16-02-2013, 10:23 AM
Common Machining Operations
Common Machining.ppt (Size: 5.56 MB / Downloads: 119)
Machining: Turning
Depth of Cut = DOC = (Dbefore – Dafter) / 2
Cutting Speed = Speed of metal moving towards cutting tip
Usually called “Surface Feet per Minute”, SFPM, SFM
Each cutting tool & workpiece material combo has a max SFM for decent tool wear.
HSS & alum: 800 SFM
HSS & 1020 steel: 110 SFM
HSS & 1090 steel: 80 SFM
HSS & hard 4140: 30 SFM
TC & 1020 steel: 1000 SFM
SFM = r*w
= D * RPM * (π/12)
≈ D * RPM / 4
RPMmax = 4 * SFM / D
(most useful machining formula)
E.g., find RPM for turning
2” dia. 1020 steel:
RPM ≈ 4*110/2 = 220
RPM may need to be less due to chatter!
Most relations are similar
for milling, but D=cutter dia.
Chatter
Vibrational resonance of entire machining system, especially workpiece-cutter.
Causes poor surface finish, fast tool wear, noise
Factors: stiffnesses of workpiece, cutter, machine
cutting params: speed, feed, DOC
cutter geometry: rake, clearances
Solutions:
Change the cutting params
esp. speed
Increase stiffnesses