Search Results for cutting parameters

Fundamental to the machining process, is the metal-cutting operation, which involves extensive plastic deformation of the work piece ahead of the tool tip, high temperatures, and severe frictional conditions at the interfaces of the tool, chip, and work piece. This article explains that the basic mechanism of chip formation is shear deformation, which is controlled by work material properties such as yield strength, shear strength, friction behavior, hardness, and ductility. It describes various chip types, as well as the cutting parameters that influence chip formation. It also demonstrates how the service life of cutting tools is determined by a number of wear processes, including tool wear, machining parameters, and tool force and power requirements. It concludes by presenting a comprehensive collection of formulas for turning, milling, drilling, and broaching, and its average unit power requirement.

This article describes the use of conventional machining techniques, laser cutting and water-jet cutting for producing finished composite parts. It explains two representative polymer-matrix composites--graphite and aramid composites--and discusses the machining and drilling problems such as delamination and fiber or resin pullout. The article describes machining and drilling techniques and the necessary tools and cutting parameters. It presents a description of laser cutting. The article also provides information on the advantages, disadvantages, cutting characteristics, and applications of water-jet cutting and abrasive water-jet cutting.

The horsepower requirements to cut various metal alloys provide an indication of the relative ease and cost of machining, but several other important factors include cutting tool material, chip formation, cutting fluids, cutting tool wear, surface roughness, and surface integrity. This article reviews these general machining factors as well as specific cutting tool and cutting parameters for the six basic chip-forming processes of turning, shaping, milling, drilling, sawing, and broaching. Best practices for each of the six chip-forming processes are suggested for optimized machining of aluminum alloys. The article lists the inherent disadvantages of machining processes that involve compression/shear chip formation. It discusses the machining of aluminum metal-matrix composites and nontraditional machining of aluminum, such as abrasive jet, waterjet, electrodischarge, plasma arc, electrochemical, and chemical machining.

High removal rate (HRR) machining involves the use of extremely rigid, high-power, high-precision machines, such as roll turning lathes, to achieve material removal rates far beyond the capacity of conventional machine tools. This article reviews the machine requirements and cutting parameters of HRR machining. Machine components such as the lathe bed, tailstock, headstock, carriage, and tooling are detailed. The article also discusses the applications of HRR machining.

The relative motion between the tool and the workpiece during cutting compresses the work material near the tool and induces a shear deformation that forms the chip. This article discusses the fundamental nature of the deformation process associated with machining. It describes the mechanics of the machining process, and presents the principles of the orthogonal cutting model. The article also analyzes the effect of workpiece properties on chip formation.

Machining of cast iron involves removing metal from the cast part, usually by cutting with a power-driven machine tool. This article discusses the factors that influence machinability, the methods used to evaluate machinability of cast irons, the effects of cast iron microstructure on cutting tool life, and the importance of as-cast surface integrity on the machining variation. It presents examples of cutting tool materials selection for different cast iron grades, and describes the effects of coolants on the machining of cast irons. A chart showing different cutting materials and cutting speed ranges for selected iron-carbon alloys is also presented. Different types of cutting tool wear observed during turning are schematically illustrated.

Powder metallurgy is a near-net shape process capable of producing complex parts with little or no need for secondary operations such as machining, joining, or assembly. However, the inability to produce certain geometrical figures such as transverse holes, undercuts, and threads frequently necessitates some machining, particularly drilling. This article provides a discussion on the measures that can optimize the machining of P/M materials. It reviews the factors influencing machinability of P/M components, including workpiece and tool material properties, cutting conditions, machine and cutting tool parameters as well as some P/M material and production process parameters. These parameters discussed include the particle size, part geometry, porosity, compaction and sintering methods. In addition, the article presents guidelines for the various machining processes, namely, turning and boring, milling, drilling, grinding, reaming, burnishing, tapping, and honing and lapping.

This article describes the basic concepts of the complex factors that influence the forces, power, and stresses in machining. It provides an overview of the models of orthogonal (that is, two force) machining of metals as they are useful for understanding the basic mechanics of machining and can be extended for modeling of the production processes. The article discusses stresses on the shear plane, stresses distributions on the rake face, uniform stresses on the rake face, and nonuniform stress distributions on the rake face. It also examines the specific power consumption in turning, drilling, and milling operations. The article concludes with a section on the factors affecting specific power.

This article focuses on a variety of laser beam machining (LBM) operations of aluminum and its alloys, namely, laser cutting, laser drilling, laser milling, laser turning, laser grooving, laser scribing, laser marking, and laser micromachining. It presents different approaches for carrying out machining operations, laser processing parameters, efficiency and accuracy of the process, and the effect of laser processing parameters on the quality of the machined surface. The article provides an overview of the various conventional (chip forming) and nonconventional machining techniques employed for aluminum-based materials. A comparison of the various aspects of LBM with other non-conventional techniques is also presented. The article also describes the features of LBM techniques employed for aluminum and its alloys for different types of machining.

Machining tribology poses a significant challenge due to the multiple parameters that must be simultaneously considered to arrive at a cost-minimized solution in production. This article provides information required to make informed decisions about machining parameters. It describes the relationships between machining parameters, workpiece material properties, cutting forces, and the corresponding temperature field in the chip. The article provides information on tool life, with an empirical model, common wear features, and the relationship between tool life and machining cost. The cutting fluids and their effect on tool life are also discussed. The article discusses machining process dynamics and corresponding vibrations. It contains a table that provides a summary of high-pressure coolant research.