Turning Lathe, Milling and 3D Printing - Their Technical aspects.
Hello everyone, coming from a business background with my father in my childhood, i was closely associated with metals like Led, Aluminum etc and their processing into sheets, bars, Battery plates etc. Recently i was reading about Lathe, cutting tools and came across this software called Fusion 360 especially the CAM module which literally helped me to visualize the physical machine before being implemented. I will also touch base on the different methods like Turning, Milling and 3D printing. Lets go !!
Turning Lathe.
Basically, there are only four parts involved?in turning:
Generic lathes works based on Cartesian coordinates which basically contains the X, Y and Z axis. There is also the 4th co-ordinates the tangential ones which are on newer models.
The stock can be chipped, from "Outside-in" (External Machining) and "inside-out" (Internal machining).
Cutting Speed can be calculated using the formula:
Vc = Cutting Speed is the speed between the cutting tool and the surface being cut.
n = number of revolutions per time unit of the Chuck.
D = Diameter of the Stock in mm.
Cutting Power can be calculated using the formula:
Pc = Cutting Power measured in kW.
Vc = Cutting speed measured in meters per minute.
ap = cutting depth measured in mm.
fn = feed step in mm/rev.
Kc = cutting force in MegaPascal. This varies per material and is a constant.
Tool Surfaces:
There are three parts to the cutting material normally.
Different cutting tools can be used for different requirements. The table below shows the nose angle, tool usage.
As seen, the Round cutting tool can be used to make deep cuts but not so smooth finishing due to their low profile and finishing capabilities. While The V Rhombus shape is used for finishing and smooth profiling needs. Trigon can form a sweet spot.
Fusion 360 Software:
This software, really made my eye brows rise when i first read about it. How cool is it to visualize our Lathing needs.
The CAM(Computer Aided Manufacturing) module is what supports the visualization of the Lathing needs.
Using it, we can
Coroplus - An add on module to access thousands of tools, use it to calculate cutting parameters and more. It is licensed.
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There are more technical aspects like
This all can be done visually using the tool which i was impressed.
Milling
This is the type of cutting, to incorporate different geometric shapes.
2 co-ordinates are common.
Pc=?is the cutting power and is expressed in?kilowatts?(kW).
ap=?is the axial cutting depth and is expressed in?millimeters?(mm).
ae=?is the radial cutting depth and is measured in?millimeters?(mm).
Vf =?is the table feed value; it is expressed in?millimeters per minute?(mm/min)
Kc = is a parameter related to the material we are cutting
Milling operations can be categorized into five main categories
3D Printing.
3D Printing also called additive manufacturing, is a method contrast to lathing where the object is produced by removing material, here the objects are built by adding material.
Pros:
Cons:
Main thing is Scalability.
Over time, the traditional products can be re-used and the production cost will reduce over time. But for 3D printing, the cost remains stagnant.
There are different types of 3D Printing.
Fused Deposition modelling(FDM)
Material is supplied via large spool and supplied to a hot extruder which melts the material and deposits to build the product.
2. Stereolithography.
3. Selective Laser Sintering.
Summary:
Overall, i am impressed with the Fusion360 software tool. Was able to get into the technical aspects of turn lathing, milling and 3D printing. In the future if i get to work on an industry with a licensed version, am sure it will be fun to work with.
Hope this article was helpful in some way !