University of Gondar

Institute of technology
Departments of Mechanical Engineering

Manufacturing Engineering II meng

By;- Belete A. ( Msc.)
 Lecture one
Traditional machine process
 Presentation outline
The over all contents of dissuasion will be;-
Overviews of manufacturing Engineering
What important do manufacturing Engineering have
What are the basic manufacturing machining processes
Why traditional manufacturing
Examples of different traditional machining process
Types of cutting tools for traditional machining processes.
 Objectives of the presentation
The objectives of this presentation is to address the over all points listed in
the presentation outline
The students are expected to go through those listed presentation outline.
Introduction and Overview of Manufacturing
 What is manufacturing?
 Latin definition;- manufactus meaning ‘made by hand’ or ‘hand-made
In modern English dictionary context;-the making of products from raw
materials using various processes, equipment, operations and manpower according
to a detailed plan.
 generally manufacturing is the ;-
 the conversion of stuff into things.
 “act of making something (a product) from raw materials”
 Important of Manufacturing
1.Technologically;- since technology is the application of scienceto provide society and its members with
those things that are needed or desired;-
 Technology provides theproducts that help the society to live better .
 These technological products will be manufactured;
 Manufacturing is the essential factor that makes technology Possible.
2.Economically;- Manufacturing is one way by which nations create material wealth;
Examples in us economy;- Sector % of GNP(Gross net
product)
Manufacturing 20%
Agriculture, mineral etc. 5%
Construction and utilities 5%
Service sector;- retail, transportation, bank, 70%
communication, education and Government

3.Historically;- to establish the future relative to the existing technology

 Types of manufacturing process
The processes to accomplish manufacturing involve a combination of machinery, tools,
power, and labor,
A manufacturing process is usually carried out as a unit operation (single step in the sequence
of steps required to transform the starting material into a final product).

Two ways to define manufacturing: (a) as a technical process, and (b) as an economic process.
 Cont.
Manufacturing operations;-
(1).Processing operations;- transforms a work material from one state of completion to a
more advanced state that is closer to the final desired product.
Operations that change the geometry, properties, or appearance of the starting material.
(2).Assembly operations;- joins two or
more components to create a new entity,
called an assembly, subassembly, or some
other term that refers to the joining process
(e.g. fasteners, weldment).

Classification of manufacturing processes.

 Machining process
What is Machining?
 Machining is a group of processes that consist of the removal of material and
modification of the surfaces of a workpiece after it has been produced by various
methods. Thus, machining involves secondary and finishing operations.

 It is a shearing process in which excess materials is removed by cutting tools. It is

generally performed after other manufacturing processes such as casting or bulk
deformation (e.g., forging, bar drawing).

 The other processes create the general shape of the starting work part, and machining
provides the final geometry, dimensions, and surface finish.
Why Machining and is it Important?
it is applicable to most materials

it can produce a variety of geometries and shapes

 Screw threads

 Accurate round holes

it can achieve closer tolerances than most other processes

Good dimensional accuracy and surface finish

Disadvantages with Machining
Wasteful of material
 Chips generated in machining are wasted material

Time consuming
 A machining operation generally takes longer to shape a given part
than alternative shaping processes

The accuracy of the components produce is dependent on the efficiency

of the operation personnel (operator)
 Machining process
Types of machining process
1. Conventional/traditional/ machining process;- It is the basic method of the metal
removing process that removes a material and decreases metal mass. The principal
machining processes are classified as turning, drilling and milling. Other
operations miscellaneous categories include shaping, planning, boring, broaching
and sawing.
2. Unconventional/non traditional/ machining process;-, is a machining method
that uses electrical energy, heat energy, light energy, electrochemical energy,
chemical energy, sound energy, and special mechanical energy to remove, deform,
change properties, or plate materials.
 Traditional machining process

A material removal process in which a sharp cutting tool is used

to mechanically removes work surface so that the desired part
geometry remains.
Most common application: to shape metal parts.
Machining is the most versatile and accurate of all
manufacturing processes in its capability to produce a diversity
of part geometries and geometric features.
 TURNING
A single point cutting tool removes material from a rotating
workpiece to generate a cylindrical shape;
Performed on a machine tool called a lathe;
Various types of turning that are performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading

Turning operation
 Cont. …
Facing operation;- reduces the
length of the workpiece.

Facing Tool is fed radially inward

Contour Turning
Instead of feeding the tool parallel to the axis
of rotation, tool follows a contour that is other
than straight, thus creating a contoured form
or profile.
 Cont.
Chamfering;- Cutting edge cuts an angle on the corner of the
cylinder, forming a "chamfer"

Cutoff;- Tool is fed radially into

rotating work at some location to cut
off end of part
 Cont.
Threading;- Pointed form tool is fed
linearly across surface of rotating work
part parallel to axis of rotation at a large
feed rate, thus creating threads
Knurling;-In this, a knurling
tool having the requisite serration
is forced on to the work-piece
thus deforming the top layer.

Drilling operation;- can be performed in

lathe machine
 LATHE SPECIFICATION
There are a number of factors that should be specified to fully describes a
lathe machine.
Distance between centers;- specifies the maximum length of the
job that can be turned.
Swing over the bed;- specifies the maximum diameter of the job
that can be turned.
Swing over the cross-slide;- specifies the maximum diameter of
the job that can be turn with the job across the cross-slide.
Horse Power of motor.
Cutting speed range.
Feed range.
Screw cutting capacity.
Spindle nose diameter and hole size.
Types of cutting in lath machine

Orthogonal Cutting;- Cutting edge is

straight, parallel to the original plane
surface at the work piece and
perpendicular to the direction of cutting.
the direction of cutting.
Oblique Cutting;- Cutting edge of the
tool is inclined to the line normal to the
cutting direction. In actual machining,
Turning, Milling etc/ cutting operations
are oblique cutting
Machining parameters
 Drilling
Creates a round hole in a work part
Contrasts with boring which can only enlarge an existing hole
Cutting tool called a drill or drill bit
Customarily performed on a drill press/droll machine.

 Through Holes vs. Blind Holes

 Through-holes;- drill exits the opposite side of work
 Blind-holes;- drill does not exit work on opposite side
 Cont.
Reaming;- Used to slightly enlarge a hole,
provide better tolerance on diameter, and improve
surface finish

Tapping;- Used to provide internal screw threads on

an existing hole Tool called a tap

Counterboring Provides a
stepped hole, in which a larger
diameter follows a smaller
diameter partially into the hole
 Cont.
Upright Drill
Stands on the floor
Bench Drill ;- Similar
but smaller and mounted
on a table or bench

Work Holding for Drill Presses;- Work part can be clamped in Radial Drill
a vise, fixture, or jig Large drill press designed
 Vise;- general purpose work holder with two jaws for large parts
 Fixture;- work holding device that is usually custom-designed
for the particular work part
 Drill jig;- similar to fixture but also provides a means of
guiding the tool during drilling.
 Milling
It is one of the conventional machining process where;
 Machining operation in which work is fed past a rotating tool
with multiple cutting edges
Rotating multiple-cutting-edge tool is moved across work to cut a
plane or straight surface
Two forms: peripheral milling and face milling
 Cont.
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

peripheral milling, face milling

 Milling machine and its operations
Milling is a process of removing metal by feeding the work against a rotating
multipoint cutter.
 The machine tool intended for this purpose is known as milling machine.
 It is used for machining flat surfaces, contoured surfaces, surfaces of
revolution, external and internal threads, and helical surfaces of various
cross-sections
Types of milling machine
1. Column and knee type 2. Table type milling machine.
a) Plain milling machine. 3. Planer type milling machine.
b) Universal milling machine . 4. Special type milling machine
c) Omniversal milling machine.
d) Vertical milling machine.
 Cont..
• Nevertheless, milling machines are typically divided into vertical and
horizontal milling machines based on how the spindle axis is arranged in
relation to the plane of the work piece.
2.Horizontal oriented milling machines;-
1.Vertically oriented milling machines;- A
A spindle of a horizontal milling is
spindle of a vertical milling machine is
positioned parallel to the table. The cutter
positioned at right angles to the table. The cutter
is moved horizontally.
is moved vertically or at an angle by swiveling
the vertical head of the machine

vertically oriented milling machines Horizontally oriented milling machines

 Sizes of a milling machine
The size of a milling machine is specified as;-

1.The size of the table (length and width)

2.The maximum lengths of longitudinal, cross and vertical travel of the table.

3.Number of spindle speeds, number of feeds

4.Spindle nose taper

5.Power required

6.Net weight of the machine

7.The floor space required

8.Type of the machine vertically oriented milling machines Horizontally oriented milling machines
 Standard milling cutters

 Different types of milling cutters are used in a milling machine depending

up on the shape and size required .
1. Plain milling cutter 5. End milling cutter
2. Side milling cutter 6. ‘T’ – Slot milling cutter
3. Metal slitting saw 7. Fly cutter
4. Angle milling cutter 8.Formed cutter
Cont
 Milling operations
Peripheral Milling vs. Face Milling
 Peripheral milling
 Cutter axis is parallel to surface being machined.
 Cutting edges on outside periphery of cutter.
 Face milling
 Cutter axis is perpendicular to surface being milled
 Cutting edges on both the end and outside periphery of the cutter

peripheral milling face milling

 Other milling operations

 Slab Milling;- The basic form of peripheral milling in

which the cutter width extends beyond the workpiece on
both sides

 Slotting;- Width of cutter is less than workpiece width,

creating a slot in the work
 Conventional Face Milling Cutter overhangs work on
both sides
 Cont.
End Milling;- Cutter diameter is less than
work width, so a slot is cut into part

 Profile Milling Form of end  Pocket Milling;-Another form of end

milling in which the outside milling used to mill shallow pockets
periphery of a flat part is cut 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.
 Milling operations
Milling operations are of two types relative to the feed and cutter
rotation direction.
 Down milling;- The cutter direction is same direction as the motion of the
work piece being fed.
Up milling;-Work piece is moving towards the cutter, opposing the cutter
direction of rotation. Surface finish is better in case of down milling, but the
stress load on the teeth is abrupt that may damage the cutter.
 Difference between up and down milling
Up milling
There is propensity to lift work piece, so extra
clamping forces are required to fix job on table.
Cutter turns against direction in which the work
is being fed.
It use of cutting fluid is complicated.
Cutting force vary as of zero to maximum.
Job tool movement is in opposite way.
Chip thickness differs as of minimum to
maximum.
It surface finish is improved.
It is feasible.
Down milling
Forces are enough on job to press down. Thus
clamping difficulty is not so much.
Cutter turns in similar direction as to in which
the work is being fed.
It use of cutting fluid is simple.
Cutting forces vary as of maximum to zero.
Job tool movement is in the similar direction.
Chip thickness differs as of minimum to
maximum.
It surface finish is improved, if it is free as of
backlash error.
It is unfeasible.
 Shaping and Planning;
Similar operations and operations are performed in planning machine
 Both use a single point cutting tool moved linearly relative to the work part

 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
tools.
 Cont.

Shaper machine

planer machine
 Machining Operations and Part Geometry
Each machining operation produces a characteristic part geometry due to
two factors:
Relative motions between the tool and the work part.
Generating ;-part geometry is determined by the feed trajectory of the
cutting tool.

Generating shape: (a) straight turning, (b) taper turning, (c) contour turning, (d) plain milling, (e) profile milling
 Cont.
 Shape of the cutting tool
Forming;- part geometry is created by the shape of the cutting tool

Forming to create shape: (a) form turning, (b) drilling, and (c) broaching
 Combinations of forming and generation

Both forming and generating to create shape: (a) thread cutting on a lathe, and (b) slot milling