... Machining 11.3 Traditional Machining 51.3.1 Machining by cutting 51.3.2 Machining by abrasion 61.4 Nontraditional Machining 81.4.1 Single-action nontraditional machining 91.4.2 Hybrid machining ... removal. Machining processes that are based on the thermal machining actionare described in Chap. 5. These include electrodischarge machining (EDM), laser beam machining (LBM), electron beam machining ... hybrid machining processes. The book is written in eight chapters:Chapter 1: Material Removal Processes Chapter 2: Mechanical Processes Chapter 3: Chemical Processes Chapter 4: Electrochemical Processes Chapter...
... powder metallurgy paper concerning ‘secondary machining 1, entitled: 1 ‘Secondary machining , is a term used to cover any additional post -machining operations (e.g. drilling, turning and ... insert’s passage over the surface can be metallographically-inspected and a micro-hardness ‘footprint’ across a tapered section can be undertaken, to see if any surface/ sub -surface modica-tions ... to have the facility to stop machining at a convenient point as desired, at the press of a button – giving a measure of control to the automated CNC machining processes. If a series of testpieces...
... problem.sual aspect of machined surfaces – wherein the real situation is that surface texture continuously degen-erates, and it is only the burnishing (i.e.‘ironing’) of the surface that ‘masks’ the ... established. e faced-o surface texture re-sults can then be superimposed onto the same graph – for a direct comparison of ank wear and for that of the machined surface texture parameter. ... facing-o secondary machining operation meant that aer 10 facing passes, a pre-programmed ‘optional stop’ can then be applied, to allow both tool ank wear and compact surface tex-ture to...
... calculations.Machinability and Surface Integrity Figure 159. The generated errors produced when circular interpolating at high feedrates when high-speed machining. Machinability and Surface Integrity ... chatter in machining operations, with their machine tool damping characteristics. Chapter either entirely eliminating it, or at the very least, min-imising its aect on the overall machining ... chip width, acting as the feed-back gain31 within the closed-loop cutting process, NB e machiningprocesses ‘stability limit’ – be-ing the threshold between stable cutting and chat-ter –...
... production processes. Machinability and Surface Integrity Figure 162. Anticipated process ‘roughness’ and their respective grades. [Source: ISO 1302, 2001]. Chapter Figure 160. Surface ... of a surface tends to be either: anisotropic, or isotropic44 in nature on a machined surface topog-raphy. When attempting to characterise the potential functional performance of a surface, ... (Dagnall, 1998).44 ‘Anisotropic, or isotropic surfaces, either condition can be in-dividually represented on all machined surfaces. Anisotropy, refers to a surface topography having directional properties,...
... ‘Ternary manufacturing envelopes’ for the production processes of turning and boring, axes: feedrate, roundness and surface texture .Machinability and Surface Integrity particular, the heat generated ... pro-duces an abraded surface that approaches the grit size of the abrasive medium. erefore, to the naked eye the insert’s surface looks smooth, but at the ‘micron-level’ of surface magnication ... process envelopes’.Machinability and Surface Integrity a ‘saw-toothed prole’ to the hole’s surface, along with pores in the compact that are open to the ‘free -surface of the hole. e hole topography...
... coatings, minimise this BUE eect. If BUE does oc-cur, it can create a poor surface nish on the ma-chined surface. In any BUE machining condition, if it continues without attention, then the result ... action, promoted by either machining workpiece materials that may easily work-harden, so each successive longitudinal turning pass at the same DOC leads to the previous surface condition being ... insert’s edge. NB BUE machining data conditions have been reasonably well-dened, so fortunately, these re-spective cutting speeds can be avoided, particu-larly, as most CNC machining operations...
... .Machinability and Surface Integrity costs can be calculated, for a simple turning operation: the method can be modied for machining centres and for most other machining operations.As ... oc-curs due to plasto-mechanical processes of crack formation and chip removal, in combination with surface friction. Any form of tool wear alters the contact surfaces between the tool and workpiece, ... Even though the lowest possible machining cost per component can be calculated with the most eco-nomical cutting speed, it is oen desirable to utilise a faster machining strategy. is increased...
... now be described. Computer Simulation of Machining Processes – an IntroductionBy the application of computers to simulate and anal-yse machining processes, this provides tool manufac-turers ... non-orthogonal (three-dimen-sional) machining processes, advances in tool geometries with their accompanying force and shear relationships and the advent of applications to machining opera-tions employing ... workpiece. Lagrangian FEA Simulation Machining ModellingIn Fig. 183, just a few images of the Lagrangian FEA machining model are depicted for several applica-tions of machining operations. is simulation...
... discussing the machined surface condition in the following section. .. Residual Stresses in Machined SurfacesA machined surface is the product of either ‘abusive’ , or ‘gentle’ machining regimes, ... show the complexity of a machining operation, with the surface integrity grouping indicating for a turning operation the fol-lowing features:• Surface condition – surface texture and its associ-ated ... • Surface displacement – bulk transportation of ma-terial and residual stresses,• Surface/ sub -surface micro hardness – plastic de-formation and localised residual stress layers.Machined surfaces...
... transform the surface metallurgy by thermo-mechanical generation. e case has al-ready been made concerning the fact that machining processes impart residual stresses into the surface lay-ers, ... of Ma-chined Surfaces Produced by Plastic Deformation Mecha-nisms. WEAR, Vol. 109, 195–205, 1986.Griths, B.J. Manufacturing Surface Design and Monitor-ing for Performance. Surface Technology, ... increase in a surface material break-out and generation of debris,• Surface delamination and fatigue.Cracks may be considered as either separations, or narrow ruptures that interrupt the surface...
... Johnson, 2001]. Machining and Monitoring Strategies tion machining strategy (i.e. see Fig. 216) and, they can be succinctly summarised as follows:• Direct benets – improved machining eciency,– ... capability of machining thin walls/sections.ese production improvements are by no means all that occur, as invariably, due to the superior machined surface texture, the nal part surface may ... Yamazaki Mazak Corporation]. Machining and Monitoring Strategies Figure 214. Graphical relationship of high speed machining of metals – according to Salomon’s machining trials. [Source: Salomon,...
... cutting tool to rest and press against machined surface and thus, generate minute ‘gouging-eects’ in the surface. (Source: Seames, 1990; Smith, 1993) Machining and Monitoring Strategies Figure ... design and its operation. Machining and Monitoring Strategies Figure 222. The CNC control problem of servo-lag and its aect on the associated HSM motional kinematics. Machining and Monitoring ... and c, were drawn from an industrial HSM machining expe-rience at a precision metrology company’s premises, using several of the latest vertical machining centres with the spindle of each...