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Manufacturing Processes Fundamentals of Cutting South Bend lathe Chip Formation Chip Breakers Feeds and Speeds Tool Materials Tool Properties Tool Wear Surface Finishes Cutting Fluids CNC Lathes
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Manufacturing Processes South Bend Engine Lathe
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Manufacturing Processes Chip Formation Discontinuous Continuous Built up edge
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Manufacturing Processes Chip Breakers On the Cutting Tool In the Material –Inclusions –Sulfur
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Manufacturing Processes Speed, Feed, Depth of Cut
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Manufacturing Processes Speeds, Depth of Cut Depth of Cut Speed
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Manufacturing Processes Feed Rates or
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Manufacturing Processes Cutting Time Considerations Material removal rate Time to Cut
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Manufacturing Processes Tool Materials High Speed Steel (HSS) Coated Carbide Inserts
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Manufacturing Processes Tool Properties High Hardness Resist Abrasion Resist Chipping Hot Hardness Resist Bulk Deformation (E) Chemical Stability Adequate Thermal properties Consistent Tool Life Geometry
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Manufacturing Processes Tool Wear slow death mechanisms: gradual wear on flanks, or rake face of tool (crater) –abrasion, adhesion, diffusion, chemical sudden death mechanisms: unpredictable, catastrophic failure –brittle fracture, chipping, plastic deformation
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Manufacturing Processes Tool Life Taylor's Equation: Surface Speed Variation in material hardness –within piece and piece to piece Variation in tool material and geometry Vibrations Changing surface characteristics of workpiece
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Manufacturing Processes Tool Geometry
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Manufacturing Processes Surface Finishes Tool Geometry and Feed rate
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Manufacturing Processes Surface Finishes Surface Speed and Depth of Cut
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Manufacturing Processes Cutting Fluids Reduces Cutting Temperature –dimensional stability –reduces thermal tool wear Acts as Lubricant –reduces forces and energy consumption
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Manufacturing Processes Cutting Fluids Flood Cooling –lowers temperature –reduces oxidation Mist Cooling –Better Visibility –gets to inaccessible areas
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Manufacturing Processes Effects of Coolants On workpiece –cracking, staining, chemical attack On machines –bearings and slideways On environment –breathing apparatus, and disposal
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