PPTS LAB ASSIGNMENT 7

Conventional machining or traditional machining is cutting processes which

remove the material from the various surface of a work piece by producing chips.
The machine tools, such as lathes, milling machines, drill presses, or others, are
used with a sharp cutting tool to remove material to achieve a desired
geometry [1]. Conventional machining includes turning, boring, drilling, milling,
broaching, sawing and so much many more.
Today, as the manufacturing technology changing rapidly, the demands on the
better quality on the hardened part are increasing. Historically, grinding is more
preferred as a method to machine hardened materials with high hardness for the
final machining operation [2–6]. However, by the emergence of tool materials that
have ultimate hardness, such as ceramic and cubic boron nitride (CBN) tools, has
made it possible to circumvent the traditional machining practice for hardened
steel
Quick Comparison of Rapid Tooling vs Conventional Tooling

Rapid Tooling Conventional Tooling

Rapid tooling uses specialized Conventional tooling uses traditional

equipment and techniques to methods and master patterns to make
Definition
create prototypes and low-volume molds, dies, and many other tooling
production parts quickly. parts through various steps.

Costs Low costs Very expensive

Customization More customization Less customization

Quality High quality Higher quality

Accuracy Low accuracy Higher accuracy

 Material Choices Flexible material choices Traditional materials only

Applicable
Short-run production Mass production
Project Stage

Manufacturing
Modern Traditional
Method Type

Multi tooling

A multi-tooling setup in conventional machining involves the strategic use of multiple cutting tools in a
single machine setup to improve efficiency and reduce downtime. Here’s a detailed explanation:

### 1. *Definition and Purpose*

- *Multi-Tooling Setup*: This involves integrating several cutting tools in one machining operation,
allowing for sequential or simultaneous use without needing to stop the machine for tool changes.

- *Purpose*: The primary goals are to reduce setup times, increase productivity, enhance precision, and
ensure consistency in the production process.

### 2. *Types of Multi-Tooling Setups*

#### *a. Turret Tool Post*

- *Common in Lathes*: A turret tool post can hold multiple tools and index them into position as
needed, allowing for rapid tool changes.

- *Application*: Ideal for turning operations where different cutting tools (e.g., turning tools, boring bars,
parting tools) are required in quick succession.

#### *b. Tool Carousels or Magazines*

- *Used in Milling Machines*: These devices can hold a variety of tools and automatically change them
as programmed.

- *Application*: Useful in milling operations where different tools (e.g., end mills, drill bits, reamers) are
required.

#### *c. Quick-Change Tool Holders*

- *Versatile Setup*: These allow for rapid manual tool changes, reducing downtime between operations.

- *Application*: Suitable for both lathes and milling machines where quick manual intervention is
acceptable.

### 3. *Advantages of Multi-Tooling Setups*

- *Increased Efficiency*: Reduces machine downtime associated with manual tool changes.

- *Higher Precision*: Maintains better alignment and positioning accuracy by minimizing the number of
times a workpiece is repositioned.

- *Improved Productivity*: Enables continuous operation, increasing the number of parts produced in a
given time.

- *Enhanced Flexibility*: Allows for complex machining operations to be performed in a single setup,
reducing the need for multiple machine setups.

### 4. *Considerations for Implementation*

- *Machine Compatibility*: Ensure that the machine can accommodate a multi-tool setup, considering
factors like spindle power, rigidity, and control capabilities.

- *Tool Selection*: Choose tools that complement each other and the operations to be performed.

- *Programming*: For CNC machines, ensure the program is optimized for tool changes and sequences
to minimize non-productive time.

- *Maintenance*: Regularly inspect and maintain tools and tool holders to ensure optimal performance
and longevity.

### 5. *Examples of Applications*

- *Automotive Industry*: Production of complex parts requiring multiple machining operations (e.g.,
engine components).

- *Aerospace Industry*: High-precision components that necessitate multiple tool changes for milling,
drilling, and finishing operations.

- *General Manufacturing*: Any production environment where reducing cycle times and improving
efficiency are critical.

By integrating a multi-tooling setup, manufacturers can achieve significant improvements in machining

efficiency, precision, and overall productivity.

New tooling and tools for commonly machine surfaces

Advancements in tooling methods and the introduction of new tools have significantly enhanced the
capabilities of conventional machining processes. Here’s an in-depth look at the latest tools and methods
used for machining surfaces:

### 1. *Advanced Cutting Tools*

#### *a. Carbide Tools*

- *Material*: Tungsten carbide tools offer high hardness and heat resistance, making them ideal for high-
speed machining.

- *Applications*: Used for turning, milling, and drilling operations on hard materials like stainless steel
and titanium.

#### *b. Ceramic Tools*

- *Material*: Made from ceramic materials like alumina and silicon nitride, these tools can withstand
extremely high temperatures.

- *Applications*: Suitable for high-speed machining of hard and abrasive materials where carbide tools
may wear quickly.
#### *c. Coated Tools*

- *Coatings*: Tools coated with materials such as Titanium Nitride (TiN), Titanium Carbonitride (TiCN),
and Diamond-Like Carbon (DLC) enhance wear resistance and reduce friction.

- *Applications*: Extend tool life and improve surface finish in turning, milling, and drilling operations.

#### *d. Polycrystalline Diamond (PCD) Tools*

- *Material*: PCD tools provide superior hardness and wear resistance.

- *Applications*: Ideal for machining non-ferrous metals, composites, and abrasive materials.

### 2. *Innovative Tooling Methods*

#### *a. High-Speed Machining (HSM)*

- *Technique*: Involves using higher spindle speeds and feed rates to increase productivity and improve
surface finish.

- *Advantages*: Reduces cycle times and enhances the quality of the machined surface.

#### *b. High-Performance Machining (HPM)*

- *Technique*: Combines high-speed machining with optimized cutting parameters and advanced tooling
to maximize material removal rates.

- *Advantages*: Enhances efficiency and reduces tool wear.

#### *c. Cryogenic Machining*

- *Technique*: Uses liquid nitrogen or carbon dioxide to cool the cutting tool and workpiece.

- *Advantages*: Extends tool life, improves surface finish, and reduces the need for conventional
coolants.

#### *d. Minimum Quantity Lubrication (MQL)*

- *Technique*: Delivers a small amount of lubricant directly to the cutting zone, minimizing the use of
traditional coolants.
- *Advantages*: Reduces environmental impact, improves surface finish, and enhances tool life.

### 3. *Tool Holding and Fixturing*

#### *a. Hydraulic Chucks*

- *Technique*: Uses hydraulic pressure to clamp the tool, providing excellent grip and concentricity.

- *Advantages*: Reduces runout and improves surface finish.

#### *b. Shrink Fit Holders*

- *Technique*: Uses thermal expansion to grip the tool tightly.

- *Advantages*: Provides high precision and stability, enhancing the quality of the machined surface.

#### *c. Modular Fixturing Systems*

- *Technique*: Uses interchangeable components to create flexible and repeatable setups.

- *Advantages*: Reduces setup time and improves accuracy.

### 4. *Surface Finishing Techniques*

#### *a. Burnishing Tools*

- *Technique*: Uses a hard, polished tool to plastically deform the surface, creating a smooth finish.

- *Advantages*: Improves surface finish and hardness without removing material.

#### *b. Superfinishing*

- *Technique*: Involves using fine abrasive stones or tapes to achieve a mirror-like surface finish.

- *Advantages*: Reduces surface roughness and improves part performance.

#### *c. Vibratory Finishing*

- *Technique*: Uses a vibrating container filled with abrasive media to polish and deburr parts.

- *Advantages*: Provides consistent and uniform surface finishes.

### 5. *Monitoring and Control Technologies*

#### *a. Tool Condition Monitoring (TCM)*

- *Technique*: Uses sensors and software to monitor tool wear and predict tool life.

- *Advantages*: Enhances tool management, reduces downtime, and ensures consistent surface quality.

#### *b. Adaptive Control*

- *Technique*: Adjusts machining parameters in real-time based on sensor feedback.

- *Advantages*: Optimizes cutting conditions, improves surface finish, and extends tool life.

### Conclusion

The integration of these advanced tools and innovative tooling methods in conventional machining
processes can significantly enhance productivity, precision, and surface finish. By leveraging these
technologies, manufacturers can achieve higher quality and more efficient machining operations