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State of Art in Material Removal Process
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Transcript of State of Art in Material Removal Process
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8/18/2019 State of Art in Material Removal Process
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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" $ndamentals of material removal
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ntended co$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.
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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. $1
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/vervie over the co$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
$. Cutting materials
%. &rocesses with geometrical non'defined cutting edges
(a!rasive processes)
*. +urface properties
1,.-on'conventional processes
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/vervie of todas topics
1. Introduction
2. #orpiece /ualit3. Classification of processes
4. 0ovements tool geometr and process input /uantities
5. escription of drilling and milling and !roaching
oals for toda
1. +howing the sstematic in material removal processes
2. &roviding (English) terminolog
3. efreshing the !asics of classical material removal
processes
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Man$fact$rin technolo as 3ecomponent
m o ! i l i t c o m m u n i c a t i o n
source 6ir!us olls oce &orsche 6+07 8odafone 9-o chips without chips:;
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4hat is a micron 5m8
source E.
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9$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
=⋅=∆
⋅⋅
⋅⋅⋅=∆
∆⋅⋅=∆
−
−−
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:pdate of %ani$chi- acc$rac
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p r e c i s i o nm a c h i n i n g
a t o m i c l a t t i c e d i s t a n c e
c o n v e n t i o n a lm a c h i n i n g
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:pdate of %ani$chi- ro$hness
1 * , , 1 * 2 , 1 * 4 , 1 * " , 1 * % , 2 , , ,
1 , ,
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= & ' m a c h i n i n g
p r e c i s i o n
m a c h i n i n g
a t o m i c l a t t i c e d i s t a n c e
c o n v e n t i o n a lm a c h i n i n g
c
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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 % ,
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;lassi
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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
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;$ttin processes
cutting with geometricall well'defined cutting edge
• turning
worpiece
tool
•••
drilling counter!oring reaming
worpiece
• milling
tool
tool
worpiece
other processes
planing slotting !roaching sawing
filing shaving rasping
•••
•••
accord. to I- %5%*
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%$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
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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
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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
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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
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/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
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>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
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%he dierence
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/vervie of todas topics
1. Introduction
2. #orpiece /ualit3. 0ovements tool geometr and process input /uantities
4. escription of drilling and milling and !roaching
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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 )
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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
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Sstem of s$rface deviations, D?(760s h a p e d e v i a t i o n
1 . o r d e r f o r m d e v i a t i o n
2 . o r d e r w a v i n e s s
3 . o r d e r r o u g h n e s s
4 . o r d e r r o u g h n e s s
5 . o r d e r r o u g h n e s s( n o t s i m p l t o d e s c r i ! e )
" . o r d e r r o u g h n e s s( n o t s i m p l t o d e s c r i ! e )
e A a m p l e
s t r a i g h t n e s s '
f l a t n e s s ' r o u n d n e s s ' d e v i a t i o n
w a v e s
g r o o v e s
s l o t sf l a e s
d o m e s
s t r u c t u r e
l a t t i c e s t r u c t u r eo f t h e m a t e r i a l
e A a m p l e s o f t h e o r i g i n
e r r o r o f m a c h i n e t o o l g u i d e w a s
d e f l e c t i o n o f m a c h i n e o f w o r p i e c e w r o n g c l a m p i n g h e a t t r e a t m e n td i s t o r t i o n w e a r
e c c e n t r i c c h u c i n g f o r m o r p o s i t i o nd e v i a t i o n o f t h e m i l l i n g t o o l v i ! r a t i o no f m a c h i n e o r t o o l
f o r m o f c u t t i n g e d g e f e e d o r d e p t h o f c u t o f t h e t o o l
t p e o f c h i p f o r m a t i o n ( s e g m e n t e d ! u i l t ' u p e d g e ) m a t e r i a l d e f o r m a t i o nd u r i n g @ e t m a c h i n i n g m o d i f i c a t i o nd u r i n g g a l v a n i c c o a t i n g
c r s t a l l i s a t i o n p r o c e s s e s s u r f a c em o d i f i c a t i o n ! c h e m i c a l r e a c t i o n c o r r o s i o n p r o c e s s e s
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9$estion
,hat is the implication of theincreasing machining accuracy on
the deFnitions of roughness and form
deviations3
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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
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/vervie of todas topics
1. Introduction2. #orpiece /ualit
3. 0ovements tool geometr and process input /uantities
4. escription of drilling and milling
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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
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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
w o r i n g p l a n e
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
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!Eample" %$rnin of steel
• )ecommended values from the tool*manufacturer
• d G $# mm
• vc G +!4 m9min
•
ap G ! mm• f G 4.!# mm9rev.
• n G +.444 rpm
• vf G 1444mm9minG1 m9min
woring plane
toolworpiece(fiAed in space)
ϕ
η
ve vc
vf
turning
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%erms at the c$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
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%erms at the c$ttin tool 52s e c t i o n A - B ( t o o l o r t h o g o n a l p l a n e )
r a e f a c ef l a n f a c e
t o o l c u t t i n ge d g e p l a n e
α β
γ L
t o o l r e f e r e n c e
p l a n eκ
6
<
G
f e e d m o t i o n
t o o l c u t t i n ge d g e p l a n e
'
c o n s i d e r e dw o r i n g p l a n e
p r i n c i p a l v i e w
a c c o r d i n g t o I - " 5 % 1
v i e w Z ( o n t o o l c u t t i n g e d g e p l a n e )ε
ε
c h o s e np o i n t
L λ
'
t o o l r e f e r e n c ep l a n e
m a @ o r c u t t i n g
e d g e
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%erms at the c$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
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;$ttin and chip eometr
a p
f
hκ
6 a f ! h
h f s i n
p ⋅ ⋅
⋅ κ! a H s i n
a f p κ
e
6
af !
h
p
κ
f
!
f f
v f
h
a !p
κ ° * ,
c h i p c r o s s ' s e c t i o n d e p t h o f c u t f e e d w i d t h
c h i p t h i c n e s s t o o l c u t t i n g
e d g e a n g l e
c h i p
v f
Imagine vf and ap are eHual; what do you thin6 about the cutting
forces33
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$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
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heav dut cutting
source +andvi
C
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Cariants of tool holders
source +andvi
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/vervie of todas topics
1. Introduction2. #orpiece /ualit
3. 0ovements tool geometr and process input /uantities
4. escription of drilling and milling and !roaching
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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
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;$ttin anle at a drill
r e f e r e n c ep l a n e
r
τ
γ /
r /
r /
r a
t o o l c u t t i n g
e d g e p l a n e
t o o l o r t h o g o n a lp l a n e
* , Pσ
2
σ
γ h
γ hN
2 r π ar H
2 r π /
2 r π s i m p l i f i c a t i o n ,τ
,h
i n c l i n a t i o n o f t h e d r i l l f l u t e
γ hN
γ hN
γ hN
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;hip formation d$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
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9$estion
&oo6ing at the chip formation processin the previous pictures< what do you
thin6 about the local and total
cutting forces in drilling
3
f d ill i
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%pes of common drill tipsf o r m 6
w e ! t h i n n i n g
f o r m <
f o r m C
s p l i t p o i n t ( c h i s e l e d g e e l i m i n a t e d )
f o r m
w e ! t h i n n i n g ( m o d i f i e d c h i s e l e d g e )w i t h f a c e t e d c o r n e r
w e ! t h i n n i n g w i t h m a @ o rc u t t i n g e d g e c o r r e c t i o n
D ill i
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o r ! i t a ld r i l l
t r e p a nd r i l l
c a n o nd r i l l
s / u a r ed r i l l
h e l i c a ld r i l l
d o u ! l em a r g i n
d r i l l
! r o a c h i n gd r i l l
d r i l l w i t hi n s e r t
s p a d ed r i l l
s h o r t h o l e
d r i l l i n g
l o n g h o l e
d r i l l i n g
Drill variants
c e n t r ed r i l l i n g
t r e p a n n i n g( h o l l o w d r i l l i n g ) d r i l l o u t
! o r e m a n u f a c t u r i n g
d r i l l i n g m i l l i n g
S i l t f d illi t l
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Special tpes of drillin tools
+/uaredrill with ou!le margin drill +/uaredrill without +piral drill without
coolant holes with coolant holes coolant holes coolant holes
drills with inserts drill with changea!le head
; tti diti d i f illi
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;$ttin conditions d$rin face millin
6
6
ϕ
ϕ
ϕf D
1 % , P '
f c
!a p
κc u t t i n g t o o le d g e
w o r p i e c e
s e c t i o n 6 ' 6
a e
a e 1
a e 2A
G
nϕ
ϕ
ϕc
E
6
ϕ , P
..
f D
f Dv c
v f
d e t a i l G
f c
i . t r a @ e c t o r c u r v ei . L 1 t r a @ e c t o r c u r v e
e A i t p l a n e
ϕ
e n t r a n c e p l a n e
c u t t i n g e d g e
D n u m ! e r o f c u t t i n g e d g e s
f
f f s i n
h f
D
c D
c
⋅ ϕ s i n
h f s i n s i n
⋅ κ
⋅ κ ⋅ ϕD
vn D
f ⋅
Milli i t
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MA Precision Manufacturing and Assembly
Millin variants
w o r p i e c e s u r f a c e g e n e r a t e d! m i n o r c u t t i n g e d g e
a p a e
f D f Dv f
v f
n
t o o l
c u t t i n g i n s e r t
w o r p i e c e
n
w o r p i e c e s u r f a c e g e n e r a t e d! m a @ o r c u t t i n g e d g e
f a c e m i l l i n g p e r i p h e r a l m i l l i n g
Milli i t
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Millin variants
t a n η s i n ϕv H v L c o sc f ϕ
ϕ
ϕ
v e
v e
v c
vc
v f
w o r i n g p l a n e
nn
o w n m n g !f e e d d i r e c t i o n a n g l e * , P 1 % , P≤ ≤ϕ
u p m n g !f e e d d i r e c t i o n a n g l e , P * , P≤ ≤ϕ
m i l l i n g t o o l
w o r p i e c e
w o r i n g p l a n e
η
v f
s o u r c e I - " 5 % , E
m i l l i n g t o o l
w o r p i e c e
illi
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orm millin
! a l l ' n o s ee n d m i l l
t o o l a A i sd i r e c t i o n
v f
v f 3 ' a A i s m i l l i n g
5 ' a A i s m i l l i n g
β = t o o l i n c l i n a t i o n a n g l e
s u r f a c e n o r m a l v e c t o r
m i l l i n g h e a d
!
!
t t
t o o l a A i sd i r e c t i o n
Milli h d
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Millin head
source #alter
,hats the ra6e face< primary cutting edge< ma>or Jan6 face35oes this tool has a positive or negative ra6e angle33
Solid t nsten car=ide millin c tters
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Solid t$nsten car=ide millin c$tters
source Qa!ro
*roachin tool
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*roachin tool
tool
worpiece
source #G7 6achen
*roachin machines
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*roachin machines
Kuge 5, t !roaching machine 6nn 6r!or 0achine tool =+6
8ertical !roaching machine
Chan Row ?aiwan
KoriDontal !roaching
?he ear #ors
Additional material
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Additional material
Advancin ;$ttin technolo
K. Lyrne< 5. 5ornFeld< L. 5en6ena
eynote paper in Annals of the CIRP !44!
@Lelongs to the e7amination material