Machining

Goals:

• To be able to analyze the mechanics of machining, focusing on turning.
• To be able to use the analysis of the mechanics of machining to determine force, power and energy requirements.
• To be able to use the force, power, and energy requirements to select machine tools and cutting tools.
• To understand tool wear mechanism and predict too life.
• To be able to analyze the economics of machining, focusing on turning.
• To be able to predict optimum processing conditions based on tool wear, on economics, and on their combination.
• To be able to integrate the economics and mechanics of machining to select equipment.

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ME 4210 readings and slides:

• Kalpakjian: 8.1 - 8.10, 8.14, 8.15, 9.1 - 9.6, 9.16, 9.17

Slides:

• Machining
• Grinding

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ME 6222 readings and class notes:

Machining Overview and Basics of Chip Formation Mechanics (Kalpakjian 8.1, 8.2, 8.8, 8.9; Tlusty 7.1, 7.2, 8.1, 8.2.1)

• Class notes

Chip Formation Mechanics - Power, Energy, Forces, Torques and Temperature (readings as above)

• Class notes

Cutting Tools (Kalpakjian 8.6; Tlusty 8.3)

• Class notes

Tool Wear and Tool Life (Kalpakjian 8.3, 8.4, 8.5; Tlusty 8.4.1, 8.5)

• Papers about tool wear

• Tool Wear by Solution: A Quantitative Understanding
• Computational Design of Wear Coatings
• Predicted Wear Resistances of Binary Carbide Coatings

• Class notes

Chip Formation, Cutting Fluids, Vibration, Chatter (Kalpakjian 8.7, 8.11, 8.13; Tlusty 9.6.1, 9.2.3, 9.6.3)

• Class notes

Machining Economics (Kalpakjian 8.14)

• Class notes - Part 1
• Class notes - Part 2

Micromachining (Kalpakjian: Chapter 13, esp. 13.13)

• Class notes

Grinding (Kalpakjian 9.1 - 9.6, 9.16, 9.17)

• Class notes

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Videos

Simulation Tools:

• Rake angle vs. chip thickness
• Cutting forces vs. cutting parameters
• Cutting temperature
• Recommended cutting conditions
• Machine tool rigidity

Animations of Cutting Processes:

• Multiple turning
• Multiple turning
• Turning with face off
• Engine milling
• Engine milling machine
• Pocket milling
• Milling

History Channel Video at A&E Store: Modern Marvels - Machine Tools (Item AAE:43007)

Machining music - Popcorn by Hot Butter