1. Manufacturing Methods
Technology II – Jan Tomíček

2. Machining operations Machined parts Elementary shapes
Rotational – cylindrical (shafts) or disk-like
Nonrotational(Prismatic) – block-like or plate-like
Elementary shapes
Rotational,
planes,
contoured.
Rotational – cylinder (válec) cone (kužel) eliptical surface (eliptický povrch)
Planes – pyramid (jehlan) cube (krychle) block (kvádr)
Contoured – different shapes (různé tvary)

3. Examples

4. Machining operations:
creating a shape
generating – by the feed trajectory of the tool
forming – by the geometry of the tool
combination – of both processes

5. Machining – generating

6. Machining – forming

7. Machining – combination of forming and generating

8. Classification of manufacturing methods
Material removal processes
Conventional machining
Turning and related ops.
Drilling and related ops.
Milling and related ops.
Broaching, Shaping,
Other machining ops.
Abrassive processes
Grinding
Other abrasive processes
Non-traditional machining
Mechanical energy processes
Electrochemical machining
Thermal energy processes
Chemical machining
Material forming processes
Classification of manufacturing methods
Material removal processes

9. A CUTTING TOOL
single-point tool (a)
multiple cutting edge tool (b)

10. CUTTING EDGE
face - rake angle RA α
flank - relief angle ERA γ

11. Manufacturing Methods
Turning, Milling, Drilling
Only very brief description – should be allready known from the course „Fundamentals of technology“ or from other course as required assumption to enter the course TE2

12. Turning
Main movement – rotational – workpiece Feed movement – linear – tool
Versatile technology

13. Lathe operations

14. Turning tools - examples

15. Turning machine - lathe
Very long history (Egypt, Greece)
1300 BC
Manually powered
Water, steam
Transmisions, gearbox
Electric power, electronic control

16. A lathe – workholding methods

17. PART QUALITY CHARACTERISTICS
The quality of functional surfaces of a part –
4 main parameters (in a part drawing):
dimension accuracy (a tolerance) –
a grade of fit (marked IT)
shape accuracy
relative location parameters
surface roughness Ra

19. Turning – work time x IT relation

20. Turning – work time x Ra relation

21. Turning – tolerances and surface finish
Type of cut IT Ra
roughing
12,
finishing
9 - 11
1,6 - 12,5
NC machines finishing
6 – 9
1,6 - 6,3
fine finishing (sintered carbide)
6 – 8
0,4 - 1,6
fine finishing (diamond)
5 – 6
0,2 - 0,8

22. DRILLING

23. Operations related to drilling

24. Drilling machine – drill
Hand drill
Table drill
Stand drill
Radial drill

25. Drilling – tolerances and surface finish
Process/tool IT Ra
drilling (twist drill)
11 – 13
3,2 – 12,5
rough reaming
(reamer drill)
9 – 10
1,6 – 6,3
reaming (reamer)
6 – 8
0,4 – 1,6
counterboring
7 – 10

26. MILLING
plain (peripheral) milling – the axis of the tool is parallel to the surface being machined
face milling – the axis of the cutter is perpendicular to the surface being milled

27. Face milling - examples
►facing ► end milling
(a milling head) (an end mill)

28. End milling
Variation of tool shapes
Generative process

29. Milling machine

30. Milling – tolerances and surface finish
Type of cut IT Ra
roughing
10 – 13
6,3 – 25
finishing
8 – 10
1,6 – 6,3
fine finishing
7 – 8
0,8 – 1,6

31. Manufacturing Methods
BROACHING

32. BROACHING a multiple tooth cutting tool
the forming tool moves linearly relative to the workpiece in the direction of the tool axis
Movement through or along the part

33. Broaching tool

34. External broaching tool

35. Broaching process on a press – the tool is pushed
on a broaching machine – the tool is pulled
Using special machine – stationary broach

36. Broaching machines
vertical ►
horizontal ▼

37. Broached shapes
Internal – holes and other round shapes, keyways, profiles, gears
Need leading hole to place the pilot
External – faces, T-shape, co-planar surfaces, gears
Holes calibration – Broach diameter slightly bigger than the hole.

39. Keyway broaches

40. Rotary broaching
internal

41. Rotary broaching - limitations
Broach length
Spiraling

42. Broaching limitions Machined volume Speed Tool costs
Limited by chip thickness long broach
Speed
No wear demands  low temperature, forces
Tool costs
Expensive production long tool life

43. Broaching – tolerances and surface finish
Type of cut IT Ra
surface roughing
7 – 9
0,8 – 3,2
surface finishing
5 – 7
0,1 – 0,8
hole roughing
7 – 8
hole finishing

44. Video links Turning https://youtu.be/8EsAxOnzEms Milling

45. Video links Broaching http://www.youtube.com/watch?v=e26kCaPjX8E
Rotary
Making a broach