Basic machining processes

Laboratory report n°4 – Manufacturing techniques

Edgar DAVID
Mechanical ingineering

1
 Summary

I. Introduction .......................................................................................................................... 3
II. General equipment needed to make resistance welding........................................................... 4
III. The different basic machining processes ................................................................................. 5
A. Turning .............................................................................................................................. 5
1. General principle ............................................................................................................ 5
2. Part to be made in the laboratory .................................................................................... 6
B. Milling ............................................................................................................................... 7
1. General principle ............................................................................................................ 7
2. Part to be made in the laboratory .................................................................................... 8
C. Drilling .............................................................................................................................. 8
1. General principle ............................................................................................................ 8
2. Part to be made in the laboratory .................................................................................... 9
IV. Conclusion ...........................................................................................................................11

2
 I. Introduction
Machining constitutes a set of fundamental techniques in the realm of industrial manufacturing,
enabling the transformation of raw materials into finished parts with precise tolerances and required
specifications. These machining processes form the backbone of numerous industries, ranging from
aerospace to automotive, electronics, and many other sectors.

In this document, we will cover traditional methods such as turning, milling and drilling which remain
the pillars of industrial manufacturing.

Basic machining processes has several advantages and disadvantages. Here is a general list of the main
advantages and disadvantages of this methods:

Advantages:

• Precision: Machining techniques achieve highly precise tolerances, ensuring the manufacturing
of parts with exact required dimensions.
• Versatility: These processes can be applied to a wide range of materials, from metals to plastics
and composites.
• Surface Finish: They offer the capability to achieve high-quality surface finishes, crucial in many
applications where a smooth surface is required.
• Mass Production: Certain processes like milling or turning enable the manufacturing of parts
in large quantities and relatively quickly.
• Quality Control: These processes provide means for quality control to ensure that design
specifications are met.

Disadvantages:

• Material Waste: Machining often involves the loss of a significant amount of raw material to
achieve the desired final shape, which can be costly and generate waste.
• Tool Wear: Tools used in machining have a limited lifespan and require regular replacement,
increasing production costs.
• Production Time: Some machining processes can be relatively slow, especially for complex parts
or materials that are difficult to machine.
• Complexity: Certain machining processes, especially those requiring specialized machines or
complex operations, may demand technical skills and deep expertise.

It's important to note that these advantages and disadvantages may vary depending on the specific
type of machining process, the processed material, the complexity of the part, and other inherent
production factors.

3
 II. General equipment needed to make basic machining processes
The basic machining processes are not limited to turning, milling and drilling, there are many other
machining processes. However, we were only able to see these three processes during our laboratory.
In this section, we will look at the machines needed to carry out these three basic machining processes.

• Turning machine: A lathe is a machine tool used in the

manufacturing process to perform turning operations. This
machine is employed to produce cylindrical or conical parts by
rotating a raw material piece (referred to as "bar" or "blank")
around an axis, while a cutting tool moves along the piece to
shape it as required. The lathe is a versatile piece of equipment
widely used in industries to manufacture parts of various
shapes, sizes, and materials. It is an essential tool in numerous
manufacturing processes.

• Milling machine: A milling machine is a versatile machine tool used

primarily for shaping solid materials. It operates by rotating a cutting tool
against the workpiece, removing material to create complex shapes,
surfaces, or features. Milling machines are widely used in various
industries for their ability to produce a wide range of parts with different
shapes and sizes. Their versatility makes them essential in manufacturing
processes requiring intricate detailing and precision.

• Drilling machine: A drilling machine, commonly known as a drill press, is a

machine tool designed to create holes in various materials by rotating a drill
bit. Drilling machines are widely used in various industries for creating
precise holes in materials such as metal, wood, plastic, and more. They are
essential tools in manufacturing, construction, woodworking, and
metalworking operations.

4
III. The different basic machining processes
A. Turning
1. General principle
The turning process is a machining technique used to give cylindrical shape to a rotating workpiece by
removing material using a cutting tool. Here is the general principle of turning:

First, the workpiece to be machined is clamped onto the lathe's spindle using a chuck or another
clamping device. It rotates around its main axis. The lathe's spindle rotates the workpiece at a
controlled and steady speed. The cutting tool is mounted on the tool post and positioned near the
rotating workpiece. It gradually advances towards the rotating workpiece. This feed can be done
manually or automatically, depending on the type of lathe used. When the tool comes into contact
with the workpiece, it removes chips of material, thereby creating the desired shape. Precise control
of the cutting and tool movements allows for achieving accurate dimensions and quality surface finish.
During the process, the machinist carefully monitors the process to ensure accurate measurements
and optimal quality of the workpiece being manufactured. Adjustments may be necessary to correct
the cutting or machine settings. Once the workpiece is machined, finishing operations may be carried
out to achieve the required dimensional tolerances and surface quality. The workpiece is then
inspected to ensure it meets the design specifications.

5
 2. Part to be made in the laboratory

For our laboratory, the plan of the part above had to be made from a raw piece of aluminium with a
diameter of 20mm. The first step in producing this part was to surface the flat surface to make it
perfectly flat and free of imperfections.

The second step was to determine the outside diameter of the cylinder. To do this, the cutting speed
and feed parameters had to be pre-set on the lathe. In our case we had a speed of rotation of 700
rev/min and feed per revolution of 0.1 mm/rev. You also need to check the position of the tool on the
desired axis on the machine screen so that you can move from an outside diameter of 20mm to 18mm
as accurately as possible.

The next step is to make the hole in the cylinder. To do this, the same parameters are retained, but the
tool must change. It's a drill bit that is placed at the end of the lathe and that sinks into the workpiece
as it rotates.

6
The final step is to cut the required part from the aluminium raw to give it the desired length on the
plan. In our case, we worked on a length of 23mm and the part must be 20mm long. So, we're using a
3mm tool that will allow us to both detach the part and give it the length specified on the plan.

B. Milling
1. General principle
Milling is a machining process that involves removing material chips from a workpiece using a rotating
cutter to achieve a specific shape, surface, or precise features. Here is the general principle of milling

First, the workpiece to be machined is secured on the milling machine's table using clamping devices
such as vises or clamps. It can be moved in different directions along the X, Y, and Z axes. A rotating
cutter, suitable for the material and required shape, is attached to the milling machine's spindle. After
that, we need to adjust the cutting parameters. The rotational speed of the cutter and the feed rate of
the milling machine's table or head are adjusted based on the material, cutter size, and cutting
requirements. The cutter now rotates and moves along the X, Y, and Z axes to gradually remove material
chips from the workpiece. Movements can be controlled manually or programmed for more complex
operations. When the cutter comes into contact with the workpiece, it cuts the material, removing
chips. This process shapes the workpiece according to the required specifications, creating flat surfaces,
grooves, contours, or other features. The machinist monitors the process to ensure that dimensions
and surface quality meet requirements. Adjustments may be made to cutting parameters if necessary.
Once the milling operation is complete, finishing operations may be performed to achieve precise
dimensions and a quality surface. The workpiece is inspected to verify that it meets the design
specifications.

7
 2. Part to be made in the laboratory
For this process, we need to surface a raw aluminium part. To do this, as with turning, we need to
define the precise parameters to be set on the machine. For milling, we need to define the cutting
speed and the tool rotation frequency. In our case, the cutting speed set is 58 mm/min and the tool
rotation frequency is 112 rev/min. Once the machine has been set up, it can be run to produce the
desired surface finish. The result is the following surface after milling.

C. Drilling
1. General principle
Drilling is a machining process that involves creating holes in a material using a machine tool called a
drill or drill press. Here is the general principle of drilling:

First of all, we need to fix the workpiece. The workpiece to be drilled is secured on the table or held
firmly using clamping devices such as vises or clamps to prevent movement during drilling. Then, a drill
bit suitable for the material and the required hole size is chosen and inserted into the drill's chuck. The
larger the hole, the more intermediate diameters drills will be needed to make the desired hole. The
rotational speed of the drill bit is next set based on the material being drilled and the hole diameter
required. The drill is positioned to precisely align the drill bit with the spot where the hole needs to be
made. Once these steps have been completed, the process can begin. Applying controlled pressure,
the drill is engaged to begin rotating the drill bit and penetrate the material. The drill bit cuts through
the material by rotating rapidly and gradually advancing into the workpiece until achieving the desired

8
diameter and depth for the hole. Once drilling is completed, the drill bit is removed from the hole. The
workpiece is inspected to check the hole quality, dimensional accuracy, and surface finish.

2. Part to be made in the laboratory

For this process, a 27mm hole had to be made in a blank plate. To do this, two intermediate holes were
created in order to obtain our final hole. Indeed, as mentioned previously, it is necessary to make pre-
holes to avoid breaking the drill and to make the drilling as clean as possible. The first hole is a 3.15mm
pre-hole made manually to prepare the plate for a larger drill bit later on. This process also requires
settings to be made on the machine. Before each hole, we need to define the drill rotation speed and
the tool feed per revolution. These parameters are similar to the turning process. For this hole, only
the speed of rotation of the drill is required, as the feed is done manually with such a small tool. In our
case, the rotation speed is 630 rev/min.

The second hole has a diameter of 16mm. It is necessary to drill this hole before the desired final
diameter, as it first enlarges the pre-hole and allows the next hole to be more precise and better
finished. In this case, the set rotation speed is 160 rev/min and the feed speed is 0.125 mm/rev. During
drilling, it is necessary to lubricate the drill bit to avoid overheating the tool and the drilling plate.

9
Finally, we can make our final 27mm hole. The speed of rotation for this hole is 112 rev/min and the
feed rate is 0.16 mm/rev. This last hole also requires lubrication during drilling, for the same reasons
as the previous hole.

10
IV. Conclusion
To conclude this report, I was already familiar with these machining methods as I had already studied
them during my engineering course. However, I really enjoyed revisiting these processes because, in
my opinion, they represent basic engineering. When we think of creating and making parts in a
workshop, we immediately think of turning, milling and drilling processes. In fact, they are an essential
part of our engineering training, as these three machines can be used to make 90% of all machinable
parts. Turning, for example, not only enables us to produce the shape of a part, but we can also make
threads and taps with the same machine. The drilling machine can also do this. There's so much that
can be done with these processes that this laboratory was one of the most essential for me to do in
the manufacturing techniques course.

Ultimately, these machining techniques remain essential to meet the demands of quality, precision,
and mass production across a wide array of industries. Ongoing innovation in this field will enhance the
efficiency, sustainability, and cost-effectiveness of these processes while meeting the evolving needs of
the manufacturing sector.

11