ENS2110/ENS6134 – Materials and Manufacturing 2

Dr. Majid Rad

m.rad@ecu.edu.au
Office: JO 5.246
Phone: (08) 6304 5883

MACHINING OPERATIONS AND

MACHINE TOOLS

1. Turning and Related Operations

2. Drilling and Related Operations
3. Milling
4. Other Machining Operations

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Material Removal Processes
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, drilling, milling
 Abrasive processes – material removal by
hard, abrasive particles, e.g., grinding
 Nontraditional processes – various energy
forms other than sharp cutting tool to remove
material

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Machining
A material removal process in which a sharp
cutting tool is used to mechanically cut away
material so that the desired part geometry
remains
 Most common application: to shape metal parts
 Most versatile of all manufacturing processes
in its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
 Casting can also produce a variety of
shapes, but it lacks the precision and
accuracy of machining

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Material Removal Processes

Turning Shaping

Milling Planing

Drilling Broaching
Machining Other Sawing
Boring
Mechanical
Reaming
Material Removal Electromech.
Non-traditional Tapping
Processes Thermal
Chemical
Honning
Grinding
Abrasive Lapping
Other
Superfinishing
Other

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Machining Operations
 Most important machining operations:
 Turning
 Drilling
 Milling
 Other machining operations:
 Shaping and planing
 Broaching
 Sawing

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Classification of Machined Parts

 Rotational - cylindrical or disk-like shape

 Nonrotational (also called prismatic) -
block-like or plate-like

Machined parts are classified as: (a) rotational, or (b) nonrotational,

shown here by block and flat parts.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Question

Which machining operations are capable of

producing these parts?

Adapted from
Kalpakjian, 5e

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
 Why Machining is Important
 Variety of work materials can be machined
 Most frequently used to cut metals
 Variety of part shapes and special
geometric features possible, such as:
 Screw threads
 Accurate round holes
 Very straight edges and surfaces
 Good dimensional accuracy and surface
finish

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Disadvantages with Machining
 Wasteful of material
 Chips generated in machining are
wasted material, at least in the unit
operation
 Time consuming
 A machining operation generally takes
more time to shape a given part than
alternative shaping processes, such as
casting, powder metallurgy, or forming

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Machining in Manufacturing Sequence
 Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
 Other processes create the general shape
of the starting workpart
 Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot create

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Machining Operations and Part Geometry
Each machining operation produces a
characteristic part geometry due to two
factors:
1. Relative motions between tool and workpart
• Generating – part geometry determined
by feed trajectory of cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by
the shape of the cutting tool

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Generating Shape

Generating
shape: (a)
straight turning,
(b) taper
turning, (c)
contour turning,
(d) plain milling,
(e) profile
milling.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Forming to Create Shape

Forming to create shape: (a) form turning, (b) drilling, and (c) broaching.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Forming and Generating

Combination of forming and generating to create shape: (a) thread

cutting on a lathe, and (b) slot milling.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Turning
Single point cutting tool removes material from a
rotating workpiece to generate a cylinder
 Performed on a machine tool called a lathe
 Variations of turning performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Turning

Cutting speed equation

v=pDN
v = cutting speed (m/min)
D = initial dia of work (m)
N = spindle speed (rev/min) or (RPM) Turning operation

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Adapted from Kalpakjian, 5e.

Turning Turning
 A Typical Lathe

Various major components of a typical lathe.

Source: Courtesy of Heidenreich & Harbeck.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Methods of Holding the Work in a Lathe

Between centers using a "dog” Three-jaw chuck

Collet
Face plate for non-cylindrical workparts
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
 Multiple Spindle Bar Machines
 More than one spindle, so multiple parts
machined simultaneously by multiple tools
 Example: six spindle automatic bar machine
works on six parts at a time
 After each machining cycle, spindles (including
collets and workbars) are indexed (rotated) to
next position

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Multiple Spindle Bar Machine

(a) Part produced on a six-spindle automatic bar machine; and (b)

sequence of operations to produce the part: (1) feed stock to stop,
(2) turn main diameter, (3) form second diameter and spotface, (4)
drill, (5) chamfer, and (6) cutoff.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Boring
 Boring is in fact internal
turning operation!
 Horizontal
 Vertical

How can we perform boring

operations on a lathe?

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Boring on the Lathe

 Common methods of performing boring

operations on a lathe

What is the difference between these two boring operations?

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Drilling and Related Operations

 Creates a round hole

 Compare to boring which can only enlarge an
existing hole

Cutting speed
equation
v=pDN
v = cutting speed (m/min)
D = Drill dia (m)
N = spindle speed (rev/min) or (RPM) Through-hole
Blind-hole

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Operations Related to Drilling
 (a) Reaming, (b) tapping, (c) counterboring, (d)
Countersinking, (e) center drilling, (f) spot facing

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Drill Press and Radial Drill

Upright drill press Radial drill press

Source: Willis Machinery & Tools
Work is held by
a vise, fixture
What is the distinguishing feature of a radial drill press?
or drill jig.

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Milling
Machining operation in which work is fed past a
rotating tool with multiple cutting edges
 Axis of tool rotation is perpendicular to feed

Cutting speed
equation
v=pDN
v = cutting speed (m/min)
D = Cutting tool dia (m)
N = spindle speed (rev/min) Peripheral milling Face milling

What is the distinguishing feature of each?

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
 CLASS ACTIVITY
Conventional vs Climb Milling
Form small groups and compare these two
conventional and climb milling methods shown
below.

Conventional Milling Climb Milling

 More power needed  Less power needed
 Tends to lift work part  Holds workpart
 Smoother machining  Longer tool life
 Used for finishing  More vibrations
 Used for roughing
©2007 John
John Wiley
Wiley & Sons,
& Sons, Inc.M M
Inc. P Groover,
P Groover, Fundamentals
Fundamentals of of Modern
Modern Manufacturing 3/e
Manufacturing
 Types of Milling Operations

Peripheral Milling

Slab milling

Side milling

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Types of Milling
Face Milling
 (a) Conventional face milling, (b) partial face milling, (c) end
milling, and (d) profile milling (e) pocket milling and (f) contour
milling

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

High speed face
milling using
indexable inserts
(photo courtesy
of Kennametal
Inc.).

©2007 John
John Wiley
Wiley & Sons,
& Sons, Inc.M M
Inc. P Groover,
P Groover, Fundamentals
Fundamentals of of Modern
Modern Manufacturing 3/e
Manufacturing
 Milling Machines

Horizontal knee-and- Vertical knee-and-column

column milling machine milling machine

What is the distinguishing feature of each?

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
 Face Milling
 Distance A for face milling

A
A

Face-milling operation showing (a) action of an insert in face milling; (b) climb milling;
(c) conventional milling; (d) dimensions in face milling. Kalpakjian, 5e.
 Shaping and Planing
 Similar operations
 Both use a single point cutting tool moved
linearly relative to the workpart

What is the
difference?
(a) Shaping, and (b) planing.
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
 Shaper and Planner

Planer

Shaper

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Shaping and Planing
 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
 Typical tooling: single point high speed steel
tools

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Question

 How would you machine following internal shapes?

A vertical broaching machine:

Courtesy of Ty Miles, Inc.

©2007 John
John Wiley
Wiley & Sons,
& Sons, Inc.M M
Inc. P Groover,
P Groover, Fundamentals
Fundamentals of of Modern
Modern Manufacturing 3/e
Manufacturing
 Broaching

 Moves a multiple tooth cutting tool linearly

relative to work in direction of tool axis

Adapted from Kalpakjian, 5e

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Broaching
Advantages:
 Good surface finish
 Close tolerances
 Variety of work shapes possible
Cutting tool called a broach
 Owing to complicated and often
custom-shaped geometry, tooling is expensive

John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

 Internal Broaching
 Performed on internal surface of a hole
 A starting hole must be present in the part to
insert broach at beginning of stroke

(a) External and (b) internal broaching. Cross-hatching indicates

the surfaces broached.
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
 Power Saws
a) Power hacksaw –linear
reciprocating motion of hacksaw
blade against work.

(b) Bandsaw (vertical) –

linear continuous
motion of bandsaw
blade, which is in the
form of an endless
flexible loop with teeth (c) Rotating saw blade
on one edge. provides continuous motion
of tool past workpart
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing