2963 - Fall 2008
Class Manager - Sam Chiappone
 Featured Processes For This
Class
 Milling
 Turning
 Drilling

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 Milling Processes

 Milling is one of the basic machining processes.

Milling is a very versatile process capable of
producing simple two dimensional flat shapes to
complex three dimensional interlaced surface
configurations.

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 The Process
 The milling process:
– Typically uses a multi-tooth
cutter
– Work is fed into the rotating
cutter
– Capable of high MRR
– Well suited for mass production
applications
– Cutting tools for this process are
called milling cutters
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 Classifications
 Milling operations are classified into two major
categories:
– Peripheral (side)
» Generally in a plane parallel to the axis of the cutter
» Cross section of the milled surface corresponds to the contour of
the cutter
– Face
» Generally at right angles to the axis of rotation of the cutter
» Milled surface is flat and has no relationship to the contour of the
cutter
» Combined cutting action of the side and face of the milling cutter

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 Related Operations
– Thread milling - milling treads using the capability of a
three axis contouring CNC machine.

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 Operating Parameters
 Rpm
– CS converted into Rpm based on cutter diameter
 Feed rate
– Feed per tooth
– Table feed rate

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 Operating Parameters
 Feed direction -- Conventional vs. Climb
– Conventional milling
» Most common method of feed
» Feed work against the rotation of the cutter

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 Operating Parameters
 Feed direction - Conventional vs. Climb
– Climb milling
» Load of the cutter tends to “pull” the work into the cutter
» This results in a small feed force and about 20% less Hp than
conventional milling
» Downward motion increases the load on the table ways
» This method can “pull” the work into the cutter and scrap the
work and/or damage the fixture and tool.
» Machine must be very ridged to safely utilize climb
milling(CNC machines)
» USE CAUTION!

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 Operating Parameters
 Conventional vs. Climb Milling

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 Operating Parameters
– Depth of cut
– Horsepower

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 Milling machines
 Two Major Classifications - Knee & Column and Bed
– Knee & Column (Bridgeport type)
» Basic job shop type mill
» Column mounted to the base which is the major support frame.
» Construction provides controlled motion of the worktable in three
mutual perpendicular directions.
» Knee moves vertically on the ways in the front of the machine
» Table moves longitudinally on the ways on the saddle
» Saddle moves transversely on the ways on the knee
» Quill moves parallel in Z axis or, if head is rotated, X axis
» Versatile general purpose machine

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 Milling Machines
– Bed
» Used extensively in production milling operations
» Rigid construction capable of heavy cuts
» Table is mounted directly to the bed
» Spindle head moves vertically to set depth of cut
» Head locks into position for cut
» Base of machine functions as a coolant reservoir

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 Machines
Conventional

Computer
Numerical
Control

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Milling Machines

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Milling Machines

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Milling Machines

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 CNC Machines
 CNC
» Horizontal, Vertical,and Planner (up to 5 axis)

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 Process Accuracy
 Accuracy of milling machines
» Factors to consider
 Fixture

 Rigidity of machine tool

 Accuracy of the spindle

 Cutter condition

 Coolant

– Type
– Delivery method
 Material condition

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 Process Accuracy
 +/- .0005” - Optimum situation
 +/- .001”-.002” - Typical
 +/- .001” - Flatness

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 Milling Cutters & Holding
Systems
 Cutter Types
– 2 to 4 Lip Cutters
 Face Mills
 Ball End Mills
 Collect Holding Systems
 Direct Mount Holders
 Face Mill Holders

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Milling Cutters

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 Workholding Devices for CNC
Milling Machines
 Vise
 Chucks
 Special fixtures
 Modular fixturing systems
 Clamp work to table

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Workholding Devices

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 Turning
 Turning is the process of machining external
cylindrical and conical surfaces. The process uses
a machine tool called a lathe.

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 Turning Processes
 Turning typically involves roughing procedures
followed by a finishing operation.

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 Turning Operations
 Turning operations performed on a lathe include:
– Straight turning
– Taper turning
– End facing
– Facing

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 Turning Operations
– Shoulder Facing
– Contour Turing
– Grooving
– Form turning
– Parting-off

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 Turning Operations
– Threading
» Internal / External
– Knurling
– Drilling
– Reaming
– Milling-CNC
turning centers

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 Process Calculations
 Rpm calculation
– RPM
– CS

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 Process Calculations
 Feed is typically a given distance per revolution.
This value is dependent on the operation, depth of
cut, cutting speed, tool material, surface finish----
etc. Units are--- in. per rev (in./rev)

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 Machine Classification
 Size designation
– Swing - maximum diameter that can be rotated on the
lathe
» 2x’s distance from spindle center line to ways
 Maximum distance between centers

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 Conventional and CNC Lathes
 Engine
– Most frequently used lathe
– Heavy duty
– Power drive for most tool movements
– Size range 12”x24” to 24”x48” - can be larger
 CNC
– Computer controlled
– Wide variety of process capability
– Multiple axis
– Indexing and contouring head
– On- line and off- line programming available

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 Other Types of Lathes
 Tracer
– Hydraulic attachment used to copy the shape of a part
from a master.

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 Types of Lathes

2
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Types of Lathes

Combination
Conventional / CNC

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 Cutting Tools for Lathes
 External
– Right hand turning
– Left hand turning
– Round nose turning
– Cut-off
– Left hand facing

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 Cutting tools for Lathes
 External (con’t)
– Broad nose finishing
– Right hand facing
– Threading
– Form
 Internal
– Boring
– Threading
– Grooving
– Form

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Typical Carbide Insert & Holder

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 Workholding on a Lathe
 Between centers
– Live-tailstock
– Dead-headstock
– Face plate
– Drive dog

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 Workholding on a Lathe
 Chuck
– 3,4, or 6 jaw
– Soft jaws

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 Workholding on a Lathe
 Collect system

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 Workholding on a Lathe
 Others
– Face driver system
– Sub-spindle system

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 Drilling & Related Hole Making
Processes
 Basic hole making processes account for
approximately 50-70% of all the metal removal
processes utilized today.
 Holes
– Casting
» Sand, die, molding
– Punching
– Machining,
» Drilling, milling, EDM, AWJ, etc.
– Burning

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 Processes
 Standard hole making processes include:
– Drilling - Drilling is the process of producing or
enlarging a hole. This is accomplished by rotating the
tool and/or workpiece.
– Reaming - Enlarging an existing hole with a multi-
edged tool (reamer) for dimensional accuracy and/or
surface finish
– Spot facing - Smoothing, squaring, and/or flattening a
surface

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 Processes
– Counter sinking - operation or producing a tapered
feature at the end of a hole. Most popular application is
a feature for a flathead screw (82 degrees) to sit flush
with a surface.
– Counter boring - Enlarging of an existing hole at one
end. This enlarged hole is concentric with the existing
hole and is flat at the bottom. One application of this
process is a feature to set the head of a bolt below a
surface.

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 Process Parameters

 Cutting speed
 Rpm
 Feed (in/rev ---- in/min) (Rpm x in/rev)

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Process Parameters

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Drill Variations

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 Reamers

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 Machine Tools
 Machine tools used in this process include; drill
presses, lathes, milling machines, and special
purpose machines. One of the most popular is the
drill press.

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 Drill Presses
 Upright Drill Press
– Larger than the sensitive
– Can be equipped with a gearbox
and variable speed head
– Hand and automatic feed
mechanism
– Automatic coolant system
– Table can move on a rack and
pinion system

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 Drill Presses
 Gang Drilling Machine
– Equipped with more than one
spindle
– Multi-head arrangement
– Single table
– Used for production set-up
– Multiple operations at one location
(drill, ream, tap, c’sink, c’borte
etc.)

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 Drill Presses
 CNC Turret
(Conventional)
– 2 axis motion
– Computer controlled
– Series of operations
– Turret indexes to different
tools
» Individual speeds / feeds

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 Tool Holding Devices
 Drill chucks
– Key type or keyless
 Drill Sleeves
 Collet

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 Lecture 2 – Tooling & Tools

Overview to Computer Aided Manufacturing -

ENGR-2963 - Fall 2008
Class Manager - Sam Chiappone
 Process Basics
 Components
 Speed & Feed Calculations
 Carbide Insert Specifications

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 Process Basics
 Tools
– Refers to devices used to cut or deform the metal.
» Cutting tools - examples include end mills, carbide inserts,
drills, grinding wheels, shell mills, etc.

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 Process Basics

 Tooling
– Refers to holding devices
» Examples include- vises, fixtures, jigs…...etc.

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 Process Basics

 Cutting fluid
– Act as a coolant and lubricant
– Reduce friction between chip and tool face
– Extend tool life
– Help to remove chips from cutting area

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 Metal Removal Related
Calculations
 To efficiently use these components, different
input parameters have to be calculated. They
include:
– RPM of cutter
» Milling or drilling operation = Rpm for cutter
» Turning operation = Rpm for part
 Basically the rotating component

– Feed
» The distance in inches, feet, or millimeters per minute that the
work advances into the cutter.
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 Metal Removal Related
Calculations
 Input parameters (con’t)
– Cutting speed(CS)-the surface feet per minute or
meters per minute, at which a metal can be machined
efficiently. This variable has a direct relationship to the
diameter of the cutter, in a milling or drilling operation,
or the diameter of the work piece in a lathe operation.
» Example - When machining(using a milling machine) a
medium grade steel, the cutter must achieve a surface speed of
about 90 ft/min. The diameter of the cutter will have a direct
relationship to the rpm calculation.

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 Metal Removal Related
Calculations
 Input parameters (con’t)
– Depth of cut - Amount of material being removed.
– Horsepower required for cut
– Material removal rate (MRR) - volume of material
being removed per unit of time
– In a milling operation, you also have to take into
account the thickness of the chip each tooth will
remover per revolution as it advances into the work.
This value is expressed in feed per tooth.
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Metal Removal Problem

1.
Cutting
Tools
4.

2.
3.
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Metal Removal Problem

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 Factors Effecting Calculations

 Set-up conditions
 Machine conditions
 Tooling conditions
 Material conditions
 Cutting fluid

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Tool Selection Process

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 Tool Materials
 Wide variety of materials and compositions are
available to choose from when selecting a cutting
tool

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 Tool Materials
 They include:
– Tool steels - low end of scale. Used to make some
drills, taps, reamers, etc. Low cost equals low tool life.
– High speed steel(HSS) - can withstand cutting
temperatures up to 1100F. Have improved hardness
and wear resistance, used to manufacture drills,
reamers, single point tool bits, milling cutters, etc.
HSS cutting tools can be purchased with additional
coatings such as TiN which add additional protection
against wear.
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 Tool Materials
– Cobalt - one step above HSS, cutting speeds are
generally 25% higher.
– Carbides - Most widely used cutting tool today.
Cutting speeds are three to five times faster than HSS.
Basic composition is tungsten carbide with a cobalt
binder. Today a wide variety of chemical compositions
are available to meet different applications. In addition
to tool composition, coatings are added to tool
materials to incerase resistance to wear.

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 Tool Materials
– Ceramics - Contain pure aluminum oxide and can cut at
two to three times faster than carbides. Ceramic tools
have poor thermal and shock resistance and are not
recommended for interrupted cuts. Caution should be
taken when selecting these tools for cutting aluminum,
titanium, or other materials that may react with
aluminum oxide.

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 Tool Materials
– Cubic Boron Nitride(CBN) - This tool material
maintains its hardness and resistance to wear at elevated
temperatures and has a low chemical reactivity to the
chip/tool interface. Typically used to machine hard
aerospace materials. Cutting speeds and metal removal
rates are up to five times faster than carbide.
– Industrial Diamonds - diamonds are used to produce
smooth surface finishes such as mirrored surfaces. Can
also be used in “hard turning” operations to eliminate
finish grinding processes. Diamond machining is
performed at high speeds and generally fine feeds. Is
used to machine a variety of metals.

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 Carbide Inset Selection

M1-Fine
M2-Medium
M3-S.S
M4-Cast iron
M5-General
Purpose

A.N.S.I. Insert Identification

System
ANSI - B212.4-1986 Intro to CAM
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Carbide Inset Selection

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