State of Art in Material Removal Process

8/18/2019 State of Art in Material Removal Process

1/56

April 7, 2016

1

State-of-the-art in material removalprocessesDr. ir. André M. Hoostrate

!mail" a.m.hoostrate#t$delft.nl%el" 01&-27' 6'0(

)oom" '*-02-2'A

+ect$re 1" $ndamentals of material removal

mailto:[email protected]:[email protected]


2/56

MA Precision Manufacturing and Assembly

ntended co$rse sched$le 2006 -

Topic date room

lecture1

Introduction to material removalprocesses

Overview of classical mat. removalprocesses

th. feb. 8

lecture!

hip formation"orces during cutting

th. feb.1#

lecture$

%O &'T()'th. feb.!!

*

lecture

+

'nergy distribution

,ear

th. mar. 1

lecture#

utting materialsth mar. 8

lecture-

Machine tool constructionth. mar.1#

lectureMillin and micro*millin

th. mar.


3/56


ntended co$rse sched$le 2006 -

Topic dateroom

lecture 8 Abrasive processes th. apr. 1!

lecture /Advanced grinding0 .. 2aurwalt

'%3th. apr. !43

lecture14

5ressing0 .A.,.M. 5er67 th. apr. !-

AATIO% th. may. +

lecture11

'M9'5M0 :. Altena; Philips< 5AP 3th. may 143

(%I')2IT= &O2'5 th. may 1

lecture1$

%on*conventional Processes th. may !#

lecture

1+

2urface Properties; "uture

Outloo6 th. may. $1


4/56


/vervie over the co$rse

1. Introduction to material removal processes

2. Overview of classical mat. removal processes3. Chip formation

4. Forces during cutting

5. Energ distri!ution

". #ear

$. Cutting materials

%. &rocesses with geometrical non'defined cutting edges

(a!rasive processes)

*. +urface properties

1,.-on'conventional processes


5/56


/vervie of todas topics

1. Introduction

2. #orpiece /ualit3. Classification of processes

4. 0ovements tool geometr and process input /uantities

5. escription of drilling and milling and !roaching

oals for toda

1. +howing the sstematic in material removal processes

2. &roviding (English) terminolog

3. efreshing the !asics of classical material removal

processes


6/56


Man$fact$rin technolo as 3ecomponent

m o ! i l i t c o m m u n i c a t i o n

source 6ir!us olls oce &orsche 6+07 8odafone 9-o chips without chips:;


7/56MA Precision Manufacturing and Assembly

4hat is a micron 5m8

source E.



9$estion

,hat is the thermal e7pansion of a steel piece with a length of14 mm< when heated from !4 ? @room*temp to $4?3

a 4.41! µm b 4.1! µm c 1.! µm d 1! µm

BC!.1BC14!.1

BC14BC141!BC1414

-

-$

4

mmL

K K m

m

mL

T LL

µ

α

=⋅=∆

⋅⋅

⋅⋅⋅=∆

∆⋅⋅=∆

−

−−



:pdate of %ani$chi- acc$rac

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Man$fact$rin processes

p r i m a r y s h a p i n g

c a s t i n g e A t r u s i o n i n @ e c t i o n m o u l d i n g p o w d e r m e t a l l u r g e l e c t r o ' f o r m i n g B

••••••

( m e t a l ) f o r m i n g

d i s t i n c t i o n r e g a r d i n gl o a d i n i t i a t i o n

( c o m p r e s s i o n t e n s i o n ! e n d i n g s h e a r i n g . . . )

d i s t i n c t i o n r e g a r d i n g a p p l i c a t i o n f i e l d ( s h e e t m e t a l f o r m i n g

m a s s i v e f o r m i n g f o r g i n g )

•

•

c u t t i n g

s e p a r a t i n g c u t t i n g w i t h g e o m e t r i c a l l

w e l l ' d e f i n e d t o o l e d g e s

••

• c u t t i n g w i t h g e o m e t r i c a l l n o n ' d e f i n e d t o o l e d g e s

e r o s i o n ( t h e r m a l c h e m i c a l e l e c t r o c h e m i c a l )

s h e a r i n g a n d ! l a n i n g c l e a n i n g e v a c u a t i n g

•

••• j o i n i n g

w e l d i n g ! r a D i n g g l u e i n g p r e s s i n g @ o i n i n g ! f o r g i n g @ o i n i n g ! c a s t i n g B

•••••••

c o a t i n g

& 8 C 8 p l a s m a s p r a i n g g a l v a n i c B

•••••

c h a n g e o f m a t e r i a lp r o p e r t i e s

l o c a l c h a n g e o f p a r t i c l e s e l i m i n a t i o n o f p a r t i c l e s i n s e r t i n g o f p a r t i c l e s

•••

s o u r c e I - % 5 % ,



;lassi



w o r p i e c e

t o o l

c h i p s

m a c h i n e

s u p p o r t i n g m e d i a

d e s c r i ! e

o u t p u t/ u a n t i t i e s

a f t e r m a t e r i a lr e m o v a l

Material removal sstem

d e t e r m i n e d

!

m a t e r i a l

t o o l s

m a c h i n e s e t t i n g

c h a r a c t e r i s t i c so f t h e m a c h i n e

s u p p o r t i n g m e d i a

i n p u t/ u a n t i t i e s

p r o c e s s

m e c h a n i c a l

t h e r m a l

c h e m i c a l

i n t e r a c t i o n s d u r i n g

p r o c e s s / u a n t i t i e s

d e s c r i ! e

m a t e r i a l r e m o v a l



;$ttin processes

cutting with geometricall well'defined cutting edge

• turning

worpiece

tool

•••

drilling counter!oring reaming

worpiece

• milling

tool

tool

worpiece

other processes

planing slotting !roaching sawing

filing shaving rasping

•••

•••

accord. to I- %5%*



%$rnin variants

f e e dd i r e c t i o n

r o t a t i o n a ld i r e c t i o n

a c c o r d i n g t o I - % 5 % * ? 1

f a c e t u r n i n g O t u r n i n g

t h r e a d t u r n i n g p r o f i l e t u r n i n g f o r m t u r n i n g

2 3 4 5

- 1 , A . . D F

.

.

.

.

D

7

t u r n i n g

c u t o f f t u r n i n g

w o r p i e c e w o r p i e c e w o r p i e c e

w o r p i e c e w o r p i e c e ( s t o r e d i nt o o l g e o m e t r )

w o r p i e c e

t o o l t o o l t o o l

t o o l

t o o l

t o o l


16/56


Drillin operations

d r i l l i n g

t r e p a n n i n g t a p p i n g r e a m i n g

( e n l a r g i n g ) c o u n t e r ! o r i n g c e n t e r d r i l l i n g

t w i s td r i l l

t a p m a c h i n er e a m e r

t w i s tc o u n t e r '! o r e

p r o f i l es i n e r

c e n t e rd r i l l

s o l i d d r i l l i n g

t r e p a n n i n gc u t t e r


17/56


Millin variants

h e l i c a l m i l l i n g h o ! ! i n g

m

i l l i n

g

s l a ! m i l l i n g

f a c e m i l l i n g p e r i p h e r a l m i l l i n g s i d e m i l l i n g

w o r p i e c e

p r o f i l e m i l l i n g f o r m m i l l i n g

A D 1 2 3 4

- 5 . . . G . . . F . . .

.

.

.

.

.

.

f e e d d i r e c t i o n

w o r p i e c e H t o o l r o t a t i o n w o r p i e c e H t o o l

s o u r c e a c c o r d i n g t o I - % 5 % *

t o o lt o o l t o o l

t o o l

t o o l

t o o l t o o l

w o r p i e c e w o r p i e c e

w o r p i e c e

w o r p i e c e

w o r p i e c e w o r p i e c e


18/56


rinciple of =roachin

?t

α

h

v cvht?

c c u t t i n g s p e e d c h i p t h i c n e s s t o o l p i t c h t o t a l ! r o a c h i n g d e p t h

7 ! r o a c h i n g l e n g t h r a e a n g l e

f l a n a n g l e

γ

α

7

tool

worpiece


19/56


/vervie of a=rasive processes

m a t e r i a l r e m o v a l w i t h n o n ' d e f i n e d c u t t i n g e d g e s

w i t h ! o n d e d a ! r a s i v e s

g r i n d i n g w i t hr o t a t i n g t o o l

! e l t g r i n d i n g

s t r o e g r i n d i n g

h o n i n g

w i t h l o o s e a ! r a s i v e s

l a p p i n g

a ! r a s i v e @ e t c u t t i n g

a ! r a s i v e d r u m t u m ! l i n g


20/56


>rindin variants 5D? '&'@ -S/DB002C

v c

a e a p

v f r ! sn w

a e a p

v f a

! s

v w

a e a p

v f a! sv w

v c

v c

a e

a p

! sv w

a p v c

v c

a ea p

v f tv w

v f r

a e

v f r

a e

a p

v f a

v w

v c

v ca e

a p

v f r

v w

v wv c

a e

a p

v f a

! s

vw

v c

a e

v f a

! s

! wv c

a e

a p! s

v cv w

a p

v f r

!s

v c

a e

v w

a e

a p

v f a

! s

v w

v c

v c

a e

a p

v f a

v w

o u t e r d i a m e t e r i n n e r d i a m e t e r s u r f a c e r o t a t i o n a l

c i r c u m f e r e n t i a lp l u n g e g r i n d i n g

c i r c u m f e r e n t i a lt r a v e r s e

g r i n d i n g

f a c e p l u n g eg r i n d i n g

f a c e t r a v e r s eg r i n d i n g

,hat is thediEerence3


21/56


%he dierence


22/56



1. Introduction

2. #orpiece /ualit3. 0ovements tool geometr and process input /uantities



23/56


S$rface ro$hness characterisation

( E - I + O 4 2 % $ )

D

l e

G 1

l

c

D

AD

G 2 G 3 G 4 G 5

GD i∑15 i 1

5

D ≥ m a A

( G Jm a A i m a A )

a D d A ( f o r m e r l )∫ | | a1

l ,

l

m r 1 , , ∑ × ( f o r m e r l t )pl

lc i

l c 1 l c 1 l c 1 l c 1

(

(

D a

m r

D

m a A

cl

' t e n p o i n t h e i g h t )

' m a A s i n g l e r o u g h n e s s h e i g h t )

' m a A . r o u g h n e s s' a v e r a g e r o u g h n e s s

' ! e a r i n g r a t i o

' m a t e r i a l f i l l e d p a r t o f r o u g h n e s s

( o f f i c i a l l n o tu s e d a n m o r e )


24/56


9$antities of the =earin ratio c$rve

1 , ,

! e a r i n g r a t i o

, 2 , 4 , " , r o u g h n e s s p r o f i l e

5

p

' m a A . r o u g h n e s s ' e r n e l r o u g h n e s s

' r e d u c e d p e a h e i g h t ' r e d u c e d v a l l e d e p t h

' r e s u l t i n g r o u g h n e s s

p v

r e s

r o u g h n e s s / u a n t i t i e s


25/56


Sstem of s$rface deviations, D?(760s h a p e d e v i a t i o n

1 . o r d e r f o r m d e v i a t i o n

2 . o r d e r w a v i n e s s

3 . o r d e r r o u g h n e s s

4 . o r d e r r o u g h n e s s

5 . o r d e r r o u g h n e s s( n o t s i m p l t o d e s c r i ! e )

" . o r d e r r o u g h n e s s( n o t s i m p l t o d e s c r i ! e )

e A a m p l e

s t r a i g h t n e s s '

f l a t n e s s ' r o u n d n e s s ' d e v i a t i o n

w a v e s

g r o o v e s

s l o t sf l a e s

d o m e s

s t r u c t u r e

l a t t i c e s t r u c t u r eo f t h e m a t e r i a l

e A a m p l e s o f t h e o r i g i n

e r r o r o f m a c h i n e t o o l g u i d e w a s

d e f l e c t i o n o f m a c h i n e o f w o r p i e c e w r o n g c l a m p i n g h e a t t r e a t m e n td i s t o r t i o n w e a r

e c c e n t r i c c h u c i n g f o r m o r p o s i t i o nd e v i a t i o n o f t h e m i l l i n g t o o l v i ! r a t i o no f m a c h i n e o r t o o l

f o r m o f c u t t i n g e d g e f e e d o r d e p t h o f c u t o f t h e t o o l

t p e o f c h i p f o r m a t i o n ( s e g m e n t e d ! u i l t ' u p e d g e ) m a t e r i a l d e f o r m a t i o nd u r i n g @ e t m a c h i n i n g m o d i f i c a t i o nd u r i n g g a l v a n i c c o a t i n g

c r s t a l l i s a t i o n p r o c e s s e s s u r f a c em o d i f i c a t i o n ! c h e m i c a l r e a c t i o n c o r r o s i o n p r o c e s s e s


26/56


9$estion

,hat is the implication of theincreasing machining accuracy on

the deFnitions of roughness and form

deviations3


27/56


hsical s$rface properties aftert$rnin or rindin

K 8

h a r d n e s ss t r u c t u r e

c r a c s

v f

v c

n wn w

v c v f r t u r n i n g g r i n d i n g

r e s i d u a l s t r e s s e s

d i s t a n c e f r o mt h e s u r f a c e

p a r a l l e l t om a c h i n i n g

d i r e c t i o n

p e r p e n d i c u l a r t om a c h i n i n g d i r e c t i o n

σ I I

σ I'

m a c h i n e d s u r f a c e


28/56



1. Introduction2. #orpiece /ualit


4. escription of drilling and milling


29/56


Movements d$rin t$rnin

a p

d e p t h o f c u t

v c

f e e d m o t i o n

p r i m a r ( c u t t i n g ) m o t i o n

n wv f

w o r p i e c e r o t a t i o n


30/56


4or3in plane conditions

w o r i n g p l a n e

t o o lw o r p i e c e( f i A e d i n s p a c e )

ϕ

ϕv e v ev cv c

v f v f

v c u t t i n g s p e e dv e f f e c t i v e c u t t i n g s p e e dv f e e d s p e e d

c

e

f

e f f e c t i v e c u t t i n g s p e e d a n g l e f e e d m o t i o n a n g l e

t a n ηs i n ϕ

v H v L c o sc f ϕηϕ


t o o l

w o r p i e c e( f i A e d i n s p a c e )

t u r n i n g m i l l i n g

n


31/56


!Eample" %$rnin of steel

• )ecommended values from the tool*manufacturer

• d G $# mm

• vc G +!4 m9min

•

ap G ! mm• f G 4.!# mm9rev.

• n G +.444 rpm

• vf G 1444mm9minG1 m9min

woring plane

toolworpiece(fiAed in space)

ϕ

η

ve vc

vf

turning


32/56


%erms at the c$ttin tool 51

m i n o r c u t t i n ge d g e

m i n o r f l a n

m a @ o r c u t t i n ge d g e

m a @ o r f l a n

i n s e r t

c o r n e r

r a e f a c er a e f a c e

c h i p

w e d g e

w o r p i e c e

m a @ o r f l a n

I + O 3 , , 2 H 1

n w


33/56


%erms at the c$ttin tool 52s e c t i o n A - B ( t o o l o r t h o g o n a l p l a n e )

r a e f a c ef l a n f a c e

t o o l c u t t i n ge d g e p l a n e

α β

γ L

t o o l r e f e r e n c e

p l a n eκ

6

<

G

f e e d m o t i o n

t o o l c u t t i n ge d g e p l a n e

'

c o n s i d e r e dw o r i n g p l a n e

p r i n c i p a l v i e w

a c c o r d i n g t o I - " 5 % 1

v i e w Z ( o n t o o l c u t t i n g e d g e p l a n e )ε

ε

c h o s e np o i n t

L λ

'

t o o l r e f e r e n c ep l a n e

m a @ o r c u t t i n g

e d g e


34/56


%erms at the c$ttin tool 5B

αM

α β

γ

εκ

κ M

cutting direction

feed

<

6

section 6 ' 6

6

view <

λt o o l c l e a r a n c e a n g l e

m i n o r t o o l c l e a r a n c e a n g l e w e d g e a n g l e r a e a n g l e

t o o l i n c l u d e d a n g l e m a @ o r c u t t i n g e d g e a n g l e m i n o r c u t t i n g e d g e a n g l e

i n c l i n a t i o n a n g l e

( v r i j l o o p h o e k )

( h u l p v r i j l o o p h o e k )

( w i g h o e k )

( s p a a n h o e k )

( p u n t h o e k )

( i n s t e l h o e k )

( i n s t e l h o e k v a n d e h u l p s n i j k a n t )

( h e l l i n g s h o e k )

α

α

β

γ

ε

κ

κ

λ

N

N


35/56


;$ttin and chip eometr

a p

f

hκ

6 a f ! h

h f s i n

p ⋅ ⋅

⋅ κ! a H s i n

a f p κ

e

6

af !

h

p

κ

f

!

f f

v f

h

a !p

κ ° * ,

c h i p c r o s s ' s e c t i o n d e p t h o f c u t f e e d w i d t h

c h i p t h i c n e s s t o o l c u t t i n g

e d g e a n g l e

c h i p

v f

Imagine vf and ap are eHual; what do you thin6 about the cutting

forces33


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$ndamental eF$ations

a f vw p c

⋅ ⋅

a

f

v

a

v

n

d

wp

c

e

f

w

m a A

a a vw p e f ⋅ ⋅

v d nc m a A wπ ⋅ ⋅f

v

n

f

w

' m a t e r i a l r e m o v a l r a t e

' d e p t h o f c u t

' f e e d

' c u t t i n g s p e e d

' w i d t h o f c u t

' f e e d s p e e d

' w o r p i e c e r o t a t i o n

' m a A . w o r p i e c e d i a m e t e r


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Cariants of t$rnin inserts 51

source +andvi

6luminium manufacturing


38/56


heav dut cutting

source +andvi

C


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Cariants of tool holders

source +andvi


40/56



1. Introduction2. #orpiece /ualit




41/56


Description of a helical drill

c h i p f l u t e

m a @ o r c u t t i n g e d g e

t o o l a A i s

m a @ o r f l a n

c u t t i n ge d g e c o r n e r

m i n o r c u t t i n g e d g e

r a e f a c e

c h a m f e r o f t h em i n o r f l a n

l a n d w i d t h

c h i s e l e d g e

l a n d ( e n g l . )

m a r g i n ( = + )

σ

δt o o l

w o r p i e c e

2 r a

v c

v f v e

ηφ

m i n o r f l a n f a c e

w e ! t h i c n e s s


42/56


;$ttin anle at a drill

r e f e r e n c ep l a n e

r

τ

γ /

r /

r /

r a

t o o l c u t t i n g

e d g e p l a n e

t o o l o r t h o g o n a lp l a n e

* , Pσ

2

σ

γ h

γ hN

2 r π ar H

2 r π /

2 r π s i m p l i f i c a t i o n ,τ

,h

i n c l i n a t i o n o f t h e d r i l l f l u t e

γ hN

γ hN

γ hN


43/56


;hip formation d$rin drillin

, , 5 1 m m r a d i u s 3 " m m r a d i u s

, , 2 5 m m r a d i u s " 1 m m r a d i u s

, . , $ " m m r a d i u s , 1 3 m m r a d i u s

m a @ o r c u t t i n ge d g e

c h i s e le d g e


44/56


9$estion

&oo6ing at the chip formation processin the previous pictures< what do you

thin6 about the local and total

cutting forces in drilling

3

f d ill i


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%pes of common drill tipsf o r m 6

w e ! t h i n n i n g

f o r m <

f o r m C

s p l i t p o i n t ( c h i s e l e d g e e l i m i n a t e d )

f o r m

w e ! t h i n n i n g ( m o d i f i e d c h i s e l e d g e )w i t h f a c e t e d c o r n e r

w e ! t h i n n i n g w i t h m a @ o rc u t t i n g e d g e c o r r e c t i o n

D ill i


46/56


o r ! i t a ld r i l l

t r e p a nd r i l l

c a n o nd r i l l

s / u a r ed r i l l

h e l i c a ld r i l l

d o u ! l em a r g i n

d r i l l

! r o a c h i n gd r i l l

d r i l l w i t hi n s e r t

s p a d ed r i l l

s h o r t h o l e

d r i l l i n g

l o n g h o l e

d r i l l i n g

Drill variants

c e n t r ed r i l l i n g

t r e p a n n i n g( h o l l o w d r i l l i n g ) d r i l l o u t

! o r e m a n u f a c t u r i n g

d r i l l i n g m i l l i n g

S i l t f d illi t l


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Special tpes of drillin tools

+/uaredrill with ou!le margin drill +/uaredrill without +piral drill without

coolant holes with coolant holes coolant holes coolant holes

drills with inserts drill with changea!le head

; tti diti d i f illi


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;$ttin conditions d$rin face millin

6

6

ϕ

ϕ

ϕf D

1 % , P '

f c

!a p

κc u t t i n g t o o le d g e

w o r p i e c e

s e c t i o n 6 ' 6

a e

a e 1

a e 2A

G

nϕ

ϕ

ϕc

E

6

ϕ , P

..

f D

f Dv c

v f

d e t a i l G

f c

i . t r a @ e c t o r c u r v ei . L 1 t r a @ e c t o r c u r v e

e A i t p l a n e

ϕ

e n t r a n c e p l a n e

c u t t i n g e d g e

D n u m ! e r o f c u t t i n g e d g e s

f

f f s i n

h f

D

c D

c

⋅ ϕ s i n

h f s i n s i n

⋅ κ

⋅ κ ⋅ ϕD

vn D

f ⋅

Milli i t


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Millin variants

w o r p i e c e s u r f a c e g e n e r a t e d! m i n o r c u t t i n g e d g e

a p a e

f D f Dv f

v f

n

t o o l

c u t t i n g i n s e r t

w o r p i e c e

n

w o r p i e c e s u r f a c e g e n e r a t e d! m a @ o r c u t t i n g e d g e

f a c e m i l l i n g p e r i p h e r a l m i l l i n g

Milli i t


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Millin variants

t a n η s i n ϕv H v L c o sc f ϕ

ϕ

ϕ

v e

v e

v c

vc

v f


nn

o w n m n g !f e e d d i r e c t i o n a n g l e * , P 1 % , P≤ ≤ϕ

u p m n g !f e e d d i r e c t i o n a n g l e , P * , P≤ ≤ϕ

m i l l i n g t o o l

w o r p i e c e


η

v f

s o u r c e I - " 5 % , E

m i l l i n g t o o l

w o r p i e c e

illi


51/56


orm millin

! a l l ' n o s ee n d m i l l

t o o l a A i sd i r e c t i o n

v f

v f 3 ' a A i s m i l l i n g

5 ' a A i s m i l l i n g

β = t o o l i n c l i n a t i o n a n g l e

s u r f a c e n o r m a l v e c t o r

m i l l i n g h e a d

!

!

t t

t o o l a A i sd i r e c t i o n

Milli h d


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Millin head

source #alter

,hats the ra6e face< primary cutting edge< ma>or Jan6 face35oes this tool has a positive or negative ra6e angle33

Solid t nsten car=ide millin c tters


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Solid t$nsten car=ide millin c$tters

source Qa!ro

*roachin tool


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*roachin tool

tool

worpiece

source #G7 6achen

*roachin machines


55/56


*roachin machines

Kuge 5, t !roaching machine 6nn 6r!or 0achine tool =+6

8ertical !roaching machine

Chan Row ?aiwan

KoriDontal !roaching

?he ear #ors

Additional material


56/56

Additional material

Advancin ;$ttin technolo

K. Lyrne< 5. 5ornFeld< L. 5en6ena

eynote paper in Annals of the CIRP !44!

@Lelongs to the e7amination material

Documents

State of Art in Material Removal Process