02 - Proses Pemesinan

Bandung, September 2014

Big lathe with big chips
Giant lathe
Machining = Chip formation by a tool
 Machining / Pemesinan
• Cutting action involves shear deformation of work material to
form a chip, and as chip is removed, new surface is exposed:
(a) positive and (b) negative rake tools
 Machining Operations
• Most important machining operations:
– Turning
– Drilling
– Milling
• Other machining operations:
– Shaping and planing
– Broaching
– Sawing
 Turning and Drillng

• Single point cutting tool  Used to create a round

removes material from a hole, usually by means of a
rotating workpiece to rotating tool (drill bit) with
form a cylindrical shape two cutting edges

https://www.youtube.com/watch?v=
Mn9jpqI8rao&feature=related
 Milling

• Rotating multiple-cutting-edge tool is moved across

work to cut a plane or straight surface
• Two forms: (c) peripheral milling and (d) face milling
 Cutting Tool Classification
1. Single-Point Tools
– One dominant cutting edge
– Point is usually rounded to form a nose radius
– Turning uses single point tools
2. Multiple Cutting Edge Tools
– More than one cutting edge
– Motion relative to work achieved by rotating
– Drilling and milling use rotating multiple cutting edge tools
 Cutting Conditions in Machining

• Three dimensions of a machining process

– Cutting speed v – primary motion
– Feed f – secondary motion
– Depth of cut d – penetration of tool below original work surface
• For certain operations (e.g., turning), material removal rate
RMR can be computed as

RMR = v f d
 Orthogonal Cutting Model
• Simplified 2-D model of machining that describes the
mechanics of machining fairly accurately
 Chip Thickness Ratio
to
r 
tc
where r = chip thickness ratio; to = thickness of the chip
prior to chip formation; and tc = chip thickness after
separation
• Chip thickness after cut is always greater
than before, so chip ratio is always less than
1.0
 Determining Shear Plane Angle
• Based on the geometric parameters of the orthogonal model, the
shear plane angle  can be determined as:

r cos 
tan  
1  r sin
where r = chip ratio, and  = rake angle
 Shear Strain in Chip Formation
• (a) Chip formation depicted as a series of parallel plates sliding relative
to each other, (b) one of the plates isolated to show shear strain, and (c)
shear strain triangle used to derive strain equation
 Chip Formation
• More realistic view of
chip formation,
showing shear zone
rather than shear
plane
• Also shown is the
secondary shear zone
resulting from
tool-chip friction
Four Basic Types of Chip in Machining
 Four Basic Types of Chip in Machining

 Ductile materials
 Low-to-medium cutting speeds Serrated Chip
 Tool-chip friction causes portions of chip
to adhere to rake face
 BUE forms, then breaks off, cyclically
 Generating Shape
• Generating shape: (a) straight turning, (b) taper
turning, (c) contour turning, (d) plain milling, (e)
profile milling
 Forming to Create Shape

• Forming to create shape: (a) form turning, (b)

drilling, and (c) broaching
 Forming and Generating

• Combination of forming and generating to

create shape: (a) thread cutting on a lathe,
and (b) slot milling
Turning Operation
 More Operations Related to Turning
• (d) Form turning, (e) chamfering, (f) cutoff
 Methods of Holding Workpiece in a Lathe
• (a) Holding the work between centers, (b) chuck,
(c) collet, and (d) face plate

http://www.youtube.com/watch?v=Q7QUiCJJmew
More Operations Related to Turning
• (g) Threading, (h) boring, (i) drilling
 Operations Related to Drilling
• (a) Reaming, (b) tapping, (c) counterboring
 More Operations Related to Drilling
• (d) Countersinking, (e) center drilling, (f) spot
facing
 Two Forms of Milling
• (a) Peripheral milling and (b) face milling
 Types of Peripheral Milling
• (a) Slab milling, (b) slotting, (c) side milling, (e) straddle milling, and
(e) form milling
 Types of Face Milling
• (a) Conventional face milling, (b) partial face milling, (c) end milling,
and (d) profile milling using an end mill
 Types of Face Milling
• (e) Pocket milling and (f) contour milling

https://www.youtube.com/watch?v=U99asuDT97I

https://www.youtube.com/watch?v=9OsNUi_o6C4
 Shaping and Planing

• Similar operations, both use a single point cutting

tool moved linearly relative to the workpart
Shaper
 Broaching

• A multiple tooth cutting tool is moved linearly

relative to work in direction of tool axis
 Broaching
Advantages:
• Good surface finish
• Close tolerances
• Variety of work shapes possible
Cutting tool called a broach
• Owing to complicated and often
custom-shaped geometry, tooling is expensive
 Power Hacksaw

• Linear reciprocating motion  Rotating saw blade provides

of hacksaw blade against continuous motion of tool
work past workpart
 Geometric Factors Affecting Surface Finish
• Effect of (a) nose radius, (b) feed, and (c) ECEA
 Ideal Surface Roughness


2
Ri f
32NR
where Ri = theoretical arithmetic average
surface roughness; f = feed; and NR = nose
radius
 Work Material Factors
• Built-up edge effects
• Damage to surface caused by chip
• Tearing of surface when machining ductile
materials
• Cracks in surface when machining brittle
materials
• Friction between tool flank and new work
surface
 Effect of Work Material Factors
• Multiply theoretical
surface roughness by
the ratio of actual to
theoretical roughness
for the given cutting
speed to obtain
estimate of actual
surface roughness