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Mr . CNC

CNC & CAD & CAM

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12/10/2024

Factors that affect vibration tendencies
Vibration tendencies grow towards the right.
Lead (entering) angle
• Choose an entering angle as close to 90°
(lead angle as close to 0°) as possible,
never less than 75° (more than 15° for
lead angle).
Corner radius
• Choose a corner radius which is some-
what smaller than the cutting depth.
Micro and macro geometry
• Use a positive basic-shape insert, as
these give lower cutting forces com-
pared to negative inserts.
Edge design
• Insert wear changes the clearance
between the insert and the hole wall. This
can affect the cutting action and lead to
vibration.
• Inserts with thin coatings, or uncoated
inserts, are to be preferred as they
normally give lower cutting forces.
Depth of cut (DOC)
• Choose a corner radius which is some-
what smaller than the cutting depth.

12/10/2024

EasyFix sleeves
For correct clamping of cylindrical bars
Guarantees correct center height
Benefits:
• Cutting edge in right position
• Best cutting action gives better surface finish
• Reduced setup time
• Even insert wear.
A spring plunger mounted in the sleeve clicks into a
groove in the bar and guarantees correct center height.
The slot in the cylindrical sleeve is filled with a silicon
sealer which allows the existing coolant supply system to be used.

10/10/2024

Tool requirements for clamping.
Maximum contact between tool and tool holder

10/10/2024

Clamping the boring bar.
Critical stability factors for optimized performance.
• Maximum contact between tool and tool
holder (design, dimensional tolerance).
• Clamping length 3 to 4 times bar dia-
meter (to balance cutting forces).
• Holder strength and stability.

09/10/2024

Selecting the insert clearance angle
Positive inserts generate lower cutting force and tool deflection.

• Inserts with clearance angle 7°
- First choice for small and medium holes
from 6 mm (.236 inch) diameter.
• For best economy
- Use negative inserts in stable condi-
tions and with short overhang.

08/10/2024

Back boring
Back boring is a boring operation with reverse feed.
• It is used for turning shoulders less than 90°.
• Boring bars with 93° (–3°) entering (lead) angles and D-style 55° inserts are commonly used.

08/10/2024

Four main application areas
1- Longitudinal turning/facing.
The most commonly used internal turning operation.
• Rhombic shape C-style 80° insert is frequently used.
• Boring bars with an entering (lead) angle of 95° (-5°) and 93° (-3°)
are commonly used.
• D-style 55°, W-style 80° and T-style 60° insert shapes are also
frequently used.
2- Profiling
Versatility and accessibility is the determining factor.
• The effective entering angle, KAPR (lead angle, PSIR) should be
considered.
• Bars with entering (lead) angle of 93° (–3°), allowing an in-copy-
ing angle between 22–27°, are commonly used.
• D-style 55° and V-style 35° inserts are frequently uses

07/10/2024

Selecting entering (lead) angles
Radial and tangential cutting forces deflect the boring bar
Entering (lead) angle and cutting forces

07/10/2024

Effect of cutting forces on internal turning.
Radial and tangential cutting forces deflect the boring bar.
Tangential cutting force, Ft
• Forces the tool down, away from the
center line
• Gives a reduced clearance angle.
Radial cutting force, Fr
• Alters cutting depth and chip thickness
• Gives out of tolerance dimension and
risk of vibration.
Feed force, Fa
• Directed along the feed of the tool.

07/10/2024

The entering and copying angle
Important consideration in profile turning
• In profile turning, the cut can vary with regard
to cutting depth, chip thickness and speed.
• The largest suitable nose angle on the insert
should be selected for strength and cost
efficiency, but the insert nose angle also has
to be considered in relation to accessibility for
proper clearance between material and cutting edge.
• The most common nose angles used are 55° and 35°.

06/10/2024

Design and manufacture on Siemens NX program. Using the process MULTI AXIS ROUGHING. In the manufacturing process, the mirror order was chosen to make the lower part symmetrical.

05/10/2024

Pocketing:-
A method to produce or widen shallow grooves
• Round inserts are very suitable for plunge turning as they can be used for both radial and axial feeds.
• Neutral 90° holders for round inserts are commonly used.

05/10/2024

FACING :-
The tool is fed in towards the center
• Pay attention to the cutting speed which will change pro-
gressively when feeding towards the centre.
• Entering angles of 75° and 95°/91° (Lead angles of 15° and –5°/–1°) are commonly used.
• C-style (80°) and S-style (90°), inserts are frequently used.

05/10/2024

PROFILING:-
Versatility and accessibility is the determining factor
• The effective entering angle KAPR (lead angle PSIR) should be
considered for satisfactory machining.
• Most commonly used entering angle = 93° (lead angle is –3°)
because it allows an in-copying angle between 22°-27°.
• The most frequently used insert shapes are D-style (55°) and V-style (35°) inserts.

04/10/2024

Longitudinal turning/facing
The most common turning operation
• Rhombic shape C-style (80°) insert is frequently used.
• Holders with entering angles of 95° and 93° (lead angles of –5°
and –3°) are commonly used.
• Alternatives to the C-style insert are D-style (55°), W-style (80°)
and T-style (60°).

04/10/2024

Effects of cutting speed.

03/10/2024

Cutting data parameters affect tool life
Use the potential of:

- ap – to reduce number of cuts
- fn – for shorter cutting time
- vc – for best tool life

03/10/2024

To excel in your work, you must always be informed.
Factors affecting choice of insert shape
Insert shape should be selected relative to the entering (lead)
angle accessibility required of the tool. The largest possible point
angle should be applied to give insert strength and reliability.

02/10/2024

Selection of the insert shape
The influence of large and small point angle
The insert shape and point angle varies
considerably from the smallest, at 35°, to
the round insert.
Each shape has unique properties:
- some provide the highest roughing
strength.
- others give the best profiling accessibility.
Each shape also has unique limitations.
For example:
- high edge accessibility during machining
leads to a weaker cutting edge.

02/10/2024

Dedicated grades :-
Dedicated grades minimize tool wear development:
The workpiece material influences the wear during the
cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear
mechanisms, e.g.:
- Flank wear, crater wear and plastic deformation
- Built-up edge and notch wear.

01/10/2024

The main range of cutting tool materials
The most common cutting tool materials are divided into the following
main groups:
- Uncoated cemented carbide (HW)
- Coated cemented carbides (HC)
- Cermets (HT, HC)
• HT Uncoated cermet containing
primarily titanium carbides (TiC)
or titanium nitrides (TiN) or both.
• HC Cermet as above, but coated.
- Ceramics (CA, CM, CN, CC)
• CA Oxide ceramics containing primarily
aluminum oxide (Al2O3).
• CM Mixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
than oxides.
• CN Nitride ceramics containing
primarily silicon nitride (Si3N4).
• CC Ceramics as above, but coated.
- Cubic boron nitrides (BN)
- Polycrystalline diamonds (DP, HC)
• DP Polycrystalline diamonds.
• HC Polycrystalline diamonds, but
coated.

01/10/2024

Chip forming at high pressure and temperatures.
The choice of cutting material and grade is critical for success

* The ideal cutting tool material should:
- be hard to resist flank wear and
deformation
- be tough to resist bulk breakage
- not chemically interact with the
workpiece material
- be chemically stable to resist oxidation
and diffusion
- have good resistance to sudden thermal
changes.

@أبرز المعجبين

30/09/2024

Dedicated inserts for the ISO P, M, K and S area.
The different micro and macro-geometries are adapted to the various
requirements in the applications.

30/09/2024

Three main methods in Turning.
1- Roughing:-

• Maximum metal removal rate and/or
severe conditions
• Large cutting depth and feed rate
combinations
• High cutting forces.

2- Medium machining:-

• Most applications – general purpose
• Medium operations to light roughing
• Wide range of cutting depth and feed
rate combinations.

3- Finishing

• Small cutting depths and low feed rates
• Low cutting forces.

29/09/2024

There is a distinction in cutting edge geometry between negative and positive insert
geometry:
- A negative insert has a wedge angle of 90° seen in a cross-section of the basic shape
of the cutting edge.
- A positive insert has an wedge angle of less than 90°.
The negative insert has to be inclined negatively in the tool holder so as to provide a
clearance angle tangential to the workpiece while the positive insert has this clearance
built in.

Address

Minya El-Qamh

Telephone

+201062153645

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