Milling, Broaching, Sawing And Filing (Gear Manufacturing) Flashcards
Type of milling
peripheral milling, Face milling, end milling, profile milling, slot milling, slot and groove milling, thread milling and tapping.
Type of milling operation
Conventional milling, climb milling
Milling formula
linear velocity, v = fNn
MMR= lwd/t or wdv (d= depth)
Power = dmmr(1/60)
Torque = p/rotational spd)
Cutting time, t = ( l+lc)/v
Pg 10 chap 24
Milling troubleshooting
Tool breakage - tool material lack toughness, improper tool angle, machine parameter too high
Tool wear - parameter too high, improper tool material, angle, fluid
Rough sf - feed per tooth too high, too few tooth on cutter, worn/chipped tool, built up edge, vibration
Tolerance too broad -workholding/spindle not stiff, temp, dull, chips clog
Work piece Surface burnished- dull tool, depth too low, radial relief angle too low
Back striking - dull cutting tool, tilt in cutter spindle, negative tool angle
Chatter marks - insufficient stiffness of system, external vibration, depth, width.
Burr formation - dull, angle, feed, depth, insert shape
Breakout - lead angle too low, edge geo, entry/exit angle, feed/depth.
What is broaching
Linear saw (in a way), have surface and internal broaching. Chip breaker can deep slotted, staggered, alternate.
Sawing operations
- Ripping
- Internal cut
- Angular cut
- contour cut
- Stack cutting
Saw teeth type
Straight tooth, raker tooth, wave tooth.
Type of bur
High spd bur
Carbide bur
Rotary file
Gear can be generate through:
- Form cutting
- Gear cutter
- Pinion shape cutter
- Rack shaped cutter
Hobbing
Cutting tool and workpiece rotate while hob being feed into workpiece. Gear is created. Repeated till depth is obtained
Finishing gear process
Form Grinding with shaped grinding wheel. Or with 2 wheel
