Machining Technologies

Solidification
processes
Manufacturing Processes
Processing Particulate
operations processing
Deformation
Processing processes
operations
Metal
Removal
Property
enhancing Heat
process Treatment
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Manufacturing surface treatment
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Surface Coating and
processing deposition
operations processes
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Permanent
joining
processes Brazing and
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Threaded
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fastening Permanent
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A family of shaping operations, the common feature of
which is removal of material from a starting workpart so
the remaining part has the desired geometry
• Machining – material removal by a sharp cutting tool,
e.g., turning, milling, drilling
• Abrasive processes – material removal by hard, abrasive
particles, e.g., grinding
• Nontraditional processes - various energy forms other
than sharp cutting tool to remove material
Material Removal Processes (Machining)

Machining is a generic word and refers to cutting operations that are

based on the removal of material from an originally rough-shaped
workpiece, for example, a casting or forged part, through power
driven machines.

Machining is the process of removing unwanted material from a

workpiece in the form of chips. If the workpiece is a metal, the
process is often called metal cutting or metal removal.

Machining is a manufacturing process in which a sharp cutting tool is

used to cut away material to leave the desired part shape.
 Importance of Machining
• Variety of work materials

• Variety of part shapes and geometric

features

• Dimensional accuracy

• Good surface finishes

 Disadvantages

➢Wasteful of materials

➢Time consuming
Material Removal Processes (Machining)

There are seven basic chip formation processes:

1. Turning – Done on a lathe machine

2. Milling - Done on a lathe machine
3. Drilling - Done on a drilling machine
4. Grinding - Done on a grinding machine
5. Shaping - Done on a shaping machine
6. Sawing - Done on a sawing machine
7. Broaching -Done on a broaching machine
Basic Machining Processes
 CUTTING PARAMETERS

For all metal cutting processes,

it is necessary to distinguish between
speed, feed and depth of cut, called
cutting parameters or machining
parameters.
 CUTTING PARAMETERS

Speed (V) is the primary

cutting motion, which
relates the velocity of the
rotating workpiece with
respect to the stationary
cutting tool.
V=πDN

Units: sfpm, in/min, m/min, m/s

 CUTTING PARAMETERS

Feed (f) is the amount of material

removed per revolution or per pass of the
tool over the workpiece.
The tool feeds parallel to the rotational
axis of the workpiece.

Units: in/rev, mm/rev

 CUTTING PARAMETERS

The depth of cut (DOC), d, represents

the third dimension. In turning, it is the
distance the tool is plunged into the
surface.

DOC=(D-d)/2

Units: in, mm
 Types of Chips in Machining

• Chip formation affects the surface finish, cutting forces,

temperature, tool life and dimensional tolerance.

• Understanding the chip formation during the machining

process for the specific materials is useful to determine
the machining speeds, feed rates and depth of cuts for
efficient machining and increase tool life.
 Types of Chips in Machining

During the machining process, four basic types

of chips are formed:

❑Continuous
❑Discontinuous
❑Continuous with Built-up Edge
Turning and Related Operations: (Done
on a Lathe Machine)

Turning is a machining process in which a single point tool

removes material from the surface of a rotating cylindrical
workpiece; the tool is fed linearly in a direction parallel to the axis
of rotation.
Turning is traditionally carried out on a machine called Lathe.
Operations Which Can be Performed on
a Lathe Machine:
1. Facing

The tool is fed radially into the rotating work on one end to create a
flat surface on the end.
Operations Which Can be
Performed on a Lathe Machine:
Taper Turning

Instead of feeding the tool parallel to the axis of rotation of the

work, the tool is fed at an angle, thus creating a tapered cylinder or
conical shape.
Operations Which Can be Performed on a
Lathe Machine:

Contour Turning

The tool follows a contour that is other than straight line, thus
creating a contoured form in the turned path.
Operations Which Can be
Performed on a Lathe Machine:

Form Turning

In this operation some times called forming, the tool has a shape
that is imparted to the work by plunging the tool radially into the
work.
Operations Which Can be
Performed on a Lathe Machine:

Cutoff or Parting

The tool is fed radially into the rotating work at some location along
its length to cut off the end of the part. The operation sometimes
referred to as parting.
Operations Which Can be
Performed on a Lathe Machine:

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.
Operations Which Can be
Performed on a Lathe Machine:

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. The purpose is to
achieved a desired diameter.
Operations Which Can be
Performed on a Lathe Machine:

Drilling
Drilling can be performed on a lathe by feeding the drill into the
rotating work along its axis.
Operations Which Can be
Performed on a Lathe Machine:

Knurling
This is not a machining operation because it does not involve
cutting of material. Instead it s a metal cutting operation used to
produce a regular cross hatched pattern in the work surface.
The Engine Lathe

The basic lathe used for turning and related operations is an

engine lathe. It is a versatile machine tool, manually operated and
widely used in low and medium production. The term engine dates
from the time when these machines were driven by steam engines.
The Engine Lathe
•The headstock contains the drive unit to rotate the spindle, which rotates the work.
•Opposite the headstock is the tail stock, in which a center is mounted to support
the other end of the workpiece.
•The cutting tool is held in a tool post fastened to the cross-slide, which is
assembled to the carriage.
• The carriage is designed to slide along the ways of the lathe in order to feed the
tool parallel to the axis of rotation.
 LATHE SIZE DESIGNATION

THE SIZE OF A LATHE MACHINE IS DESIGNATED BY ITS

TWO DIMENSIONS:

1. Its SWING, and

2. Maximum distance between centers

SWING: This is the maximum diameter of work that can

be rotated on a lathe.

MAXIMUM DISTANCE BETWEEN CENTERS: This indicates

The maximum length of work-piece that can be mounted between
centers.
 CUTTING TOOLS

• DEFINITION: The parts in contact with the job for doing different
operations or generation of surfaces of the product are known as
TOOLS.

• Tools may be classified according to the operation performed by the

machine, i.e.,
(a) Turning tools (for lathe machines)
(b) Milling tools (for milling machines)

• PURPOSE OF MACHINE TOOLS: Machine tools remove metal/

material from a job to produce a desired size and shape of an
object.
 PRINCIPLES OF METAL CUTTING TOOLS

1. Job material must be softer than the tool material

2. Tool shape and angles should be so designed that will produce

maximum metal removal

3. There must be relative motion between the job and the tool to
generate cutting action.

4. Proper selection of speed, fed, depth of cut, use of cutting fluid,

etc., is essential for efficient metal cutting process.
 CATEGORIZATION OF MACHINE TOOLS
1. ACCORDING TO ITS SHAPE AND SIZE: solid tool, tool bit, tip tool, tool
insert, etc.

2. WITH RESPECT TO MATERIAL OF THE TOOL: HSS tools, ceramic

tools, cemented carbides, diamond tool, abrasives, etc.

3. WITH RESPECT TO THE OPERATION IT CAN DO: Turning tool,

knurling tool, parting - off tool, etc.

5. WITH RESPECT TO NUMBER OF CUTTING POINTS/ EDGES OF THE

TOOL: Single point cutting tool ( for lathe), double edge cutting tool (drill),
multiple edge cutting tool (mill cutter, reamer, etc), etc.

6. WITH RESPECT TO DIRECTION OF TOOL MOTION: RH cutting tools,

LH cutting tools, etc.

7. WITH RESPECT TO MOTION OF THE TOOL: Translatory (lathe), rotary

(drill), reciprocating ( shaping).
 RESHARPENING/RECONDITIONING OF CUTTING
TOOLS

1. The cutting tools can be re-conditioned and brought back into use by
re- sharpening and bringing back the tool geometry, especially the
cutting edges, back to the original shape.
2. Following guide lines should be observed:

(a) Re-sharpen to original tool geometry specifications. It will

help the tool to achieve consistent results on subsequent use.
(b) Grind cutting edges & surfaces to a fine finish. Rough edges
will deteriorate the performance of tools.

(c) Remove all ‘burrs’ on re-sharpened cutting edges

(d) Avoid re-sharpening practices that over-heat and burn or melt

the tool surfaces.
 SAFETY PRECAUTIONS WHILE WORKING
ON LATHE MACHINE

1. Check all work and tooling is secure before switching

on the Lathe machine
2. CHUCK-KEYS are NEVER to be left in the chuck
3. Check coolant is available and working
4. Ensure correct feeds and speeds are being used.
5. Ensure machine guards are positioned correctly and
securely
6. Safety goggles are to be worn at all times
7. SWARF is to cleaned off the machines using a brush
8. Keep hands/ clothing/ rags clear of moving parts
9. Head stock surface must be kept clean at all times
continued…...
 SAFETY PRECAUTIONS WHILE WORKING
ON LATHE MACHINE

10. Machine should be completely stopped/ isolated to check

measurements, change of accessories or to remove/
install work
11. Complete concentration of all workers is required at all
times
12. Get yourself familiar with all controls of the machine,
specially know how to STOP the machine in an
emergency
13. Running machine should never be left unattended
14. To avoid tool chatter and possible breakage, tool over-
hang should be held to a minimum
Turret Lathe
➢ In a turret lathe, the tailstock is replaced by a turret that holds up to
six cutting tools.
➢ These tools can be rapidly brought into action against the work one
by one by indexing the turret.
➢The conventional tool post used on an engine lathe is replaced by a
four-sided turret that is capable of indexing up to four tools into
position.
➢The turret lathe is used for high production work that requires a
sequence of cuts to be made on the part.