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Manufacturing Process Project Three - Metal Removal Process

The metal removal process involves various machining techniques, including CNC drive operations and Direct Numerical Control (DNC) drives, which enhance the capability of CNC machines by providing larger memory spaces and networking capabilities.

Manufacturing Process Project Three - Metal Removal Process

Metal Removal Process By:- Shivam Naik Anilkumar Patel Aashish Sharma

Posibilities of defects

Human Errors
Defective cutters
Incorrect cutting Parameters
Errors in the design Structure
Defect in the machines, tooling and equipments
Incorrect positioning of the workpiece
Disallingment of rotaional axis of the cutters
Minor fractures in the face plates,chucks,collets and drives.
Programming errors in CNC,DNC and DFM's

Costs

Tolliing costs
Life time of tools

Cuttnig time

Cutting speed
Number of cutting tools required for the operations
Mainatainece Costs
Cleaning
Team management
Inspection of the cutting tools, machines, equipments and accessiories
Production Costs
Time required for production

Idle time

Cut time

Load time

Set up time

Total replacement time

Total Production of stocks

Material Costs
Method of cutting
Quantity of stock per unit
Shape and size of the stock

Machining

Drill Presses
Mill Press
Radial arm drill press
Gear Head Drill Press
Lathe Machines
Bed
Centre

Cup centre

Pipe centre

Soft Centre

Dead Centre

Spring centre

Revolving centre

Spindle
Tool Rest
Tail Stock
Lock Knob
Head Stock
Milling machines
Knee
Saddle
Table
Base and columes
CNC drive operation
Design for Manufacturablity (DFM) drives

Alllows to fix design flaws in the CNC operations

Direct Numerical Control (DNC) drives

Allows to network several CNC machines operating in sequence. It provides larger memory space in the control and can transfer the amount of data to each operating CNC system in a manufacturing process

Computer-Aided Design (CAM)
AutoCAD and 3D mechincal CAD softwares

Tooling

EDM Requirements
Wire EDM

EDM wires

Dielectric fluids

Cleanre and Filters

Sinker EDM

Magnetic Chuck

Rotating Spindle

Electrode Holder

Orbiting cut system

EDM fluid and filters

Milling process requirements
Vertical milling cutters

Tap

Face

Twist

Reamer

Ball End

Chamfer

Flate End

Horizontal Milling cutters

Helical

Double angle

Form Relieved

Staggered Tooth

Turining process requirements
Workhold method tolling

Collet

Chuck

Ferrous

Magnetic

Electrostatic

Jawed chuks

Drill Chuck

Independent Jaw

Seld Centering

Drive Centre

Angle and sizes of cutting tool

Sizes of Cutting tool

V- Shape

Square Shape

Angle of cutting tool

Rank angle

Relief angle

Side Rand angle

Nose radius angle

Cutting edge angle

Machinability

Tool Life
Tool wear

Edge Wear

Flank wear

Crater Wear

Cutting speed
Cutting temperature
Force and Power exerted on the Tool
Better Mechanical Properties
Ductility
Strength
Surface Finshing
Thermal Stability
Ease of chip disposal

Cutting Parameters

Cutting fluids
Types of cutting fluids

Oil

Gels

Pastes

Aerosal

Water-Oil emulsions

Glysol-Water Emulsion

Required chemical properties

Collant

Fluid Film

Lubricator

Higher visconsity

Cutting feed
Roational Feed

Feeds of workpiece in turining operations

Reciprocating Feed

Feeds of workpiece in milling, drilling Boring and Broaching operations

Cutting Speed
Broach Speed
Water Jet speed
Milling Cutter speed
Saw speed

Circular Loop

Linear Reciprocating

Roational

Drill speed
Design of the cutting Tool
Axial depths
Sharp Edges
Radial Depths
Diameter to Depth Ratio
Precise geometry according to product requirements

Final Product to be extracted

Material Requirements
Wood
Alloys
Polymers
Ceramics
Non-metals
Metal: Ferrous and non ferrous
Design of the final product
Edges
Fittings
Tolerance
Clearance
Surface finishing
Complex profiles
Limits and allowance
Dimensional Accuracy

Internal and external thickness of the holes, and pocket profiles

Length,Width,Height,Weight,Volume and Area of the material to be extracted.

Types of Technologies

Manual Technologies
Saw
Snip
Shear
Chisel
Erosion Technologies
Water Jet

A process of removal of material by means of water jets running water at high velocity on the material workpiece.

Electric Discharge Machining (EDM)

Types of Process

Wire (EDM)

A process of a drawing wire slowly on the surafce of the workpiece with a predetermined path. The system consist of a dielectric fluid between the wire and the workpiece acting as a plasmic channel in the gap developing million sparks per second. This Process allows to cut the workpiece with high thickness and construct most complicated structure preciously.

Sinker (EDM)

Consist of workpiece and a electrode tool connected to a power supply which acts as anode and cathode in the system respectively. Dielectric fluid in the system act as ionizing channel which generates sparks as the apower supply is passed through in the operating system.

A method of removing a part of the materials by conducting a a series of sub sequently occuring discharge (spark) on the workpiece. This process requires two electrodes seperated by a dielectric liquid which consist of intense electric fields.

Machine Technologies
Boring

Types of Boring

Line boring

Back Boring

Consist of cutting the internal features of the drilled workpiece.

Milliing

Mill Orientation

Vertical mill

Consist of the rotational axis of cutting tool held vertical

Horizontal mill

Consist of the rotational axis of cutting tool held horizontal

Types of milling machine

Bed mill

A conventional type of mill use in a industries

Floor mill

Consist of a rotary table and horizontal running spindle parallel to the table

Turrent Mill

Spindle can be allinged at several posistion

Column mill

Bench mounted mills

C-frame mill

Consist of more powerful hydraulic drive motors for integral power feeds

Ram type mill

Spindle can be allinged in both vertical and horizontal position

Types of milling processes

Face Milling

Types of face milling

Surface countering

Consist of a cutting tool with a curved edge, which follows a curved path on the milling surface constructing a contour on the workpiece.

Conventional Face milling

A process of milling consist of rotational axis of milling cutter perpendicular to the milling surface.

Peripheral Milling

Types of Peripheral milling

Slotting

Consist of a milling cutter with a width smaller than the periphery of the workpiece. Allows to create a slots on the workpiece.

End milling

Types of end milling

Profile milling

Consist of rotating tool cutting on the periphery of the workpiece.

Pocket milling

Consist of a cutting tool creating a shallow feature with certain depth.

Consist of a cutting tool held vertically to the milling surface with its diameter less than the width of workpiece causing a slot in the part

Slab milling

Consist of a milling cutter with a width larger than the periphery of the workpiece. Allows to create a planar surface on the workpiece.

A method which consist of axis of rotation of a milling cutter parallele to the workpiece feed. The proximity of the milling cutter teeth are at the periphery of the milling surface.

A cutting process which consist of a milling cutter with mulitiple cutting edges held perpendincular to the direction of the workpiece fedding, which allows us to develop a planar surface, slots, grooves, and certain dimensional profiles

Drilling

Types of holes

Tapping

Reaming

Blind holes

Through Holes

Counter Boring

Types of Processes

Trepanning

Allows to drill larger holes, whihc is usefull in making groves, and O rings.

Gun Drilling

Types of gun drilling

Internal chip removal type

External chip removal type

Consist of a special kind of cutting fluid compressed through the hollow structure of drill bit to the cutting metal surface. Allows to drill hole with higher depth to diameter ratio.

Microdrilling

Conduct a process of drilling holes with diameter of less than 0.5mm

Spot Drilliing

Constructs a hole as a mark which act as guide to conduct further drilling on the particularspot

Centre Drilling

Constructs a mark which represent the axis of rotation for the workpiece

Deep hole Drilling

Conists of drawing holes with depth five times grreater than the diameter of the holes

A method of contructing a holes with variable diameters, depths and shapes

Turning

Workholding Method

Collet

Chucks

Face Plate

Centre Drive

Types of Cuts

Cut Off

Radially holding a cutting tool to cut out the a part of the rotating workpiece

Facing

A method of rotating a metal part with a cutting tool held perpendicular to the rotational axis of the workpiece.

Threading

Consist of rotating metal part against the Pointed cuttng tool held parallel to the rotational axis causing threads in the work piece.

Chamfering

Consist of a Metal part rotated aginst a cuting tool with a sharp edge, cutting the surface at an angle causing a formation of a chamfer.

Contour Turing

A turinng process which consist of rotating metal part with a cutting tool following a contour path on the metal surface formig contour.

Sawing

Hacksaw

Linear reciprocation of the blade over the workpiece by a hydraulic drive frame.

Band saw

Consist of a saw blade moving in continous loop over the workpiece

Circular saw

Roatating cutting balde used over workpiece

Broaching

Types of Broaching Process

Rotary Broaching

Consist of roataing broach over the surface of the materials. It allows to construct complex and irregular holes over the surfaces without using broachnig machine.

Internal Broaches

Method consist of broaching the internal surface of the holes in the workpiece

Surface Broaching

Methods consist of reciprocation of broachagainst the surface of the materials.

Consist of toothed tool whcih is moved againsts the surface of workpiece. It allows better surfaces and dimensions

Welding/Buring Technologies
Laser

A Process of emmiting light through several loptical amplifiers on the metal surface primarily used for preciously cutting complex workpieces. It mainly conists of stimulated emission of photon flow with certaing frequency,polarizationa and phase.

Plasma

Process of generating a direct flow of plasma from plasma jet which can be used for plasma cutting, sparying and plasma waste treatments. Plasma cutter generate high temperature and hence they are useful in generating thin and thick dimensions.

Oxy-Fuel Welding

Types of Fuels

Gasoline

Hydrogen

Acetylene

Butane, Propane and Propylene

Methylacetylene propadine gas (MPS) and MAPP

Types of torches

Cutting torch

Allows us to cut several materials. It consist of three pipes containg gaseoues fuels and an oxygen trigger which is used to cut materials.Element is preheated so as oxygen blast trigger is conducted, oxygen react with themetal forming metal oxides, reducing its strength and thereby cutting the worpiece.

Injector torch

Consist of an oxygen flow with two gaseous fuels through the venturi effect along which allows to maintain an equilibriium between the amount of oxygen and gaseous fuels in the flow.

Welding torch

Allows us to weld several materials, cracks and major fracturs in the metals. It consist of two pipes containg gaseoues fuels which are used to weld materials.

Rose bud torch

Primarily used to heat materials to allow bending and straightnening.

Process of welding or cutting metal workpice by means of fuel gases or oxygen.