Milling Lathe Drill

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
Intro to CAM
Rensselaer Polytechnic Chiappone
Institute
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.
Intro to CAM
Institute
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
Intro to CAM
Institute
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
Intro to CAM
Institute
Related Operations
Thread milling - milling treads using the capability of a
three axis contouring CNC machine.
Intro to CAM
Institute
Operating Parameters
Rpm
CS converted into Rpm based on cutter diameter
Feed rate
Feed per tooth
Table feed rate
Intro to CAM
Institute
Feed direction -- Conventional vs. Climb
Conventional milling
Most common method of feed
Feed work against the rotation of the cutter
Intro to CAM
Institute
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!
Intro to CAM
Institute
Conventional vs. Climb Milling
Intro to CAM
Institute
Depth of cut
Horsepower
Intro to CAM
Institute
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
Intro to CAM
Institute
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
Intro to CAM
Institute
Machines
Conventional
Computer
Numerical
Control
Intro to CAM
Institute
Milling Machines
Intro to CAM
Institute
Milling Machines
Intro to CAM
Institute
Milling Machines
Intro to CAM
Institute
CNC Machines
CNC
Horizontal, Vertical,and Planner (up to 5 axis)
Intro to CAM
Institute
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
Intro to CAM
Institute
Process Accuracy
+/- .0005 - Optimum situation
+/- .001-.002 - Typical
+/- .001 - Flatness
Intro to CAM
Institute
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
Intro to CAM
Institute
Milling Cutters
Intro to CAM
Institute
Workholding Devices for CNC
Milling Machines
Vise
Chucks
Special fixtures
Modular fixturing systems
Clamp work to table
Intro to CAM
Institute
Workholding Devices
Intro to CAM
Institute
Turning
Turning is the process of machining external
cylindrical and conical surfaces. The process uses
a machine tool called a lathe.
Intro to CAM
Institute
Turning Processes
Turning typically involves roughing procedures
followed by a finishing operation.
Intro to CAM
Institute
Turning Operations
Turning operations performed on a lathe include:
Straight turning
Taper turning
End facing
Facing
Intro to CAM
Institute
Turning Operations
Shoulder Facing
Contour Turing
Grooving
Form turning
Parting-off
Intro to CAM
Institute
Turning Operations
Threading
Internal / External
Knurling
Drilling
Reaming
Milling-CNC
turning centers
Intro to CAM
Institute
Process Calculations
Rpm calculation
RPM
CS
Intro to CAM
Institute
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)
Intro to CAM
Institute
Machine Classification
Size designation
Swing - maximum diameter that can be rotated on the
lathe
2xs distance from spindle center line to ways
Maximum distance between centers
Intro to CAM
Institute
Conventional and CNC Lathes
Engine
Most frequently used lathe
Heavy duty
Power drive for most tool movements
Size range 12x24 to 24x48 - can be larger
CNC
Computer controlled
Wide variety of process capability
Multiple axis
Indexing and contouring head
On- line and off- line programming available
Intro to CAM
Institute
Other Types of Lathes
Tracer
Hydraulic attachment used to copy the shape of a part
from a master.
Intro to CAM
Institute
Types of Lathes
2
Intro to CAM
Institute
Types of Lathes
Combination
Conventional / CNC
Intro to CAM
Institute
Cutting Tools for Lathes
External
Right hand turning
Left hand turning
Round nose turning
Cut-off
Left hand facing
Intro to CAM
Institute
Cutting tools for Lathes
External (cont)
Broad nose finishing
Right hand facing
Threading
Form
Internal
Boring
Threading
Grooving
Form
Intro to CAM
Institute
Typical Carbide Insert & Holder
Intro to CAM
Institute
Workholding on a Lathe
Between centers
Live-tailstock
Dead-headstock
Face plate
Drive dog
Intro to CAM
Institute
Chuck
3,4, or 6 jaw
Soft jaws
Intro to CAM
Institute
Collect system
Intro to CAM
Institute
Others
Face driver system
Sub-spindle system
Intro to CAM
Institute
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
Intro to CAM
Institute
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
Intro to CAM
Institute
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.
Intro to CAM
Institute
Process Parameters
Cutting speed
Rpm
Feed (in/rev ---- in/min) (Rpm x in/rev)
Intro to CAM
Institute
Process Parameters
Intro to CAM
Institute
Drill Variations
Intro to CAM
Institute
Reamers
Intro to CAM
Institute
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.
Intro to CAM
Institute
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
Intro to CAM
Institute
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, csink, cborte
etc.)
Intro to CAM
Institute
Drill Presses
CNC Turret
(Conventional)
2 axis motion
Computer controlled
Series of operations
Turret indexes to different
tools
Individual speeds / feeds
Intro to CAM
Institute
Tool Holding Devices
Drill chucks
Key type or keyless
Drill Sleeves
Collet
Intro to CAM
Institute
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
Intro to CAM
Institute
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.
Intro to CAM
Institute
Process Basics
Tooling
Refers to holding devices
Examples include- vises, fixtures, jigs...etc.
Intro to CAM
Institute
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
Intro to CAM
Institute
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.
Intro to CAM
Institute
Calculations
Input parameters (cont)
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.
Intro to CAM
Institute
Calculations
Input parameters (cont)
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.
Intro to CAM
Institute
Metal Removal Problem
1.
Cutting
Tools
4.
2.
3.
Intro to CAM
Institute
Metal Removal Problem
Intro to CAM
Institute
Factors Effecting Calculations
Set-up conditions
Machine conditions
Tooling conditions
Material conditions
Cutting fluid
Intro to CAM
Institute
Tool Selection Process
Intro to CAM
Institute
Tool Materials
Wide variety of materials and compositions are
available to choose from when selecting a cutting
tool
Intro to CAM
Institute
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.
Intro to CAM
Institute
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.
Intro to CAM
Institute
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.
Intro to CAM
Institute
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.
Intro to CAM
Institute
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
Institute
Carbide Inset Selection
Intro to CAM
Institute

Milling Lathe Drill

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Milling Lathe Drill

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Lecture 1& 2

Processes & Tooling

Overview to Computer Aided

Milling is one of the basic machining processes.

Rigidity of machine tool

Accuracy of the spindle

Overview to Computer Aided

A.N.S.I. Insert Identification

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