Manufacturing Processes Coursework

Homework Report #3: Abrasive Processes

MET 33800 Manufacturing Processes – Fall 2015

Department of Engineering Technology

Report By: Joseph Legan

Report Date: 10/22/15

Abrasive Process Abstract: Students will investigate in-depth the grinding category of manufacturing processes. Investigation will include machine operation, types of geometry generated, cutting tools and workholding devices.

Part 1: Answer the following questions:

1) Define and identify unique characteristics of the items below:

a. Abrasive Machining is the process of removing a small amount of material by the interaction of abrasive grits and the workpiece at high speeds. It is a chip removal process but the chips are very small. Depending upon type of machine it can done to flat, round or profile shapes and almost any size.

b. Honing is uses fine bonded stones to remove a very small amount of material. Honing can be done to the ID or OD of a cylinder. When used for a part that must seal a specific lay pattern can be achieved by controlling the spindle speed and the reciprocating of the stones along the workpiece.

c. Lapping is the process of allowing hard free abrasive particles to embed themselves into a softer material that is then used to remove a very small amount of material from a workpiece. Usually this is done with a lapping machine and diamond free abrasive embedded into a cast iron lap. It is used to create a very accurate and flat shape on the workpiece that has a high surface finish, such as gauge blocks.

d. Surface Grinding is used to create flat and parallel surfaces on the workpiece. Machines use a combination of horizontal and vertical spindles with rotary or reciprocating tables. Each combination creates a different lay or pattern to the finish. The grinding media is fed into the workpiece while the table either reciprocates or rotates.

e. Centerless Grinding uses no workholding device, instead uses either support rolls for ID grinding or a blade for OD grinding. The workpiece moves along the grinding wheel by the regulating wheel. Creates a round profile for internal or external operation.

f. Creep Feed Grinding is the process cutting a deep groove or profile in a single pass with a very low feed rate. A soft wheel is used often with a continuous dressing process.

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g. Abrasive Flow is primarily used to deburr material or workpieces. It is the process of forcing a slurry or gel that contains abrasive over or through the material. In doing this it removes a small material amount while increases the surface finish and rounding edges. I have seen it used as extrude honing on engine intakes to increase the flowrate.

2) Name four different shapes of grinding wheels.

Straight

Recessed one side

Flaring cup

Tapered

3) Define the characteristics of a grinding wheel with the marking A-36-L-5-V

A for regular aluminum oxide

36 grit

L for a medium grade wheel

5 for relatively dense structure

V for vitrified bond

Type Of Cutting Tools Used

Type Of Work Holding Devices

Typical Workpiece Geometry Produced

Safety Hazards Associated with the

Machine Tool

Surface Grinder

Grinding wheels o bonded stones

Table clamps, magnetic chucks,

mechanical fasteners.

Flat surfaces. Sparks, airborne chips in dust form.

Centerless Grinder Grinding Wheel Blade or support

rollsRound profiles either ID or OD

Being pulled into the machine as the regulating wheel

and grinding wheel rotate in opposite

directions.

Part 2: Complete the following table. On the following pages, Insert the correct term or function for the machine component indicated.

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Abstract: Students will develop a manufacturing process plan for a simple component. Project will include determination of appropriate manufacturing processes, workholding device, manufacturing sequence and machining parameters. This process is not limited to the equipment available in the Machine Tool Laboratory.

Part 3: Process Planning

Instructions:

1. Using the drawing shown below, develop a manufacturing process plan showing all necessary machining operations.

2. Use the format shown on the following page: specify the machine type; work holding method; cutting tool type and material; dimensional characteristics machined; and inspection method for each operation.

3. Material is 1040 wrought medium carbon steel 225/275 BHN hardness. The material

does not require any heat-treating operation. Raw stock is 3.25-inch diameter bar

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Op# Machine Type Process Description Workholding Cutting

ToolInspection Procedure

10 Stores Release 3.25” dia 1040 medium carbon (225/275 BHN) bar stock to mfg

20 Cutoff Saw Rough finish length to 24.00” Vise HSS Blade Vernier Caliper

30 Engine Lathe Cut 1 Depth 0.375” along entire piece. New OD = 2.5”+0.000, -0.001

3 jaw chuck with dead

center and tail stock with live

center

Carbide cutter

Vernier Micrometer

40 Engine Lathe Cut 2 at 21.75” from left end, Depth 0.2495” to the right end of piece.



center

Carbide cutter

Vernier Micrometer

50 Engine Lathe Thread Cutting, from left end, set lathe to cut 2 threads per inch and cut for 1.5”



center

ACME thread profile

carbide cutter

ACME 3”-2 thread gauge

60 Engine Lathe Thread Cutting, from right end of 2.5” OD, set lathe to cut 2 threads per inch and cut for 11”



center

ACME thread profile

carbide cutter

ACME 3”-2 thread gauge

70 Engine Lathe Right End Chamfer, chamfer the right end of workpiece with tool rest at 45 degrees to centerline of workpiece



center

1/16” wide carbide cutter

Compass and steel ruler

80 Engine Lathe Left End Radius, radius left end of workpiece with tool rest at 90 degrees to centerline of workpiece



center

1/8” radius carbide cutter

Radius gauge

90 Horizontal mill Cut Keyway, locate along the centerline or workpiece and Vise ½” W x 1” Vernier Caliper

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1” in from left end plunge to a depth of ½” and transverse table 10.75” in the X direction.

dia. woodruff key seat

cutter100 Vertical Mill Drill # 1 for taper pin through workpiece, rotate workpiece

so keyway is horizontal and locate a point along centerline and 1.28125” in from right edge.

Vise 25/64” drill bit

Telescpoing Gauge and

Vernier micrometer

110 Vertical Mill Drill # 2 for taper pin to depth of 1.3334” Vise 27/64” drill bit


Vernier micrometer

120 Vertical Mill Drill # 3 for taper pin to depth of 0.6667” Vise 29/64” drill bit


Vernier micrometer

130 Vertical Mill Ream for #8 taper pin Vise #8 taper pin reamer

#8 taper pin

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Education

Manufacturing Processes Coursework