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Conventional Machining Presented by Aniruddh Pratap Singh 2008AMD3105.

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Presentation on theme: "Conventional Machining Presented by Aniruddh Pratap Singh 2008AMD3105."— Presentation transcript:

1 Conventional Machining Presented by Aniruddh Pratap Singh 2008AMD3105

2 Introduction What is conventional machining? Various machining operations

3 Basic Process Image courtesy - Wiki

4 Turning To produce rotational, axis-symmetric parts. Feed motion Feed relative to work piece. Fig-2 Basic scheme of Turning Image Courtesy:- Ghosh and Mallik; Manufacturing Science

5 Turning Operations Facing Parting Grooving Drilling Screw cutting Workpiece Materials Aluminum Brass Plastics Cast Iron Mild Steel Ref: Manufacturing Science - Ghosh and MallikRef: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid

6 Effect of Turning on Work Material Properties Mechanical Creates residual stresses, micro cracks May cause workhardening of unhardened materials Physical Little effect Chemical Little effect Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

7 Advantages Increased production with medium and high turret lathes. Disadvantages Limited to rotational parts. High equipment cost. Significant tool wear. Low production rate. Large amount of scrap. Ref: Manufacturing Science - Ghosh and Mallik

8 Drilling Drilling Operations Reaming Tapping Counterboring Countersinking Centering Spot facing Fig-3 Basic scheme of Drilling Image Courtesy:- Ghosh and Mallik; Manufacturing ScienceRef: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid

9 Workpiece Materials Aluminum alloys Magnesium alloys Copper alloys Stainless steels Cast iron Plastics Effect of Drilling on Work Material Properties Mechanical Very thin layer of highly stressed and disturbed material on new surface. Physical Little effect Chemical Increased probability of corrosion at stressed surface Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

10 Advantages High production rate. Disadvantages Skilled labor is required according to the hole location and accuracy.

11 Milling Fig-4 Basic scheme of Milling Image Courtesy:- Ghosh and Mallik; Manufacturing Science

12 Milling Operations Slab Milling Face Milling End Milling Fig-6 Face Milling Fig-5 Slab Milling Image Courtesy:- Ghosh and Mallik; Manufacturing Science

13 Workpiece Materials Aluminum Brass Magnesium Nickel Steel Thermostat plastics Titanium Zinc Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

14 Advantages Variety of shapes can be obtained Disadvantages Skilled labor is required Low to medium production rate Limited shape complexity High equipment cost Significant tool wear Large amount of scrap Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid

15 Boring Fig-7 Boring operation Image Courtesy:-

16 Boring Operations Single-Edge Boring Multi-Edge Boring Step Boring Reaming Workpiece Materials Aluminum Brass Plastics Cast Iron Mild Steel Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo AltingRef:

17 Effect of Boring on Work Material Properties Mechanical Creates residual stresses, micro cracks May cause workhardening of unhardened materials Physical Little effect Chemical Little effect Advantages Finish machining of cylindrical surfaces on very large workpieces. Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alting

18 Broaching Broaching Operations Surface Broaching Pull down Broaching Push Broaching Pot Broaching Image Courtesy:- wiki Fig-8 Broaching Tool Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux

19 Workpiece Materials Aluminum Brass Bronze Plastic Malleable Iron Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux

20 Advantages External and internal flat surfaces Good surface finish High production rate Less skilled labor is required Reduced cycle times Increased tool life Reduced maintenance Complex and irregular shapes. Disadvantages Costly tooling Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid

21 Shaping Fig-9 Basic scheme of Shaping Image Courtesy:- Ghosh and Mallik; Manufacturing Science

22 Fig-10 Shaper Mechanism Image Courtesy:-

23 Advantages Suitable for low quantity production. Flat surfaces and straight profiles can be obtained on relatively small surfaces. Disadvantages Complex parts require skilled labor. Ref: Manufacturing Science - Ghosh and Mallik

24 Planing Fig-11 Basic scheme of Planing Image Courtesy:- Ghosh and Mallik; Manufacturing Science

25 Advantages Suitable for low quantity production. Flat surfaces and straight profiles can be obtained on large surfaces. Disadvantages Complex parts require skilled labor. Ref: Manufacturing Science - Ghosh and Mallik

26 References Books Manufacturing Science by Amitabha Ghosh and Asok Kumar Mallik, East- West Press Pvt Ltd. Tool and Manufacturing Engineers Handbook, Volume 1 – Machining by Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux, Society of Manufacturing Engineers Publications Committee Troubleshooting Manufacturing Processes by Laroux K. Gillespie, Society of Manufacturing Engineers Publications Committee Manufacturing Engineering and Technology by Serope Kalpakjian and Steven R. Schimid, Pearson Education Manufacturing Processes Reference Guide by Robert H. Tadd, Dell K. Allen and Leo Alting, Industrial Press Websites

27 Thank you


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