Composite Materials and Machining Techniques

Machine tools that use a master form or model to create copies of the desired shape.

A device that guides the cutting tool of a tracer controlled machine tool, following the contours of a master model.

The master form used to create the desired shape in a tracer controlled machine tool. It can be a previously machined part or a template.

A type of tracer controlled machine tool that can copy both internal and external profiles in three dimensions.

A type of tracer controlled machine tool that can copy profiles in two dimensions.

A simple form of copying device used for cutting straight line tapers on a lathe.

A composite material consisting of hollow spherical inclusions filled with gas in a polymer or metal matrix.

Mechanical copying machines are used to replicate complex shapes, especially on small parts or templates, where precision within 0.1-0.2 mm is needed.

The master shape or design is called the 'former' and the workpiece being machined is called the 'work'.

The cutter is the tool that removes material from the work, while the follower is connected to the former and guides the cutter.

The cutter and follower head can move in two directions: X (horizontal) and Y (vertical), enabling the machine to copy complex three-dimensional shapes.

The work and the former are secured to the work-table, and their relative positions can be adjusted for accurate copying.

The work-table can move horizontally (YY) along the bed ways, while the cutter head moves vertically (XX) to follow the contour of the former.

A spring, compressed air, hydraulic cylinder, or deadweight can be used to keep the follower in constant contact with the former, ensuring accurate copying.

By moving either the work-table or the cutter head, the machine can copy different sections of the former accurately.

The ability of the cutter and follower head to move vertically allows the machine to copy three-dimensional shapes, creating complex contours.

The ratio of the cutter movement to the tracer movement, determined by the pantograph's link adjustments.

A device that holds and moves the cutting tool in a pantograph system.

A fixed point on the pantograph that serves as a pivot for the entire system.

The part of the pantograph that connects the cutter and the pivot point.

The part of the pantograph that connects the tracer and the pivot point.

A mechanism within the pantograph that ensures arms CA and TB remain parallel.

The process of creating a scaled-up or scaled-down copy of a master form using a pantograph.

A type of pantograph system that allows for creating three-dimensional copies.

A type of machine that uses a template to guide the cutting tool, enabling it to create accurate copies of a desired shape.

A mechanical tracer device that uses a template instead of a straight guide bar, similar to a taper-turning attachment.

The point of contact between the template and the stylus in a mechanically controlled tracer machine.

A machine that creates precise copies of objects by using a template and a tracer.

A template with a specific shape used to guide the cutting tool in a tracer machine.

A specialized control system that amplifies a small input signal to produce a larger output force.

A system in which a stylus following a master form transmits signals to a hydraulic unit, which then moves the cutting tool.

The primary advantage of non-mechanical tracing systems like hydraulic and electrical tracing.

The key benefit of using low pressure on the template in hydraulic tracing systems.

The principle of operation in a simple hydraulic circuit for a tracer controlled milling machine.

A hydraulic tracer-controlled milling machine uses a stylus to follow a template, which in turn controls the movement of a cutting tool, allowing for the reproduction of complex shapes on a workpiece.

The tracer valve is a crucial component that directs the flow of oil to the actuating cylinder, causing the spindle head to move up and down in response to the stylus's movements. This allows the machine to accurately follow the contours of the template.

Oil pressure is essential for powering the actuating cylinder, which moves the spindle head up and down to recreate the shape of the template. The pump delivers oil under pressure, allowing for precise control over the cutting tool's movement.

The tracer controlled milling machine can achieve a high degree of precision, with a tracing efficiency as low as 0.01 or 0.02 mm, ensuring accurate reproduction of the template's shape on the workpiece.

The system's efficiency is measured as the difference between the spindle's movement and the template's dimensions. A lower number indicates higher accuracy, as the system can closely replicate the desired shape.

A machine tool that follows a master form to create copies of the desired shape using a tracer.

The process of using a master form to guide a cutter, enabling the machine to produce accurate copies of the shape. It's like using stencils to reproduce patterns.

Systems that use a master form to create copies of the desired shape, but instead of direct mechanical contact, a stylus and electronic signals control the tool's movement.

A system where a scanner directly follows line drawings instead of physical templates, often using conductive ink to trace the lines.

The system is valuable because it's simple and reliable, despite its limitations.

The machine can either move the head down constantly while the column moves in steps or vice versa, creating a series of ridges and hollows.

Duplicators can copy both internal and external profiles in three dimensions while profilers copy only profiles in two dimensions.

A tracer controlled lathe uses a template to guide the cutting tool, while a manually operated lathe requires the operator to manually control the tool.

Both tracer controlled and numerically controlled lathes are automated but tracer controlled lathes use a master template while numerically controlled lathes use programmed instructions.

Tracer control uses a physical template to guide the cutting tool, while numerical control uses a program of instructions.

Mechanical copying machines are used to copy shapes and patterns using a tracer that follows a master form, replicating the profile on the workpiece.

The pantograph machine utilizes a system of levers and linkages to create scaled copies of a master form while maintaining the proportions and shape of the original.

A 3D system allows for copying shapes with a depth dimension, while a 2D system only allows for copying profiles in one plane.

The tracing system in a machine tool uses a tracer (usually a stylus) to follow a master form, translating the movements to guide the cutting tool and create a replica of the master form.

Fibers that are arranged in a continuous and aligned way, providing high strength in one direction. Think of how threads in a fabric run parallel for strength.

Fibers that are discontinuous and arranged in a straight line, offering a balance of strength and flexibility. Picture small pieces of wood stacked neatly.

Fibers that are continuous but randomly oriented, providing strength in all directions. Think of a net with randomly interwoven strands.

A type of synthetic fiber known for its exceptional strength and lightweight nature, often used in bulletproof vests, cables, and even space vehicles.

Materials made by combining two or more distinct components to achieve superior properties. Think of how concrete is stronger with steel reinforcement.

A category of composites where the main material is a polymer, like plastic. This type is often used in car parts, aircraft components, or even sports equipment.

Composites where the primary constituent is a metal, like aluminum or steel, providing high strength and heat resistance. They are often used in aerospace, automotive, or tooling applications.

Composites with a ceramic matrix, offering excellent heat resistance and durability. These are used in high-temperature applications like heat shields or engine components.

A key component of a composite. It acts as a binder, holding the reinforcement together and providing overall structural integrity. Think of the 'glue' in a composite material.

These components are added to composites to enhance specific qualities like strength, durability, or appearance. They are often used to improve the composite's overall performance.

The stylus, in following the template form, moves downward, causing ports b and d of the tracer valve to open. This allows oil from the pump to enter the headend of the hydraulic cylinder, forcing the piston and spindle head to move downward and reproduce the template shape on the workpiece.

When the stylus moves upward, ports a and c of the tracer valve open. Oil from the pump enters the rod end of the actuating cylinder, pushing the piston and spindle head upward, following the template's contour. This movement continues until the ports a and c are closed by the valve body, mirroring the upward movement of the stylus.

The tracing efficiency measures the difference between the spindle's movement and the template's dimensions. A lower number indicates higher accuracy, as the system closely replicates the desired shape. For example, a tracing efficiency of 0.01 mm means the spindle's movement deviates from the template by only 0.01 mm, resulting in very precise copying.

Hydraulic tracing systems offer precision and control, enabling accurate reproduction of intricate shapes. This system is particularly advantageous for copying complex templates or small parts requiring high precision.

This refers to a machine tool that utilizes a tracing device to follow a template or master model, guiding the cutting tool to create precise copies of the desired shape. The system ensures accuracy and efficiency in replicating intricate designs.

A control system that amplifies a small input force or signal to produce a larger output force or signal, often used in hydraulic tracing systems to control the movement of the cutting tool.

The stylus in a hydraulic tracing system follows the master form, continuously sending signals to the hydraulic unit, which then moves the cutting tool to create an exact replica of the master form.

The chief advantage of hydraulic or electrical tracing systems over mechanical tracing systems, as it eliminates the cutting force influencing the contact between the stylus and the template, allowing for lighter contact pressure and smoother movement.

In hydraulic tracing, the reduced contact pressure on the template allows for tracing steep transitions and contours at higher speeds and feeds, enabling the use of inexpensive materials for templates.

A mechanical contouring device on a lathe that uses a template instead of a straight guide bar to create complex shapes, similar to a taper turning attachment.

A pantograph die-sinking and engraving machine consists of two tables, a copy table holding the template and a work table for the workpiece, with movements controlled by screws and sleeves.

The contact between the stylus and the template in a mechanically controlled tracer machine is crucial for accurate copying, as it ensures proper guidance of the cutting tool.

The system in a tracer-controlled machine where the stylus follows a master form, and the machine translates those movements to control the cutting tool, replicating the shape onto the workpiece.

The form of the cutter in a pantograph die-sinking and engraving machine determines the shape of the mold or cavity in the workpiece. This is the tool that cuts and creates the final shape.