1. Manufacturing Processes Fundamentals of Cutting South Bend lathe Chip Formation Chip Breakers Feeds and Speeds Tool Materials Tool Properties Tool Wear Surface Finishes Cutting Fluids CNC Lathes

2. Manufacturing Processes South Bend Engine Lathe

3. Manufacturing Processes Chip Formation Discontinuous Continuous Built up edge

4. Manufacturing Processes Chip Breakers On the Cutting Tool In the Material –Inclusions –Sulfur

5. Manufacturing Processes Speed, Feed, Depth of Cut

6. Manufacturing Processes Speeds, Depth of Cut Depth of Cut Speed

7. Manufacturing Processes Feed Rates or

8. Manufacturing Processes Cutting Time Considerations Material removal rate Time to Cut

9. Manufacturing Processes Tool Materials High Speed Steel (HSS) Coated Carbide Inserts

10. Manufacturing Processes Tool Properties High Hardness Resist Abrasion Resist Chipping Hot Hardness Resist Bulk Deformation (E) Chemical Stability Adequate Thermal properties Consistent Tool Life Geometry

11. Manufacturing Processes Tool Wear slow death mechanisms: gradual wear on flanks, or rake face of tool (crater) –abrasion, adhesion, diffusion, chemical sudden death mechanisms: unpredictable, catastrophic failure –brittle fracture, chipping, plastic deformation

12. Manufacturing Processes Tool Life Taylor's Equation: Surface Speed Variation in material hardness –within piece and piece to piece Variation in tool material and geometry Vibrations Changing surface characteristics of workpiece

13. Manufacturing Processes Tool Geometry

14. Manufacturing Processes Surface Finishes Tool Geometry and Feed rate

15. Manufacturing Processes Surface Finishes Surface Speed and Depth of Cut

16. Manufacturing Processes Cutting Fluids Reduces Cutting Temperature –dimensional stability –reduces thermal tool wear Acts as Lubricant –reduces forces and energy consumption

17. Manufacturing Processes Cutting Fluids Flood Cooling –lowers temperature –reduces oxidation Mist Cooling –Better Visibility –gets to inaccessible areas

18. Manufacturing Processes Effects of Coolants On workpiece –cracking, staining, chemical attack On machines –bearings and slideways On environment –breathing apparatus, and disposal