Metal cutting

Workshops 2nd
2022
Process of Metal Cutting
❑ A family of shaping operations,
the common feature of which
is removal of material from a
starting workpiece so the
remaining part has the desired
geometry.
❑ Metal cutting processes
consists in removing a layer of
metal from blank to obtain a
machine part of the required
shape and dimensions and
with the specified quality of
surface finish.
Examples of Parts Produced Using the
Machining Processes
 Machining – material
removal by a sharp
cutting tool, e.g., turning,
milling, drilling

Chip removal processes

Abrasive processes –
material removal by
hard, abrasive
Material removal particles, e.g., grinding.

Nontraditional processes -
various energy forms other
than sharp cutting tool to
Chipless processes
remove material, e.g.
electrochemical and thermal
energy processes.
1.Material Removal Processes (chip removal)
• Traditional Chip Removal
1. Machining :
1. Sawing
2. Broaching
3. Planning
4. Turning
5. Milling
6. Drilling
7. Boring
8. Reaming
9. Shaping
2.Material Removal Processes (chip removal)
• 2.abrasaive
1. Grinding
2. Honing
3. Lapping
4. Polishing
3.Nontraditional processes

1. Ultrasonic
2. Electrical Discharge
3. Electro-arc
4. Optical Lasers
5. Electrochemical
6. Chem-milling
7. Abrasive Jet Cutting
8. Electron Beam Machining
9. Plasma Arc Machining
 Common types pf chips
A . shows continuous chips coming out during machining in machine shop. These types of chips are obtained while
machining ductile material such as mild steel and copper. A continuous chip comes from the cutting edge of a
cutting tool as a single one piece, and it will remain as one piece unless purposely broken for safety or for
convenience in handling
B. discontinuous chips In this type, the chip is produced in the form of small pieces. These types of chips are
obtained while machining brittle material like cast iron, brass and bronze. Fairly good surface finish is obtained
and tool life is increased with this type of chips.
C. During cutting operation, the temperature rises and as the hot chip passes over s the face of the tool, alloying
and welding action may take place due to high pressure, which results in the formation of weak bonds in
microstructure and weakened particles might pullout. Owing to high heat and pressure generated, these particles
get welded to the cutting tip of the tool and form a false cutting edge. This is known as built-up edge
Metal cutting operations classifications
• According to the Kinematics of the operation it can be classified as :
1. Flat surfaces
2. Internal and External cylindrical and curved surfaces
• Classification of Machined Parts
Machining Operations

• Most important machining operations:

1. Turning
2. Drilling
3. Milling
• Other machining operations:
1. Shaping and planning
2. Broaching
3. Sawing
Cutting Tool Classification
1. Single-Point Tools
– One dominant cutting edge
– Point is usually rounded to form a nose
radius
– Turning uses single point tools
2. Multiple Cutting Edge Tools
– More than one cutting edge
– Motion relative to work
• achieved by rotating
– Drilling and milling use rotating multiple cutting
edge tools
Lath operations

• Internal and External

cylindrical and curved
surfaces
• Worked on lathe machines
a single point cutting tool
 Turning
Single point cutting tool
removes material from a
rotating workpiece to form a
cylindrical shape
Boring
• Internal turning operation
which is performed on the
• inside diameter of an existing
hole

(Turning is performed on the

outside diameter of an existing
cylinder)
Milling
• Machining operation in which
work is fed past a rotating tool
with multiple cutting edges
• Axis of tool rotation is
perpendicular to feed direction
• Creates a planar surface; other
geometries possible either by cutter
path or shape
• Other factors and terms: – Milling
is an interrupted cutting operation –
Cutting tool called a milling cutter,
cutting edges called "teeth"
– Machine tool called a milling
machine
Milling cuts
a) A.Slab Milling :The basic form of peripheral milling in
which the cutter width extends beyond the workpiece
on both sides
b) B. Slotting • Width of cutter is less than workpiece
width, creating a slot in the work
c) End Milling Cutter diameter is less than work width, so
a slot is cut into part
Cont’d Milling cuts
• Conventional Face Milling Cutter overhangs work on both
sides

• Profile Milling Form of end milling in which the outside

periphery of a flat part is cut

• Pocket Milling Another form of end milling used to mill

shallow pockets into flat parts

• Surface Contouring Ball-nose cutter is fed back and forth

across the work along a curvilinear path at close intervals to
create a three dimensional surface form
Drilling
• Used to create a round hole,
usually by means of a rotating tool
with two cutting edges or more
Reaming
• Used to slightly enlarge a
hole, provide better
tolerance on diameter,
and improve surface finish
Broaching
• This process is performed using a
multiple tooth cutting tool. The
tool is moved linearly relative to
the work.
• Broaching
• operation.
• The tool is called a broach.
The machine is called the
broaching machine.
Tapping
• Used to provide internal screw threads
on an existing hole
• Tapping can be done :
• Manually
• On milling machine
• On lathe machine for cylindrical shapes
Shaping & Planing
• Shaping: Tool has a linear speed motion. Work has occasional feed motion.
• Planing: Work has a linear speed motion. Tool has occasional feed motion.
• A straight, flat surface is created in both operations • Interrupted cutting –
Subjects tool to impact loading when entering work • Low cutting speeds due to
start-and-stop motion • Usual tooling: single point high speed steel (HSS) tools

(a) Shaping (, and (b) planing.

Sawing operations
• Cuts narrow slit in
work by a tool
consisting of a
series of narrowly
spaced teeth
• • Tool called a saw
blade
• • Typical
functions: –
Separate a
workpart into two
pieces – Cut off
unwanted
portions of part
Grinding
Cutting tools requirement
1. It should be strong enough to withstand the forces being applied due
the cutting i.e. bending compression, shear etc.
2. It should be tough (resistant to shock loads). It is quite important when
• tool is used for intermittent cutting.
3. It should be sufficient harder (resistant to wear, abrasion and
indentation) the material being cut.
4. It should be able to resist high temperature (red hardness).
5. It should be capable of withstanding,, the sudden cooling effect of
coolant used during cutting.
6. The coefficient of friction between the chip and the tool should be as low
• as possible in the operating range of speed and feed.
7. should be easily formed to the required cutting shape.
Functions or Uses of Collents or Cutting Fluids
• The important functions of cutting fluids are given as under.
1. Cutting fluid washes away the chips and hence keeps the cutting region free.
2. It helps in keeping freshly machined surface bright by giving a protective
coating against atmospheric, oxygen and thus protects the finished surface
from corrosion.
3. It decreases wear and tear of cutting tool and hence increases tool life.
4. It improves machinability and reduce power requirements
5. It prevents expansion of work pieces.
6. It cools the tool and work piece and remove the generated heat from the
cutting zone.
7. It decreases adhesion between chip and tool; provide lower friction and wear,
and a smaller built-up edge.
Machining in Manufacturing Sequence

• Generally performed after other

manufacturing processes, such as casting,
forging, and bar drawing
– Other processes create the general shape of the
starting workpart.
– Machining provides the final shape, dimensions,
finish, and special geometric details that other
processes cannot create