Manufacturing

Processes II

Lecture 1 – Introduction

Dr. James Wakiru

Mechanical Engineering Depart.
School of Engineering -DeKUT
Dedan Kimathi University of Technology
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 BIO
• PhD (Mech. Eng), MSc (Industrial Engineering),
MBA (Marketing), BSc. (Mech. Eng)
• Editor (Lubezine) www.lubezine.com
• Email: jmwakiru@gmail.com
• Cell: +254 737 737023 or +254 722 803504

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 Course objectives
1. Understand various types of traditional machining operations
2. Be able to operate various machines for traditional machining in the
workshop.
3. Be able to choose the correct parameters for quality machining of
parts in specific traditional machining methods.
4. Be able to undertake basic optimization of traditional machining
processes.

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 Course content
1. Introduction to traditional machining processes
2. Lathes
3. Milling and milling machines
4. Abrasive machining processes
5. Introduction to basic optimizations & design in machining operations
Practical Activity 1: Parameter-machining quality interactions during lathe
operations.
Practical Activity 2: Parameter-machining quality interactions during
milling operations.
Practical activity 3: Surface grinding of hard-to-machine materials such as
Ti6Al4V: An optimization study.

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 Course textbooks
Core Textbooks
•R. K. Rajput. (2007). A Textbook of Manufacturing Technology:
Manufacturing Processes. Firewall Media. ISBN 9788131802441

•Serope Kalpakjian, Steven R. Schmid. (2005). Manufacturing Engineering and

Technology, 4th Edition. Pearson Education. ISBN-13: 978-0201361315
ISBN-10: 0201361310

Reference Textbooks
•J. Paulo Davim. (2014). Traditional Machining Processes: Research Advances.
Springer. ISBN: 978-1-4471-5178-4

•Helmi A. Youssef, Hassan El-Hofy. (2008). Machining Technology: Machine

Tools and Operations. CRC Press publishers. ISBN-13 : 978-1420043396

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 Course evaluation
• Ordinary Examination at end of Semester: 70 %
• Continuous Assessment: 30 %
❖ 10 % shall be continuous assessment tests
❖ 5 % shall be assignments
❖ 15% Practicals

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 MACHINING PROCESSES
Machining
Machining is the process of cold working the metals into different shapes by
using different types of machine tools
Machinability which is defined as the ease of removing metal while
maintaining dimensions and developing a satisfactory surface finish is an
important aspect affecting the metallurgical and properties stand-point of
metals. Tool wear and power consumption are two factors which affect the
metal removal rate.
Machining is accomplished with the use of machines known as “Machine
tools”.
The kind of surface produced depends upon the shape of cutting, the path of the tool
as it passes through the material or both.

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 Machining

Principal machining methods

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 Machining processes classification
1. Metal Cutting :
(i) Single point cutting :
◦ Turning The metal cutting (machining, a generic term, refers to
◦ Boring all material removal processes)refers to only those
◦ Shaping processes where material removal is affected by the
◦ Planing. relative motion between tool made of harder material
and the workpiece.
(ii) Multi-point cutting :
◦ Milling The tool would be single-point cutting tool as used in
◦ Drilling operations like turning or shaping, or a multi-point tool
◦ Tapping as used in milling or drilling operation
◦ Hobbing
◦ Broaching.

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 Machining processes classificati

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 Machining processes classification

Hobbing

Milling

Broaching

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 Machining processes classification
2. Grinding and finishing :
(i) Grinding :
Grinding and finishing processes are
◦ Surface grinding
those where metal is removed by a large
◦ Cylindrical grinding
number of hard abrasive particles or
◦ Centreless grinding. grains which may be bonded as in
(ii) Finishing : grinding wheels, or be
◦ Lapping in loose form as in lapping.
◦ Honing
Unconventional machining processes
are those which use electrical, chemical
◦ Superfinishing.
and other means of material removal for
3. Unconventional Machining : shaping high strength materials and for
◦ Ultrasonic machining producing
◦ Electrodischarge machining complicated shapes.
◦ Electro-chemical machining
◦ Laser beam machining.

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 Ultrasonic machining
• Ultrasonic Machining is a non-traditional
process, in which abrasives contained in a
slurry are driven against the work by a tool
oscillating at low amplitude (25-100 microns)
and high frequency (15-30 kHz).

• With ultrasonic machining, a tool creates

vibrations that projects micro-sized particles
towards the workpiece. The particles are
typically mixed with water or other liquids to
create a slurry. When the ultrasonic tool is
activated, it projects these particles at a fast
rate of speed towards the workpiece's surface

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 Electrodischarge machining
• Electrical discharge machining (EDM) is a non-traditional machining process based on
removing material from a part by means of a series of repeated electrical discharges
between tools, called electrodes, and the part being machined in the presence of a
dielectric fluid.

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 Electro-chemical machining
• Electrochemical machining (ECM) is a method of removing metal by an electrochemical
process. ... ECM can cut small or odd-shaped angles, intricate contours or cavities in hard
and exotic metals, such as titanium aluminides, Inconel, Waspaloy, and high nickel, cobalt,
and rhenium alloys.

• Electrochemical Machining (ECM) is based upon Faraday's law of electrolysis. Faraday's

law states that the the mass of a metal altered by the electrode is proportional to the
quantity of electrical charges transferred to that electrode.

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 Laser beam machining
• Laser beam machining (LBM) is a form of
machining that uses heat directed from a laser
beam. This process uses thermal energy to
remove material from metallic or nonmetallic
surfaces.

• Focuses on the workpiece to mechanize this

laser beam produced. When the laser beam hits
the surfaces of the W/P, the thermal energy of
the laser beam is transferred to the surfaces of
the W/P. It heats, melts, evaporates, and
eventually makes the material a workpiece.

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 Assignment 1
Different non-conventional machining techniques exist. They include:
◦ Ultrasonic machining
◦ Electrodischarge machining
◦ Electro-chemical machining
◦ Laser beam machining.

For each of the technique:

a) Describe the process

b) Discuss the types involved in the technique

c) What are the applications

d) What are the merits and demerits of the technique

Hand in the assignment by 28th February 2022

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 Machine tools
Machines tools are the kind of *machines on which the metal cutting or
metal forming processes are carried out. They employ cutting tools to
remove excess material from the given job.
The functions of a machine tool are :
(i) To hold the tool ;
(ii) To move the tool or the workpiece or both relative to each other ;
(iii) To supply energy required to cause the metal cutting.

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 Machine tools
The machine tools are classified as follows :
1. General purpose :
(i) Lathe (ii) Drilling machine
(iii) Shaping machine (iv) Planing machine
(v) Milling machine (vi) Sawing machine.
2. Special purpose :
(i) Special lathes like capstan, turret and copying lathes
(ii) Boring machine (iii) Broaching machine
(iv) Production milling machine (v) Production drilling machine

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 Machine tools
The machine tools are classified as follows :
3. Automatic machine tools :
These machine tools, also called Automatic screw cutting machines (or simply auto-
mats), are used for mass production of essentially small parts using a set of pre-
designed and job-specific cams.
4. Computer numerical control (CNC) machine tools :
Under CNC machine tools, we have CNC turning centre, which does all the work of a
lathe and CNC machining centre which does milling, drilling etc., with provision for
automatic tool changing and tool wear correction built into it.

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 Traditional/Conventional Machining
processes
Merits
1.Different materials can be machined.
2.Easy setup of the equipment’s.
3.Less capital cost.

Disadvantages
1.Less surface finish.
2.They can’t machine complex shapes.
3.More tool wear.
4.Lower dimensional accuracy.
5.Noisy operation causes sound pollution

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