Page 678 - Manufacturing Engineering and Technology - Kalpakjian, Serope : Schmid, Steven R.

Machining

Processes: Milling,

Broaching, Sawing,

Filing, and Gear

Manufacturing

24.l Introduction 659
° This chapter begins with milling, one of the most versatile machining processes, 24.2 Millingand Milling
in which a rotating cutter removes material while traveling along various axes Machines 660
with respect to the workpiece. 24.3 Planing and Shaping 674
24.4 Broaching and Broaching
° Several other machining processes are then described, such as planing, shaping, Machines 675
and broaching, in which either the cutting tool or the workpiece travels along a 24.5 Sawing 678
straight path, producing flat or various shaped surfaces. 24.6 Filing 681
24.7 Gear Manufacturing by
' Sawing processes are then covered, generally used for preparing blanks for sub-
Machining 68|
sequent operations such as forming, machining, and welding.
EXAMPLES:
0 Also briefly discussed is filing, used to remove small amounts of material, usu-
24.l Material-removal Rate,
ally from edges and corners.
Power, Torque, and
° The chapter ends with descriptions of gear-manufacturing methods by machin- Cutting Time in Slab
Milling 664
ing, the special cutters used, the equipment involved, and the quality and prop-
24.2 Material-removal Rate,
erties of the gears made.
Power Required, and
Cutting Time in Face
Typical parts made: Parts with complex external and internal features, splines,
Milling 667
and gears.
24.3 Broachinglnternal
Alternative processes: Die casting, precision casting, precision forging, powder Splines 678
metallurgy, powdeninjection molding, creep feed grinding, electrical discharge
CASE STUDY:
machining, rapid prototyping, and fabrication.
24.l Ping Golf Putter 688
24.l Introduction
In addition to producing parts with various external or internal round profiles, ma-
chining operations can produce many other parts with more complex shapes
(Fig. 24.l). In this chapter, several cutting processes and machine tools that are ca-
pable of producing these shapes using single-point, multitooth, and cutting tools are
described (see also Table 23.1).
It is not unusual that complex shapes need to be produced to very close toler-
ances and a fine surface finish. Although processes such as die casting and precision
forging can achieve such goals to some degree, it is often necessary to perform com-
plicated machining to achieve design requirements.
The preceding chapter described machining processes that produce round
shapes. While the processes and machinery covered in this chapter also can produce
round, axisymmetric shapes, it is generally advisable to use the processes of Chapter 23
659

CHAPTER