Chip-Type Machining Processes

General Manufacturing Processes Engr.-20.2710

Instructor - Sam Chiappone
Chip-Type Machining Processes
Class 1
 Machining - “Removing unwanted material from a
workpiece in the form of chips”
 US industries spend $60 billion a year on metal
removal processes
 Most products require some type of machining
– Direct
» Add value = drill hole, mill pocket, etc.
» Rough (cleanup sand castings) to high precision (.0001”)
– Indirect
» molds, dies, jigs, fixtures

GMP-20.271
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 Why Machining Process vs.
Other Manufacturing Processes
 Accuracy is not obtainable by other methods
 Repeatability - interchangeable manufacturing
 Design requirements
– Tolerance, surface finish, mechanical strength
requirements
 Low order quantity
 Manufacturing firms capabilities

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 Process Basics
 Machine Tool
 A piece of equipment designed to accomplish a specific
process.
 Example - a milling machine, injection molding
machine, lathe, etc.

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 Process Basics
Conventional

Computer
Numerical
Control

GMP-20.271
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 Process Basics

GMP-20.271
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 Process Basics
Conventional

Computer
Numerical
Control

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 Process Basics

Combination
Conventional / CNC

GMP-20.271
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 Process Basics

GMP-20.271
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 Process Basics

GMP-20.271
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 Process Basics
 Machining Process
– Changes the value and quality of the raw material. A
process typically involves a series of steps or operations
and utilizes a machine tool.
» Examples include turning, milling, drilling, etc.
 Operation
– A distinct action being performed to produce a desired
effect.
» Material handling, packaging, inspection, drilling, threading

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 Process Basics
 Tools
– Refers to devices used to cut or deform the metal.
» Cutting tools - examples include end mills, carbide inserts,
drills, grinding wheels, shell mills, etc.

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 Process Basics

 Tooling
– Refers to holding devices
» Examples include- vises, fixtures, jigs…...etc.

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 Process Basics

 Cutting fluid
– Act as a coolant and lubricant
– Reduce friction between chip and tool face
– Extend tool life
– Help to remove chips from cutting area

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 Seven Basic Chip Formation
Processes
 Shaping
 Turning
 Milling
 Drilling
 Sawing
 Broaching
 Abrasive Machining

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 Seven Basic Chip Formation
Processes
Turning

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 Seven Basic Chip Formation
Processes
Milling

GMP-20.271
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 Seven Basic Chip Formation
Processes
Drilling

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 Seven Basic Chip Formation
Processes
Sawing

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 Seven Basic Chip Formation
Processes
Broaching

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 Seven Basic Chip Formation
Processes
Abrasive Machining

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 Metal Removal Related
Calculations
 To efficiently use these components, different
input parameters have to be calculated. They
include:
– RPM of cutter
» Milling or drilling operation = Rpm for cutter
» Turning operation = Rpm for part
 Basically the rotating component

– Feed
» The distance in inches, feet, or millimeters per minute that the
work advances into the cutter.
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 Metal Removal Related
Calculations
 Input parameters (con’t)
– Cutting speed(CS)-the surface feet per minute or meters
per minute, at which a metal can be machined
efficiently. This variable has a direct relationship to the
diameter of the cutter, in a milling or drilling operation,
or the diameter of the work piece in a lathe operation.
» Example - When machining(using a milling machine) a
medium grade steel, the cutter must achieve a surface speed of
about 90 ft/min. The diameter of the cutter will have a direct
relationship to the rpm calculation.

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 Metal Removal Related
Calculations
 Input parameters (con’t)
– Depth of cut - Amount of material being removed.
– Horsepower required for cut
– Material removal rate (MRR) - volume of material
being removed per unit of time
– In a milling operation, you also have to take into
account the thickness of the chip each tooth will
remover per revolution as it advances into the work.
This value is expressed in feed per tooth.
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Metal Removal Problem

1.
Cutting
Tools
4.

2.
3.
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Metal Removal Problem

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 Factors Effecting Calculations

 Set-up conditions
 Machine conditions
 Tooling conditions
 Material conditions
 Cutting fluid

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