Machining Processes

Introduction
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Course objectives
At the end of this course student should be aware of the
following:
1. Classification of various machining technologies.
2. Machining system components.
3. Selection of appropriate tool materials and geometries.
4. Estimating machining time for different processes .
5. Selection of the proper machining procedure for different
workpieces.

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Course Assessment
• End of Year Exam: 40 Marks
• Year Work : 60 Marks
•Midterm Exam: 20 Mark
•Quizzes (2): 10 Marks
•Lecture Assignments (5) : 10 Marks
•Tutorials Sheets (10): 20 Marks

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Reference Books
• References:
• - E. Paul Degarmo, J T. Black, Ronald A. Kohser, “ Materials
and processes in manufacturing”, John Wiley & sons, Inc.,
2003.
• - Hassan El-Hofy, “Fundamentals of Machining Processes”,
Taylor & Francis, 2007.
• - Helmi A. Youssef & Hassan El-Hofy, “Machining
Technology”, Taylor & Francis , 2008.
• - Helmi A. Youssef & Hassan El-Hofy, “ Principles of
Traditional and Nontraditional Machining”, Alexandria
University, 2012.

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Expectations and Responsibilities
• Come to class on time.
• No side talks.
• Respect your instructor/TAs and colleagues.
• Hand on assignments before due date.
• No changing in the lab schedule
• White lab coat for workshop
• Questions asked on Teams as general posts to encourage discussions
• Clear understanding of year work grade
• Fast reply to your questions posted on teams
• Fair grades in exams and assignments
• Interesting content
• If you miss more than 3 lectures/tutorials , the course will be FW

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MS Teams Code

b1h6kv0
Questions asked on Teams as general posts to encourage discussions
Direct messages may not be answered

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Machining Processes
Introduction
Intended Learning Outcomes
• Understand what manufacturing is
• List the different manufacturing processes
• Describe different material removal processes
• Compare between metal cutting processes
• Be able to chose the right metal cutting process for
different parts

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Contents

• What is manufacturing
• Manufacturing Methods
• Machining Processes
• Machining by Cutting
• Summary

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What is Manufacturing
• The word manufacture is derived from two Latin words,
manus (hand) and factus (make); the combination means
made by hand.
• Most modern manufacturing is accomplished by automated
and computer-controlled machinery

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What is Manufacturing
• Technologically, manufacturing is the application of physical
and chemical processes to alter the geometry, properties,
and/or appearance of a given starting material to make
parts or products; manufacturing also includes assembly of
multiple parts to make products.

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What is Manufacturing
• Economically, manufacturing is the transformation of materials into
items of greater value by means of one or more processing and/or
assembly operations.
• The key point is that manufacturing adds value to the material by
changing its shape or properties, or by combining it with other
materials that have been similarly altered.

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Contents

• What is manufacturing
• Manufacturing Methods
• Machining Processes
• Machining by Cutting
• Summary

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Manufacturing Technology
• Manufacturing represents 20-30% of the value of all goods and services produced
in industrialized countries.
• Machining activities constitute ~ 20% of the manufacturing activities in the USA.

Manufacturing Technology
Powder
Casting Forming Welding Machining
Metallurgy
Sand casting Bulk Gas Traditional

Investment Sheet Arc Non-traditional

metal
Lost wax Plasma

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 Methods of manufacture
• Casting: expandable mould and permanent mould.
• Forming and shaping rolling, forging, extrusion, drawing, sheet forming, powder
metallurgy and molding.
• Machining: turning, boring, drilling, milling, planning, shaping, broaching, grinding,
ultrasonic machining, chemical, electrical and electrochemical machining.
• Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding and
mechanical joining.
• Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating
and plating.

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Scales in manufacturing
• Size, shape complexity and
thickness of a part have a
major influence on the
process selected to produce
the part.

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Contents

• What is manufacturing
• Manufacturing Methods
• Machining Processes
• Machining by Cutting
• Summary

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Classification of machining processes

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 Classification of machining processes
• Cutting: machining allowance is removed in the form of visible chips.
• Abrasion: machining allowance is removed in the form of minute and invisible chips
by hard, tiny, randomly oriented abrasive grit (bonded or loose) of indefinite number
and shape.
• Erosion: machining allowance is removed in the form of successive surface layers
as a result of dissolution, melting and vaporization of the material being machined.

Erosion

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Contents

• What is manufacturing
• Manufacturing Methods
• Machining Processes
• Machining by Cutting
• Summary

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Classification of cutting processes
Machining by Cutting

Single Point Multipoint

Turning Drilling
Boring Reaming

Shaping Milling

Planing Broaching

Sawing

Filing
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Cutting by chipping
• The tool is penetrated into the w.p by a depth of cut.
• Cutting tools have definite number of cutting edges of a known geometry.
• The machining allowance is removed in the form of visible chips.
• The shape of the workpiece produced depends on the tool and workpiece
relative motions.

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General aspects of machining technology

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Center lathe
• Turning means that the part is rotating while it is being machined.

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Turning Operations

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Turning Operation Products

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Drilling Machine

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Drilling operations
Drilling is used to produce a hole which may be followed by tapping or boring to
improve the accuracy of the hole and its surface finish

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Shaping/Planning Operation

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Shaping Parts

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Milling Machine
Milling cutter is a multi-tooth cutter rotates along various axes with respect to the
workpiece
(a) horizontal-spindle, column-and-knee-type milling machine for slab milling.
(b) vertical-spindle, column-and-knee-type milling machine for face and end milling
and drilling operations.

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Side Milling Operations
• Cutters for
(a) Straddle milling;
(b) form milling;
(c) slotting; and
(d) slitting operations.

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Face Milling Operations

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Milling Operation Products

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Grinding Operations

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Grinding Operations

Schematic illustrations of surface-grinding operations.

(a) Traverse grinding with a horizontal-spindle surface grinder.
(b) Plunge grinding with a horizontal-spindle surface grinder, producing a groove in the
workpiece.
(c) Vertical-spindle rotary-table grinder.
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Grinding Operations

Before and after grinding operation

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Contents

• What is manufacturing
• Manufacturing Methods
• Machining Processes
• Machining by Cutting
• Summary

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Shapes & manufacturing process
Shape or feature Production method
Flat surfaces Rolling, planing, broaching, milling, grinding
Parts with cavities End milling, electrical discharge machining, electrochemical
machining, ultrasonic machining, casting, forging, extrusion,
injection molding
Tubular shapes Extrusion, drawing, roll forming, spinning, centrifugal casting
Square edges Fine blanking, machining, shaving
Small holes Laser or electron-beam machining, electrical-discharge
Shapes and some common methods of production
machining, electrochemical machining
Threaded parts Thread cutting, thread rolling, thread grinding, injection molding
Very large parts Casting, forging, assembly

Very small parts Investment casting, etching, powder metallurgy, nanofabrication,

micromachining

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Tool and workpiece motions

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Summary
• Manufacturing is the process of adding value to raw
material by means of one or more process.
• Manufacturing methods are various, we will focus
on the material removal/ metal cutting processes.
• The relative motion in each machine tool.
• The cutting operation performed by each machine
tool.
• The applications/part shapes produced by each
machine tool.

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Lab Sheet 1 Due date 17/2/2023

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