instructional design document machining mechanics stam interactive solutions
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Instructional Design Document
Machining Mechanics
STAM Interactive Solutions
Demo Outline (For reference)
Topic Number Topic Name Page Type
1 Piispanen’s Card Model Animated page
2 Variables in Orthogonal Cutting Animated page
3 Kinematics of Orthogonal Cutting Animated page
4 Forces in Orthogonal Cutting Animated page
5 Merchant’s Force Circle Animated page
6 Energy Dissipation in Cutting Animated page
7 Cutting Temperatures Animated page
8 Simulation Interactive page
Changes Suggested by Prof. Ramesh Singh Changes reflected on slide no.
1 Focus on “Machining Mechanics”, specifically on the influence of Machining Mechanics on tool-selection and machine sizing
All slides
2 Voiceover for initial slide to stress that the question is whether a process is feasible given a depth of cut and cutting speed – relatethis to power required for machining and temperature of the tool.Point out that to figure out the former, we need to know the forces on the tool / workpiece, and the subsequent slides will explore this for orthogonal cutting.
Slide 5
3 Omit chip-formation entirely: instead, use material from slides 3,11, 12, 13, 17 and 19 of lecture notes at me.iitb.ac.in/~ramesh/me338/machining2.pdf.
Slides 6 - 14
4 Voiceover must mention that forces should be compared with theproperties of the workpiece (shear-stress, for eg.,) since theworkpiece must “fail” under the forces applied by the tool.
Slide 10
5 Display the forces Ns, Fs, Ft, F and N on both the tool and thechip and the workpiece
Slides 9 & 10
6 Conclude with graphical display of heat dissipation Slide 14
7 References · Don’t cite the wikipedia· Add books as given
Slide 16
Change Log (as per the minutes pdf)
Note to the reviewer:
The visuals shown on each slide will be graphically enhanced to make explanation easier to follow.
Machining MechanicsAdvanced Manufacturing Process I & II
In the process of workpiece machining, as the depth of cut and the cutting speed increase, cutting forces rise and so does the temperature of the tool and the power consumed by the machining process.
This demo outlines these aspects of orthogonal cutting. It also explores the influence of machining mechanics on tool selection and machine sizing.
Machining MechanicsAdvanced Manufacturing Process I & II
Piispanen’s Card Model
Machining MechanicsAdvanced Manufacturing Process I & II
Variables in Orthogonal Cutting
Machining MechanicsAdvanced Manufacturing Process I & II
Kinematics of Orthogonal Cutting
Machining MechanicsAdvanced Manufacturing Process I & II
Forces in Orthogonal Cutting
Machining MechanicsAdvanced Manufacturing Process I & II
Forces in Orthogonal Cutting
Machining MechanicsAdvanced Manufacturing Process I & II
Merchant’s Force Circle
Machining MechanicsAdvanced Manufacturing Process I & II
Energy Dissipation in Cutting
Machining MechanicsAdvanced Manufacturing Process I & II
Energy Dissipation in Cutting
Cutting Power:
Shear Zone Power:
Friction Zone Power:
Machining MechanicsAdvanced Manufacturing Process I & II
Cutting Temperatures
Heat transfer to environment is negligible
Machining MechanicsAdvanced Manufacturing Process I & II
Rake Angle (α):
Width of Cut/Pass:
Cutting Speed (V):
Cutting Force (Fc):
Undeformed Chip Thickness (to):
Vary the cutting speed.
degrees10
2 m/s
0.25 mm
mm2.5
Deformed Chip Thickness (tc): 0.83 mm
890 N
Thrust Force (Ft): 667 N
Cutting Power (Pc): W
Cutting Power Meter (%)
0
100
40
50
30
20
10
80
70
60
90
Simulation
(Range = 0.1 to 4)
(Constant)
(Constant)
(Constant)
(Constant)
(Constant)
(Constant)
Shear Zone Power (Pc): W
Machining MechanicsAdvanced Manufacturing Process I & II
Resources
Books:
• Serope Kalpakjian & Steven R. Schmid, “Manufacturing Process for Engineering Materials”, Section 6.3 – Rolling Process
• Ghosh & Malik, “Manufacturing Science”
Machining MechanicsAdvanced Manufacturing Process I & II
Shaping Single-point Multi-point
Neither
Planning Single-point Multi-point
Neither
Turning Single-point Multi-point
Neither
Boring Single-point Multi-point
Neither
Milling Single-point Multi-point
Neither
Drilling Single-point Multi-point
Neither
Grinding Single-point Multi-point
Neither
Honing Single-point Multi-point
Neither
Identify the type of cutting process for each of thefollowing:
Machining MechanicsAdvanced Manufacturing Process I & II
Machining grey cast iron produces
continuous chips with BUE
continuous chips without BUE
discontinuous chips of irregular shape and size
discontinuous chips of regular shape and size
Machining MechanicsAdvanced Manufacturing Process I & II
A low rake angle is
desirable because it reduces the power consumed
not desirable because it weakens the tool
desirable because it reduces BUE
not desirable at all
Machining MechanicsAdvanced Manufacturing Process I & II
The thickness of the chip is independent of
cutting speed
depth of cut
tool material
rake angle
Machining MechanicsAdvanced Manufacturing Process I & II
The cutting forces affect
the power required
the design of the machine tool
the accuracy of the machined workpiece
depends on the process parameters
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