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Machining Processes

Machining ProcessesIME 240 Material Removal Processes Machining is the broad term used to describe removal of material from a workpiece Includes Cutting, Abrasive Processes (grinding), Advanced Machining Processes (electrical, chemical, thermal, hydrodynamic, lasers) Automation began when lathes were introduced in 1700s Now have computer numerical control (CNC) machines Machining operations are a systemconsisting of: Workpiece material, properties, design, temperature Cutting tool shape, material, coatings, condition Machine tool design, stiffness & damping, structure Fixture workpiece holding devices Cutting parameters speed, feed, depth of cutIndependent variablesRange of Material Removal ProcessesEnergy sourceTransfer mediumProcessEnergy sourceTransfer mediumProcessMechanicalRigidChemicalLiqu idGranularElectricalandChemicalLiquidLiq uid/Gaseous(granular)ThermalGaseousElect ricalLiquidEnergy beamGaseousorVacuumLaser beam machiningElectron beam machiningIon beam machiningtoolMachiningUltrasonicmachinin gabrasivevibrationsJet cuttinghigh pressure jetEDMtoolChemical machiningshieldfluidECMtoolelectrolyteFl ame cuttingPlasma cuttingtorchgasMaterial Removal Processes Material

Workholding Devices –Collets and Face Plates. Turning Formulae fN l tdfN dfN D D ... and them reaming, as well as possibly honing or grinding to improve internal surface and deburring the tool exit surface of through holes • Holemaking is a major cost of components such as engines

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Rolling of Metals

personal.egr.uri.edu

Rolled Metal Thicknesses • Plates –thickness greater than 6 mm (1/4 inch); •boiler supports (0.3 m, 12 inch) •reactor vessels (150 mm, 6 inch) •battleships and tanks (100-125 mm, 4-5 inch) • Sheets –less than 6 mm thick; flat pieces, strips, and …

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Sheet Metal Forming - University of Rhode Island

personal.egr.uri.edu

Bending Sheet Metal • In bending, outer fibers are in tension while inner fibers are in compression • Bend allowance is the length of the neutral axis in the bend, L b = a (R+kT) • k is a constant that ranges from 0.33 (for R<2T) to 0.5 (for R>2T) • Engineering strain during bending: • As R/T decreases, the tensile strain at outer fiber

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ACCEPTANCE SAMPLING PROBLEM STATEMENT

personal.egr.uri.edu

Sampling can be described as the activity of taking a snap-shot of a population in order to obtain an understanding of the observed population. In acceptance sampling, inspection is performed on a sample taken from a lot of incoming materials. A decision is made concerning the disposition of the lot based on the information obtained from this ...

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Extrusion and Drawing - University of Rhode Island

personal.egr.uri.edu

machining or chemical etching prior to extrusion • Internal cracking (also called center-burst, chevron cracking) ... •Ultrasonic vibration of the dies and mandrels –reduces friction and allows larger reductions per pass without failure. Drawing Defects and Equipment

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Polymer Processing - University of Rhode Island

personal.egr.uri.edu

• The polymer melt contains a dissolved inert gas; most commonly nitrogen, introduced in the extrusion screw. • A predetermined shot size is injected into the mold cavity, the extruder valve is closed, and the foam material generates internal pressure and expands to fill mold cavity. • A much lower pressure operation than the conventional

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