1、中文 2692 字 附 录 Introduction to basic machining Mechanism of Surface Finish Production There are basically five mechanisms which contribute to the production of a surface which have been machined. There are: (1) The basic geometry of the cutting process. In, for example, single point turning the tool
2、will advance a constant distance axially per revolution of the work piece and the resultant surface will have on it, when viewed perpendicularly to the direction of tool feed motion, a series of cusps which will have a basic form which replicates the shape of the tool in cut. (2) The efficiency of t
3、he cutting operation. It has already been mentioned that cutting with unstable built-up-edges will produce a surface which contains hard built-up-edge fragments which will result in a degradation of the surface finish. It can also be demonstrated that cutting under adverse conditions such as apply w
4、hen using large feeds small rake angles and low cutting speeds, besides producing conditions whichcontinuous shear occurring in the shear zone, tearing takes place, discontinuous chips of uneven thickness are produced, and the resultant surface is poor. This situation is particularly noticeable when
5、 machining very ductile materials such as copper and aluminum. (3) The stability of the machine tool. Under some combinations of cutting conditions: work piece size , method of clamping, and cutting tool rigidity relative to the machine tool structure, instability can be set up in the tool which cau
6、ses it to vibrate. Under some conditions the vibration will built up and unless cutting is stopped considerable damage to both the cutting tool and work piece may occur. This phenomenon is known as chatter and in axial turning is characterized by long pitch helical bands on the work piece surface an
7、d short pitch undulations on the transient machined surface. (4) The effectiveness of removing sward. In discontinuous chip production machining, such as milling or turning of brittle materials, it is expected that the chip (sward) will leave the cutting zone either under gravity or with the assista
8、nce of a jet of cutting fluid and that they will not influence the cut surface in any way. However, when continuous chip production is evident, unless steps ate taken to control the swarf it is likely that it will impinge on the cut surface and mark it. Inevitably, this marking beside a looking unat
9、tractive, often results in a poorer surface finishing, (5) The effective clearance angle on the cutting tool. For certain geometries of minor cutting edge relief and clearance angles it is possible to cut on the major cutting edge and burnish on the minor cutting edge. This can produce a good surfac
10、e finish but, of course, it is strictly a combination of metal cutting and metal forming and is not to be recommended as a practical cutting method. However, due to cutting tool wear, these conditions occasionally arise and lead to a marked change in the surface characteristics. Surface Finishing an
11、d Dimensional Control Products that have been completed to their proper shape and size frequently require some type of surface finishing to enable than to satisfactorily fulfill their function. In some cases, tit is necessary to improve the physical properties of the surface material for resistance
12、to penetration or abrasion. In many manufacturing processes, the product surface is left with dirt, chips, grease, or other harmful material upon it. Assemblies that are made of different materials, or from the same materials processed in different manners, many require some special surface treatmen
13、t to provide uniformity of appearance. Surface finishing many sometimes become an intermediate step processing. For instance, cleaning and polishing are usually essential before any kind of plating process. Some of the cleaning procedures are also used for improving surface smoothness on mating part
14、s and for removing burrs and sharp corners, which might be harmful in later use. Another important need for surface finishing is for corrosion protection in a variety of environments. The type of protection procedure will depend largely upon the anticipated exposure, with due consideration to the ma
15、terial being protected and the economic factors involved. Satisfying the above objectives necessitates the use of main surface-finishing methods that involve chemical change of the surface mechanical work affecting surface properties, cleaning by a variety of methods, and the application of protecti
16、ve coatings, organic and metallic. In the early days of engineering, the mating of parts was achieved by machining one part as nearly as possible to the required size, machining the mating part nearly to size, and then completing its machining, continually offering the other part to it, until the de
17、sired relationship was obtained. If it was inconvenient to offer one par to the other part during machining, the final work was done at the bench by a fitter, who scraped the mating parts until the desired fit was obtained, the fitter therefore being a fitter in the literal sense. It is obvious that
18、 the two parts would have to remain together, and in the event of one having to be replaced, the fitting would have to be done all over again. I n these days, we expect to be able to purchase a replacement for a broken part, and for it to function correctly without the need for scraping and other fi
19、tting operations. When one part can be used off the shelf to replace another of the same dimension and material specification, the parts are said to be interchangeable. A system of interchangeability usually lowers the production costs as there is no need for an expensive, fiddling operation, and it
20、 benefits the customer in the event of the need to replace worn parts. Limits and Tolerances Machine parts are manufactured so they are interchangeable. In other words, each part of a machine or mechanism is made to a certain size and shape so it will fit into any other machine or mechanism of the s
21、ame type. To make the part interchangeable, each individual part must be made to a size that will fit the mating part in the correct way. It is not only impossible, but also impractical to make many parts to an exact size. This is because machines are not perfect, and the tools become worn. A slight
22、 variation from the exact size is always allowed. The amount of this variation depends on the kind of part being manufactured. For example, a part might be made 6 in. long with a variation allowed of 0.003(three thousandths) in. above and below this size. Therefore, the part could be 5.997 to 6.003
23、in. and still be the correct size. These are known as the limits. The difference between upper and lower limits is called the tolerance. A tolerance is the total permissible variation in the size of a part. The basic size is that size from which limits of size are derived by the application of allow
24、ances and tolerances. Sometimes the limit is allowed in only one direction. This is known as unilateral tolerance. Unilateral tolerancing is a system of dimensioning where the tolerance (that is variation) is shown I only one direction from the nominal size. Unilateral tolerancing allow the changing
25、 of tolerance on a hole or shaft without seriously affecting the fit. When the tolerance is in both directions from the basic size, it is known as a bilateral tolerance (plus and minus). Bilateral tolerancing is a system of dimensioning where the tolerance (that is variation) is split and is shown o
26、n either side of the nominal size. Limit dimensioning is a system of dimensioning where only the maximum and minimum dimensions are shown. Thus, the tolerance is the difference between these two dimensions. Introduction of Machining of: Machining as a shape-producing method is the most universally u
27、sed and the most important of all manufacturing processes. Machining is a shape-producing process in which a power-driven device causes material to be removed in chip form. Most machining is done with equipment that supports both the work piece and cutting tool although in some cases portable equipm
28、ent is used with unsupported work piece. Low setup cost for small quantities. Machining has two applications in manufacturing. For casting, forging, and pressworking, each specific shape to be produced, even one part, nearly always has a high tooling cost. The shapes that may be produced by welding
29、depend to a large degree on the shapes of raw material that are available. By making use of generally high cost equipment but without special tooling, it is possible, by machining, to start with nearly any form of raw material, so long as the exterior dimensions are great enough, and produce any des
30、ired shape from any material. Therefore, machining is usually the preferred method for producing one or a few parts, even when the design of the part would logically lead to casting, forging or pressworking if a high quantity were to be produced. Close accuracies, good finishes. The second applicati
31、on for machining is based on the high accuracies and surface finishes possible. Many of the parts machined in low quantities would be produced with lower but acceptable tolerances if produced I high quantities by some other process. On the other hand, many parts are given their general shapes by some high quantity deformation process and machined only on selected surfaces where high accuracies are needed. Internal threads, for example, are
