ANALYSES OF CHIPS FORMED IN PLANO MILLER AND HORIZONTAL BORING MACHINES .
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Transcript of ANALYSES OF CHIPS FORMED IN PLANO MILLER AND HORIZONTAL BORING MACHINES .
PROJECT
AIM:- ANALYSIS OF CHIPS FORMED IN PLANO MILLERS AND BORING MACHINES
IN BM-1BY SURAJ SINGH PATWAL
Number of axisTable Size Travel (a) X (b)Y (c)Z (d)W (e)U
P-5 P-4 HB-3 HB-11X,Y,Z,W,U X,Y,Z,W X,Y,Z,W X,Y,Z,W7500*2250 6000*3000 12500*3760 8300*37608200 6000 12500 120004600 3000 3000 35001000 1000 400 4002600 3000 1600 1600500 - - -
Spindle Diameter(mm)
275 250 200 200
Spindle rpm 10-1000 700 600 600
SPECIFICATIONS OF MACHINES
90 deg lead angle
75 deg lead angle
45 deg lead
angle
LEAD ANGLE90
4575
w/p w/pw/p
MILLING
CLIMB MILLING CONVENTIONAL MILLINGCUTTER ROTATES
IN ANTICLOC
KWISE DIRECTIO
N
FEEDFEED
CUTTER ROTATES
IN ANTICLOC
KWISE DIRECTIO
N
Action of
force applied to
work
Action of
force applied to
work
HB3
RPM=410FEED=200DOC=1,2,3
RPM=284FEED=300
DOC=.2
RPM=504FEED=129
DOC=.5
HB-3RPM=202FEED=4.5DOC=1.5
RPM=269FEED=200
DOC=1
RPM=222FEED=200
DOC=.3
RPM=240FEED=40DOC=.5
RPM=251FEED=150
DOC=.8
RPM=251FEED=150
DOC=.5
RPM=418FEED=80DOC=.3
RPM=448FEED=90DOC=.5
HB-3RPM=504FEED=129
DOC=.5
RPM=306FEED=125
DOC=.2
RPM=448FEED=166
DOC=.6
RPM=448FEED=90DOC=.5
RPM=299FEED=70DOC=.5
RPM=319FEED=100
DOC=.8
RPM=301FEED=150
DOC=.5
P-5RPM=187FEED=200
DOC=1
RPM=250/275FEED=400DOC=1.5
RPM=240FEED=40DOC=.5
RPM=800FEED=400DOC=.15
RPM=190FEED=210
DOC=1
RPM=205FEED=260DOC=.145
RPM=200FEED=280
DOC=.5
HB-11RPM=538FEED=40DOC=1
RPM=229FEED=200
DOC=1
RPM=241FEED=200
DOC=.5
RPM=270FEED=150
DOC=.8
RPM=270FEED=85DOC=.8
RPM=258FEED=250DOC=.21
RPM=244FEED=50DOC=2
RPM=231FEED=50DOC=1
HB-11RPM=182FEED=420DOC=1.5
RPM=182FEED=45DOC=3
RPM=182FEED=525
DOC=3
RPM=182FEED=340
DOC=3
P-4RPM=200FEED=250DOC=.25
RPM=200FEED=256DOC=.15
RPM=210FEED=196.6
DOC=.5
RPM=210FEED=280
DOC=.6
RPM=210FEED=210
DOC=.6
W/P
EFFECT OF DIAMETER OF CUTTER WRT WIDTH OF CUT
CUTTER IF CUTTER DIAMETER IS EQUAL TO
WIDTH OF CUT • THEN THE CHIP WILL BE FORMED AT THE ENTRY
AND EXIT OF THE CUT WILL BE VERY THIN
AND THE CHIPS CANNOT CARRY AWAY HEAT AS WELL AS THICKER CHIPS, THEREFORE HEAT IS
TRANSFER BACK INTO THE INSERT , CAUSING EDGE FAILURE.• WORK-HARDENING IS ALSO MORE LIKELY TO
OCCUR IN THE ENTRY AND EXIT AREAS.
25% of cutter body
DO’S AND DON’T
• AT 45DEG LEAD ANGLE , NEVER GIVE HIGH DEPTH OF CUT DOC<=4MM BUT CAN BE USED FOR HIGHER FEED RATE.
• FOR THIN WALL WORK PEACE (BOLSTER), WHEN PERPENTICULARITY REQUIRED AT THE EDGES OF PLATE THEN USE SOLDER CUTTER .
• 75 DEG CUTTER IS NOT USED FOR WEAK MACHINES/WORKPIECE/FIXTURES BECAUSE OF HIGHER VALUE OF RADIAL FORCE.
• ALWAYS USE CLIMB MILLING.• FOR BETTER TOOL LIFE , 25 % OF THE CUTTER BODY SHOULD BE OUTSIDE THE WORK PIECE.• CUTTING FLUID SHOULD BE USED WHEN RECOMMENDED.• NEVER GIVE HIGH VALUE OF DOC IN A THIN PLATE,IT WILL CAUSE VIBRATIONS.
OBSERVATION
• IN MILLING THICKNESS OF CHIPS DEPEND ON FEED AND WIDTH OF CHIPS DEPEND ON DOC.• CORRESPONDING TO THE LARGER FEED CHIP SIZES REDUCES,IF WE KEEP RPM AND DOC
CONSTANT.• AS WE INCREASES THE DOC FROM 1MM, 2MM,3MM, CHIPS COLOR VARIES FROM WHITE ,
GOLD AND BLUE, IT MEANS WITH INCREASE IN DOC,MORE HEAT IS RELEASED.• IF FEED INCREASES THEN VIBRATION INCREASES AND CHANCES OF BREAKING OF BITS
INCREASES.• LARGER IS THE DOC , HEAT REALSE MORE AND TOOL BITS BREAK AND ALSO PRODUCE
DAMAGE TO CUTTER.• IF VIBRATIONS ARE MORE THEN DISTORTED CHIPS ARE FORMED AND IT EFFECTS
MACHINING AS A RESULT DAMAGE OUR BITS AND CUTTER.