How Plastic Deformation Makes Machining Possible

March 15, 2012

If steel did not have the property of plastic deformation, the only ways to make parts from it would be casting  or cutting into shape.

No deformation processes like cold heading, cold rolling, swaging etc. would be possible.

Slip planes in the metallic crystal explain Plastic Deformation and Plasticity in Steel. This makes cold working processes like cold drawing possible.

If one subjects a piece of steel to a heavy load, the material will measurably stretch. When the load is removed, if the steel goes back to its original dimension, the deformation that it underwent when the weight was applied is called “elastic deformation.” In this case, the steel did not take a permanent “set.”

If one subjects a piece of steel to a much greater load, if, when the load is removed, the steel does not ‘spring back’ or recover to its original dimension, the new shape or dimension is a permanent deformation. (It is often said to have ‘taken a set,’)  This is called “Plastic Deformation.”

Plastic Deformation is explained by the movement of planes of atoms from their normal positions.

Steel and most industrially useful metals are able to withstand a great deal of this Plastic Deformation before they break.

Brittle metals will just fracture under such loads;

Cold drawing of steel is a process that applies a load to the metal to make the atoms in the steel take new positions with respect to each other, resulting in lowered ductility, increased  tensile and yield strength and new dimensions or shape. These in turn, are often helpful in improving the machinability of the steel, allowing you to more economically produce the parts and components that are essential for our current technologies.

Most people think of steel’s hardness as its main advantage. The facts of the matter are that it is steel’s plasticity or ability to plastically deform that makes it such a useful and versatile material for humankind.


Three Key Factors to Understand Machinability of Carbon and Alloy Steel

March 13, 2012

The machinability of steel bars is determined by three primary factors. Those factors are 1) Cold Work; 2) Thermal Treatment; 3) Chemical Composition.

Machinability is the result of Cold Work, Thermal Processing and Chemical composition- as well as the ability of the machine tool and the machinist.

Cold Work improves the machinability of low carbon steels by reducing the high ductility of the hot rolled product. Cold working the steel by die drawing or cold rolling results in chips that are harder, more brittle, and curled, prodcuing less built up edge on the tools cutting edge.. The improved Yield to Tensile Strength ratio means that your tools and machines have less work to do to get the chip to separate. Steels between 0.15- 0.30 wt% carbon are best machining; above 0.30 wt% the machinability decreases as carbon content (and hardness) increase.

Thermal Treatment improves the machinability of steel by reducing stresses, controlling microstructure, and lowering hardness and strength. While this is usually employed in higher carbon steels, sometimes a Spheroidize Anneal is employed in very low carbon steels to improve their formability. Stress Relief Anneal, Lamellar Pearlitic Anneal, and Spheroidize Anneals are the treatments applied to improve machinability in bar steels for machining.

Chemical composition is a major factor that contributes to the steel’s machinability or lack thereof. There are a number of chemical factors that promote machinability including

Carbon- low carbon steels are too ductile, resulting in gummy chips and the build up of workpiece material on the tool edge (BUE). Between 0.15 and 0.30 wt% carbon machinability is at its best; machinability decreases as carbon content increases beyond 0.30.

Additives that promote machining include

  • Sulfur combines with Manganese to form Manganese Sulfides which help the chip to break and improve surface finish.
  • Lead is added to steel to reduce friction during cutting by providing an internal lubricant. Lead does not alter the mechanical properties of the steel.
  • Phosphorus increases the strength of the softer ferrite phase in the steel, resulting in a harder and stronger chip (less ductile) promoting breakage and improved finishes.
  • Nitrogen can promote a brittle chip as well, making it especially beneificial to internal machining operations like drilling and tapping which constrain the chip’s movement.
  • (Nitrogen also can make the steel unsuitable for subnsequent cold working operations like thread rolling, crimping, swaging or staking.)

Additives that can have a detrimental effect on machining include deoxidizers and grain refiners.

Deoxidizing and grain refining elements include

  • Silicon,
  • Aluminum,
  • Vanadium
  • Niobium

These elements reduce machinability by promoting a finer grain structure and increasing the edge breakdown on the tool by abrasion.

Alloying elements can be said to inhibit machinability by their contribution to microstructure and properties, but this is of small impact compared to the factors listed above.


What Is The Most Expensive Training In The World?

February 23, 2012

No training at all!

The money saved by not training won’t begin to cover the direct and indirect costs of failing to train, let alone actual damages, consequential damages, potential liability, and possible loss of customers or even the business itself.

What is your training budget this year?

How does it compare to your cost of claims last year?

Your cost of expedited shipping?

Photo courtesy FlightGlobal


Machinery’s Handbook-29th Edition of the Machinist’s Bible

February 21, 2012

Authoritative. Comprehensive. Invaluable. Practical. Updated.

Updated?

29th Edition of Machinery's Handbook now available.

I have relied on my 20th Edition copy since I entered the metalworking industry as a supervisor in the early 1980′s. It has served me well through the years, and while respectfully used, is showing evidence of ‘serious use’- missing thumb tabs, dust jacket in tatters, a host of bookmarks…

Here are 5 reasons why I’ll probably upgrade to the new 29th Edition:

  • New sections added on Micromachining, Statistics, and Calculating Thread Dimensions;
  • Expanded Metric content. The jobs we see in our shops today are increasingly metric as we serve a growing global market;
  • Easier to use- they have added tables of contents at the beginning of each section;
  • Extensive revisions to key sections including Mathematics, Gaging and  Dimensioning,  and Machining Operations
  • It has been re-typeset (including tables and equations) and many figures redrawn.

Now the problem for me is choice: Do I get the ‘regular edition’ to replace augment my current 20th edition handbook? Do I jump into the electronic age with the CD version? Or do I acknowledge I no longer have the eyes of a younger man and buy the “larger print” edition?

It’s time for me to buy. My investment in the 20th Edition sure paid off. How about you?

Which  would you  choose? What other books have you found critical to your practice in our precision metalworking field?

Machinery’s Handbook 29th Edition can be purchased direct from Industrial Press.


Cell Phone Ban-FAQ’s Posted

February 16, 2012

The FMCSA has posted an FAQ page about the ban on hand held cellular phones by commercial motor vehicle  (CMV) drivers.

Multitasking is against the law.

When you are at the wheel, driving safely should be your only focus.”

Here are some highlights:

Are holders of a commercial driver’s license (CDL) subject to the regulation only when driving a CMV, as defined in 49 CFR 383.5, or any vehicle?

CDL holders are subject to the Federal rule only when driving a CMV.

What is required of the employer in terms of company policy or training?

The rule does not require motor carriers to establish written policies in terms of company policy or training programs for their drivers.   However, employers are prohibited from allowing or requiring their drivers to use hand-held mobile phones.  A motor carrier may establish policies or practices that make it clear that the employer does not require or allow hand-held mobile telephone use while driving a CMV in interstate commerce.   The carrier is responsible for its drivers’ conduct.

“In the minutes before the 5:14 a.m. crash, the driver made three phone calls, the last one at 5:14.”

Is dialing a phone number allowed under this rule?

No. Dialing a mobile telephone while operating a CMV in interstate commerce is prohibited by the rule.  A driver can initiate, answer, or terminate a call by touching a single button on a mobile telephone, earpiece, steering wheel, or instrument panel – comparable to using vehicle controls or instrument panel functions, such as the radio or climate control system.

Can a driver reach for a mobile telephone even if he/she intends to use the hands-free function?

No. In order to comply with this rule, a driver must have his or her mobile telephone located where the driver is able to initiate, answer, or terminate a call by touching a single button while the driver is in the seated driving position and properly restrained by a seat belt.  If the mobile telephone is not close to the driver and operable while the driver is restrained by properly installed and adjusted seat belts, then the driver is considered to be reaching for the mobile phone, which is prohibited by the rule.

For all the FAQ’s click FMCSA_FAQ

Here is the  Mobile Phone Ban final rule (PDF)

11 People Killed Truck Crash Photo


5C Collets Are Cool- Somma Tool

February 15, 2012

In order to machine precision parts, you need to first hold the workpiece securely, accurately and precisely. 5C collets do just that.

5C collets are the result of 100 years of continuous improvement.

Work can be held using methods other than collets- 3 and 4 jaw chucks come to mind, as well as vises-  but for continuous high volume work with barstock, collets are ideal.

Here are 7 reasons Somma Tool says 5C collets are cool:

  • Collets are easier (and faster!) to set up than chucks.
  • Collets are more concentric. With chucks, tolerances stack up degrading concentricity.
  • Collets more affordably provide higher precision.
  • Collets more affordably provide higher accuracy.
  • Collets provide high holding force. As the collet is pulled axially into the bushing, the tapered sides compress radially generating static friction (holding force).
  • Collets are versatile- they can be made to hold over capacity stock; they can have steps built in; come in extra long sizes as well as have internal stops.
  • Emergency collets are available that can be custom bored to your exact need.

Hardinge invented the 5C collet back in 1901. It became a preferred choice for precision workholding in lathes, mills and grinders. Exacting standards, special alloy steel, heat treatment and spring tempering combine to assure accuracy and durability at low cost. The 5C collet became an industry standard. 5C collets range from 0.5 mm (thats 0.0196″ ) capacity to 1-1/16″  round; 5C collets hold up to 3/4″ square and and 29/32″ hex.

PMPA member Somma Tool sells 5C collets from Hardinge.

Thanks to Matt at Somma and Tom at Hardinge  for teaching this ‘steel guy’  7 reasons why 5C collets are cool.


2012 Top Shop Survey – Free Tool You Can Use

January 25, 2012

Is  there a swiss type machine in your future? How would you know?

Last year’s Top Shops Survey found that 24% of  the top tier (top 10%) of shops reporting in the survey reported Swiss technology in their shops. This compared to just 11% for the balance of shops reporting.  This is a trend that you probably ought to be following if you want to stay up to date on trends in precision machining.

Last year Modern Machine Shop launched its first annual Top Shops Survey. Almost 200 machining facilities took part in that benchmarking survey. The Top Shops Report of that survey’s results had a number of interesting shopfloor practices worth considering. The report also provided a number of operational and business metrics which can help a shop your shop stay competitive and become a better business.

Well worth a few minutes of your time.

The survey will be available until February 15th, so click the link to  go to Modern Machine Shop’s description of the survey which includes a link to the online survey site. TOP SHOP ARTICLE

Direct link to Survey.

PMPA co-publishes Production Machining Magazine in partnership with Gardner Publications in Cincinnatti Ohio. Production Machining focuses on our high precision, high mix, production industry.  Gardner’s flagship publication is Modern Machine Shop- which covers the broader contract machining industry.

The survey will only be posted for a short time, so now is the time to benchmark to your peers.


Why We Have PPE And Machine Guards

January 3, 2012

Here is a safety lesson learned from one of my Facebook Friends.

So the lesson today is……Don’t take off the guard on the giant belt sander and then adjust the belt half off the guide and then duct tape it in place so you can grind that knife “Juuuuuuuus riiiight”

Another lesson is ”PPE saves your eyesight.”

Faceshield and ANSI approved Safety Glasses

Thanks for sharing ScaryDave.


Resources: Why You Should Build Your Career in Manufacturing

December 29, 2011

Why should you consider a career in manufacturing?

Wall Street Journal: Industry Puts Heat On Schools
What the Shortage of Workers Means for Business
The Christian Science Monitor: Manufacturing Needs Workers Poll Data From the Alliance for American Manufacturing
Human Resource Executive: Filling Manufacturing Skill Gaps

My colleague Ryan Pohl at Change the Perception put this together.

Thanks Ryan. You should write more.


Drivers of CMVs: Restricting the Use of Cellular Phones

December 21, 2011

The DOT has just finalized a rule restricting mobile phone use by drivers of commercial motor vehicles (CMV’s). The new rule goes into effect Jan 3, 2012. The rule restricts CMV drivers from reaching for or holding mobile telephones while operating their vehicles, or pushing more than one button to operate the device.

What's the problem?

This rule, which goes into effect on January 3, 2012, was adopted by the Federal Motor Carrier Safety Administration and the Pipeline and Hazardous Materials Safety Administration, which are part of the Department of Transportation. It amends both Federal Motor Carrier Safety regulations and Hazardous Materials regulations. The rule restricts CMV drivers from reaching for or holding mobile telephones while operating their vehicles, or pushing more than one button to operate the device.

The popular Push-To-Talk (PTT) feature used by many drivers is prohibited by this new rule. While, functionally, the PTT feature is similar to the use of a CB or two-way radio (neither of which is addressed by the new rule and therefore still permissible), the final rule advises that PTT is prohibited because the device used for PTT comes squarely within the definition of a mobile telephone prohibited by the rule, and it also requires the driver or user to hold it and push a button more than once. Therefore, its use while driving a CMV is the same as that of a hand-held mobile telephone and is prohibited.

Exception: Emergencies. Using a hand-held mobile telephone is permissible by drivers of a CMV when necessary to communicate with law enforcement officials or other emergency services.

Bottom line, your driver is still OK to use the CB but using the cell phone to get back to you while driving is verboten.

More information: Fisher Phillips

King of multitasking photo

http://www.fmcsa.dot.gov/rules-regulations/administration/rulemakings/proposed/Mobile_phone_NPRM.pdf


Follow

Get every new post delivered to your Inbox.