1

• Manufacture: manus (hand) and factus (make); meaning:

made by hand.
• Manufacturing: is done largely by machinery today; It
changes the form of raw materials to create products.
• Production or manufacturing is a value addition process
and converting of raw material into high utility and valued
products with definite dimensions and forms.

manufacturing: (a) as a technical process, and (b) as an economic

process.
• Machining: is a material removal process to obtain a
finished product of the desired size, shape & surface
quality.
• It constitute approximately 20% of the manufacturing
activities in the developed countries.
• The technology of machining is carried out on
machine tools.
• Machine tools are responsible for generating motions
& form 70% high production accuracy compared with
metal forming.
 Machine Tool – definition

• A machine tool is a non-portable power operated and

reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size,
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s).
Basic functions of Machine tools
• Machine tools basically produce geometrical surfaces
like flat, cylindrical or any contour on the preformed
blanks by machining work with the help of cutting
tools.
• The physical functions of a machine tool in
machining are:
 Firmly holding the blank and the tool.
 Transmit motions to the tool and the blank.
 Provide power to the tool-work pair for the
machining action.
 Control of the machining parameters, i.e., speed,
feed and depth of cut.
1. Non traditional machining:
• Offered alternative methods for machining parts of
complex shapes in hard, stronger, & tougher
materials that are difficult to cut by traditional
methods.
• It removes material using mechanical, chemical, or
thermal machining effects.
2. Traditional machine tool:
• It is the machining process of materials with the
help of either single or multiple cutting tools and
abrasive cutting wheels.
• Electric power is the source for generating different
cutting and feeding motion.
• By weight
i. Light-duty machine tools weighing up to 1t,
ii. Medium-duty machine tools weighing up to 10t and
iii. Heavy-duty machine tools weighing greater than 10t.
• By the degree of specialization
i. General- purpose machine tools- which can perform
various operations on workpieces of different shapes
and sizes,
ii. Single- purpose machine tools- which can perform a
single operation on workpieces of a particular shape
and different sizes and
iii. Special machine tools- which can perform a single
operation on workpieces of a particular shape and
size.
• By the degree of automation
i. Machine tools with manual control,
• Perform the machining and work piece handling
operation manually.
• It take longer time for machine setup.
ii. Semi-automatic machine tools and
• Perform automatically controlled movements, while the
WP has to be hand loaded & unloaded.
• The operator’s interference is minimized.
iii. Automatic machine tools.
• WP handling, cutting & other auxiliary activities are
performed automatically.
• The operator’s interference is completely eliminated &
parts are machined more accurately & economically.
• The integration of CAD/CAM systems to machining
technology has created new industrial areas in die, mold,
aerospace & automobile industries.
• NC machine tools: utilize a form of programmable
automation by numbers, letters, & symbols using a
control unit & tape reader,

• While CNC machine tools utilize a stored computer

program to perform all the basic NC functions.

• The use of NC, CNC, CAD/CAM, CIM technologies

provided robust solutions to many machining problems.
Components of traditional NC systems
NC systems offer some advantages over manual
production methods:
1. Better control of tool motions under optimum
cutting conditions.
2. Improved part quality and repeatability.
3. Reduced tooling costs, tool wear, and job setup
time.
4. Reduced time to manufacture parts.
5. Reduced scrap.
6. Better production planning and placement of
machining operations in the hands of engineering.
Components of modern CNC systems
CNC opens up new possibilities and advantages not
offered by older NC machines.
1. Reduction in the hardware necessary to add a machine
function. New functions can be programmed into the
MCU as software.
2. The CNC program can be written, stored, and
executed directly at the CNC machine.
3. Any portion of an entered CNC program can be
played back and edited at will. Tool motions can be
electronically displayed upon playback.
4. Several CNC machines can be linked together to a
main computer.
Basic Motions in Machine Tools
• In conventional machine tools variety of motions
given to the tool or the WP.
• Each machining operation produces a characteristic
geometry due to two factors:
1. The relative motions between the tool and the
work part and
2. The shape of the cutting tool.

• We classify these operations by which part shape is

created as generating and forming.
• In Generating, the geometry of the work part is
determined by the feed trajectory of the cutting tool.

• Example, straight turning, taper turning, contour

turning, peripheral milling, and profile milling.

• Material removal is accomplished by the speed motion

in the operation, but part shape is determined by the
feed motion.
• In forming, the shape of the part is created by the
geometry of the cutting tool.
• In effect, the cutting edge of the tool has the reverse of
the shape to be produced on the part surface.
• Form turning, drilling, and broaching are examples of
this case.
• The cutting conditions in forming usually include the
primary speed motion combined with a feeding motion
that is directed into the work.
• Forming and generating are sometimes combined in
one operation.
• In thread cutting, the pointed shape of the cutting tool
determines the form of the threads, but the large feed rate
generates the threads.
• In slotting (also called slot milling), the width of the
cutter determines the width of the slot, but the feed
motion creates the slot.
• Machined parts are classified as rotational or non rotational.
Two types of motions in a machine tool.

1. Primary motion, generally given to the tool or

WP, constitutes the cutting speed.

2. Secondary motion feeds the tool relative to the

WP.
• In some instances, combined primary motion is
given either to the tool or to the WP.
End of Chapter One