Machining operations

• Machined parts classified as rotational and non rotational (prismatic)

Rotational: workpart has a cylindrical or disk-like shape
Prismatic: block-like or plate-like workpart
• Creation of workpiece geometry is either in the form of generating
or forming
Generating: geometry is created by the feed trajectory/motion of the
cutting tool
Forming: the shape of the part is created by the geometry of the
cutting tool. The cutting edge is the reverse of the shape to be
produced on the part surface.
Cont.

Generating
Forming
Turning and related operations
Turning is a machining process in which a single-point tool removes
material from the surface of a rotating workpiece, performed on
machine tool called lathe.
Cutting Conditions in turning
𝑣
Rotational speed (𝑁) =
𝜋𝐷𝑜
𝐷𝑓 = 𝐷𝑜 − 2𝑑
𝑓𝑟 = 𝑁𝑓
The time to machine from end to end,
𝐿 𝜋𝐷𝑜 𝐿
𝑇𝑚 = =
𝑓𝑟 𝑓𝑣
Material Removal Rate (𝑀𝑅𝑅) = 𝑣𝑓𝑑
 Operations related to turning
• Facing. The tool is fed radially into the rotating work to create a flat
surface on the end-implies create better surface finish on the end or
reduce length
• Taper turning. The cutting tool is fed at an angle, thus creating a
tapered cylinder or conical shape
• Contour turning. The tool follows a contour that is other than
straight, thus creating a contoured form in the turned part.
• Form turning. In this operation, sometimes called forming, the tool
has a shape that is imparted to the work by plunging the tool radially
into the work.
• Chamfering. The cutting edge of the tool is used to cut an angle on
the corner of the cylinder, forming what is called a ‘‘chamfer.’’
• Cutoff. The tool is fed radially into the rotating work at some location
along its length to cut off the end of the part. This operation is
sometimes referred to as parting.
• Threading. A pointed tool is fed linearly across the outside surface of
the rotating workpart in a direction parallel to the axis of rotation at a
large effective feed rate, thus creating threads in the cylinder.
• Boring. A single-point tool is fed linearly, parallel to the axis of
rotation, on the inside diameter of an existing hole in the part.
• Drilling. Drilling can be performed on a lathe by feeding the drill into
the rotating work along its axis. Reaming can be performed in a
similar way.
• Knurling. This is not a machining operation because it does not
involve cutting of material. Instead, it is a metal forming operation
used to produce a regular crosshatched pattern in the work surface
Drilling and Related operations
Drilling is a machining operation used to create a round hole in a workpart using
cutting tool called drill (drill bit)
𝑣
𝑁= , N − spindle speed, v − cutting speed and D − drill diameter
𝜋𝐷
𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒, 𝑓𝑟 = 𝑁𝑓
The machining time required to drill a through hole
𝑡+𝐴 𝜃
𝑇𝑚 = , 𝐴 = 0.5𝐷𝑡𝑎𝑛 90 − , A − approach allowance
𝑓𝑟 2
The metal removal rate of in
drilling 2 𝜋𝐷 𝑓𝑟
𝑀𝑅𝑅 =
4
Valid only after the drill reaches
full diameter
Operations related to drilling
• Reaming. used to slightly enlarge a hole, to provide a better tolerance
on its diameter, and to improve its surface finish. The tool is called a
reamer, and it usually has straight flutes.
• Tapping. This operation is performed by a tap and is used to create
internal threads on an existing hole
• Boring. A process of aligning, enlarging the existing cylindrical hole.
• Counterboring. provides a stepped hole, in which a larger diameter
follows a smaller diameter partially into the hole. A counterbored
hole is used to seat bolt heads into a hole so the heads do not
protrude above the surface.
Cont..
• Countersinking. This is similar to counterboring, except that the step
in the hole is cone-shaped for flat head screws and bolts.
• Centering. Also called center drilling, this operation drills a starting
hole to accurately establish its location for subsequent drilling. The
tool is called a center drill.
• Spot facing. Spot facing is similar to milling. It is used to provide a flat
machined surface on the workpart in a localized area.
• Trepanning. Making large hole in sheet metal
operationsrelated to drilling:
(a) reaming
(b) tapping
(c) counterboring
(d) countersinking
(e) center drilling
(f) spot facing.
Milling
• Milling is a machining operation in which a workpart is fed past a
rotating cylindrical tool with multiple cutting edges.
• The axis of rotation of the cutting tool is perpendicular to the direction
of feed, unlike to in drilling, the cutting tool is fed in a direction
parallel to its axis of rotation. The cutting tool in milling is called a
milling cutter
 Types of milling operations
Two basic types of milling operations
a) Peripheral milling
b) Face milling.
Peripheral milling/plain milling. The axis of the tool is parallel to the surface being machined,
and the operation is performed by cutting edges on the outside periphery of the cutter.
Types of peripheral milling
Slab milling, the cutter width extends beyond the workpiece on both sides
Slotting, also called slot milling, in which the width of the cutter is less than the
workpiece width, creating a slot in the work
Side milling, the cutter machines the side of the workpiece
Straddle milling, cutting takes place on both sides of the work
Form milling, in which the milling teeth have a special profile that determines the shape
of the slot that is cut in the work.
Peripheral milling
(a) slab milling
(b) slotting
(c) side milling
(d) straddle milling
(e) form milling.
 Face milling. the axis of the cutter is perpendicular to the surface being milled, and machining is
performed by cutting edges on both the end and outside periphery of the cutter

Types of Face milling

• Conventional face milling, in which the diameter of the cutter is greater than
the workpart width, so the cutter overhangs the work on both sides
• Partial face milling, where the cutter overhangs the work on only one side
• End milling, in which the cutter diameter is less than the work width
• Profile milling, a 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, in which a ball-nose cutter (rather than square-end
cutter) is fed back and forth across the work along a curvilinear path at close
intervals to create a three dimensional surface form.
Face milling
(a) conventional face milling
(b)partial face milling
(c) end milling
(d) profile milling
(e) pocket milling
(f) surface contouring
Cutting conditions in milling
𝑣
• Rotational speed (𝑁) =
𝜋𝐷
Fed rate, 𝑓𝑟 = 𝑁𝑛𝑡 𝑓

• Material Removal Rate (𝑀𝑅𝑅) = 𝑤𝑑𝑓𝑟

• The time required to mill a workpiece of length,
𝐿+𝐴
𝑇𝑚 =
𝑓𝑟
Where, A-approach distance
A= 𝑑(𝐷 − 𝑑), 𝑖𝑛 𝑐𝑎𝑠𝑒 𝑜𝑓 𝑠𝑙𝑎𝑏 𝑚𝑖𝑙𝑙𝑖𝑛𝑔
 Other machining operations
Shaping and planning
Shaping and planing are both involving the use of a single-point cutting tool moved
linearly relative to the workpart. In conventional shaping and planing, a straight, flat
surface is created by this action.
 Broaching
• Broaching is performed using a
multiple-teeth cutting tool by
moving the tool linearly relative to
the work in the direction of the tool
axis. The machine tool is called a
broaching machine, and the cutting
tool is called a broach.
Sawing
Sawing is normally used to separate a workpart into two pieces, or
to cut off an unwanted portion of a part

a) Hacksawing. Reciprocating motion of the saw against the work used in cutoff
operations on the forward stroke of the saw blade.
b) Bandsawing involves a linear continuous motion, using a bandsaw blade made in
the form of an endless flexible loop with teeth on one edge.
c) Circular sawing, Rotating saw blade to provide a continuous motion of the tool past
the work, often used to cut long bars, tubes, and similar shapes to specified length.
End