MACHINING OPERATIONS

 FACING:
Facing operation reduces the length of a workpiece and gives finish surface by
cutting to a depth along the length of the workpiece and moving the tool
perpendicular to the axis of the workpiece. Facing on a milling machine is the
process of cutting a flat surface perpendicular to the axes of the milling cutter. This
process removes the material by rotating the facing tool in the counterclockwise
direction as the table feeds the work piece across the cutter. Face milling can be
achieved with an end mill, but is often done with a face mill, shell mill or a fly
cutter. Face milling can be done in both manual machining and CNC machining.
  FACTORS:
Factors that affect the quality and effectiveness of facing operations on the mill
are speeds and feeds, material hardness, cutter size, and how the part is being
clamped down.

 ROUGHING:
The roughing operation in machining is primarily used to remove the bulk material
and to approximately shape the workpiece towards the finished form. The
manufacturing process described, utilizes a three-axis CNC machine with an
indexable fourth axis device that is used to hold and rotate the workpiece. A
finishing operation follows roughing and is used to achieve the final geometry and
surface finish. Programming rough machining operations for efficient removal of
large volumes of material is crucial when preparing a mold, pattern or other
workpiece for finish machining. However, the strategies for traditional roughing
operations, which are mainly based on rest roughing, require that each tool be
programmed separately.
  BORING:
Boring is an operation to enlarge and finish holes accurately. This may be done on
a lathe or a milling machine. It provides space for the head of a fastener, such as
bolt, to sit flush with the workpiece surface. A counter boring tool has a pilot on
the end to guide it straight into the existing hole.
Boring, also called internal turning. The original hole is made with a drill, or it
may be a cored hole in a casting. In this operation the work is in contact with a
single point tool. By Boring we achieves three things:
 Sizing: Boring brings the hole to the proper size and finish.
 Straightness: Boring will straighten the original drilled or cast hole.
 Concentricity: Boring will make the hole concentric with the outside
diameter within the limits of the accuracy of the chuck or holding device.

 DRILLING:
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool, often multi-
point. The bit is pressed against the work-piece and rotated at rates from hundreds
to thousands of revolutions per minute. This forces the cutting edge against the
work-piece, cutting off chips (swarf) from the hole as it is drilled. It is an
economical way of removing large amounts of metal to create semi-precision
round hole or cavity. It is used for last removal of stock on preparation for other
operations like boring, reaming, or tapping.
  CENTER DRILLING:
Center drilling is an operation used to drills a starting hole to accurately establish
its location for subsequent drilling with Centre drill which is A two-fluted tool
consisting of a twist drill with a 60° countersink; used to drill countersink center
holes.

 REAMING:
Reaming is a finishing operation that is performed with multi-edge tools which
provide high-precision holes. At a high penetration rate and small depth of cuts, a
superb hole quality, close dimensional tolerance and high surface finish are
achieved. The operation is performed with the help of reamers which are round
cutting tools that enlarge the size of existing holes.
The direction of rotation of the work spindle is of special importance for reaming.
When reaming, the workpiece must always rotate in opposite direction to the
cutting edges (clockwise rotation), also when the tool is retracted, since otherwise
the cutting edges would chip. The reaming technique always requires prior
machining of the hole to be reamed.
 Reaming offers the advantage that a greater number of holes can be produced with
consistently good quality. This requires a cutting tool (the reamer) which

- has exactly the diameter required,

- has an adequate edge profile (lead, straight/helical-fluted and taper reamers) and
- is well sharpened.

The use of lubricants will prolong the life of the tool. Reaming is applied for fitting
holes and taper holes.