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CNC Application and Design

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CNC Application and Design CNC Application and Design by Patrick Collins, Charles Cummings, Wesley Dittrich, Paul Jones, Andrew Sealey Major Qualifying Project Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE In partial fulfillment of the requirements for the Degree of Bachelor of Science in Mechanical Engineering ___________ _____________ _____________ Patrick Collins Charles Cummings Wesley Dittrich _____________ _____________ Paul Jones Andrew Sealey APPROVED: APRIL 2011 _______________________________ Professor M. S. Fofana, Major Advisor Mechanical Engineering Department Abstract Machining is an important manufacturing process that is used in a wide range of applications. From aerospace applications to the manufacturing of energy systems and medical robots, we see a major reliance on machining. In this project we focus on gaining an improved understanding of the mechanics of machining and the different factors that contribute to part quality. We acquired primary machine shop skills that provided us an opportunity to mill and drill a class of components to specified dimensions and tolerances. For each component, we created a detailed engineering working drawing that helped to shape and construct all the operations and procedures that must be undertaken and controlled to attain component machining without any breakdown or failure. Through hands-on machining, we discovered many different factors involved in milling, drilling, and the effects they exhibited on the tolerance and surface finish of a part. The main relevant factors that we examined were tool selection, speeds, feeds, and material selection. The extent to which these factors can influence machining is presented. The MQP project establishes new ways to systematically perform machining in a safe and stable manner without impacting the quality of the surface finish. i Table of Contents Abstract .......................................................................................................................................................... i Table of Contents .......................................................................................................................................... ii List of Figures ............................................................................................................................................... v List of Tables ................................................................................................................................................ vi List of Equations ........................................................................................................................................... vi Acknowledgements ..................................................................................................................................... vii Chapter 1: Background ................................................................................................................................. 1 Introduction ............................................................................................................................................... 1 1.1 What Is Machining? ............................................................................................................................ 1 1.2 The Origins of Cutting ........................................................................................................................ 3 The Origins of Grinding ............................................................................................................................ 4 1.3 The Origins of Turning ....................................................................................................................... 5 1.4 The Origins of Milling ........................................................................................................................ 7 1.5 The Origins of Drilling ....................................................................................................................... 9 1.6 Machining and Industrialization ....................................................................................................... 12 1.6.1 Pre- and Post-Modern Machining: A Basic Comparison ........................................................... 12 1.6.2 The First Industrial Revolution .................................................................................................. 13 1.6.3 The Second Industrial Revolution .............................................................................................. 14 1.7 Numerical Control ............................................................................................................................ 15 1.7.1 Role of MIT Servomechanisms Laboratory and Parson`s Vision .............................................. 15 1.7.2 RS-274D .................................................................................................................................... 17 1.8 Integration and Importance of Computer Systems............................................................................ 18 1.8.1 Computer Numerical Control ..................................................................................................... 18 1.8.2 Open- and Closed-Loop Machining ........................................................................................... 18 Chapter 2: Overview of the CNC Machining Process ................................................................................ 20 Introduction ............................................................................................................................................. 20 2.1 Importance ........................................................................................................................................ 21 2.2 Machining Operations ....................................................................................................................... 23 2.2.1 Milling ........................................................................................................................................ 23 ii 2.2.2 Drilling ....................................................................................................................................... 24 2.2.3 Turning ....................................................................................................................................... 25 2.3 Tooling .............................................................................................................................................. 25 2.3.1 Work Piece Alignment ............................................................................................................... 25 2.3.2 Tool Holders and Tool Selection ............................................................................................... 27 2.3.3 Cutting tools ............................................................................................................................... 28 2.3.4 End Mills .................................................................................................................................... 29 2.3.5 Face Mills ................................................................................................................................... 30 Twist Drills ............................................................................................................................................. 31 2.4 Analysis............................................................................................................................................. 32 2.4.1 Tolerance .................................................................................................................................... 32 2.5 Fits .................................................................................................................................................... 33 2.5.1 Forced Fits ................................................................................................................................. 34 2.5.2 Standard Fits .............................................................................................................................. 35 2.5.3 Running and Sliding Fits (RC): ................................................................................................. 35 2.5.4 Locational Fits (LC, LT, LN): ................................................................................................... 36 2.5.5 Force Fits (FN): .......................................................................................................................... 36 2.6 Surface Finish ................................................................................................................................... 36 2.6.1 Overview .................................................................................................................................... 36 2.6.2 Recognizing Surface Finish ....................................................................................................... 39 2.6.3 Factors Effecting Surface Finish ................................................................................................ 41 2.6.4 Terminology and Standards of Surface Finish: .......................................................................... 43 2.7Tool Chatter ....................................................................................................................................... 46 2.7.1 Methods of Surface
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