Metal Machining and Automation

(ME 3201)

PRESENTED BY

D R . S A N N D H YA R A N I B I S WA S
A S S I S TA N T P R O F E S S O R
D E PA R T M E N T O F M E C H A N I C A L E N G I N E E R I N G
NIT ROURKELA
Email: srb@nitrkl.ac.in
 Formula for Drilling

Cutting speed (Vc) = ( π ×d× N/1000) m/min

Where d= drill diameter

N= spindle speed in rpm

Feed rate (fr) = f × N mm/min

 Problem

At what speed a 15 mm diameter drill will run to drill

a hole through a brass plate of 20 mm thick in order
to cut the material at a cutting speed of 60 m/min.
 Machining Time

Cutting time (Tc) = L/ (f × N) min

N = rpm of drill
L= Length of axial travel of drill in mm
=l+a
l= depth or thickness of work piece
a = approach of drill = 0.3 d
d = diameter of drill
f= feed per revolution
 Formula for Drilling

Depth of cut = Drill diameter / 2 mm

Cutting time (Tc) = L/ (f × N) min

Material removal rate (MRR)=(π/4)× d2 × f × N mm3/min

 Problem

What is the machining time for drilling 3 holes of 16

mm diameter on a work piece using the following
data? Work piece thickness = 30 mm; cutting speed
= 22 m/min, feed = 0.2 mm/ rev
 Milling

Milling is a process of producing flat and complex

shapes with the use of multi-tooth cutting tool, which
is called a milling cutter and the cutting edges are
called teeth.
The milling machine consists basically of a motor
driven spindle, which mounts and revolves the
milling cutter, and a reciprocating adjustable
worktable, which mounts and feeds the work piece.
Horizontal Milling machine
Vertical Milling Machine
 Milling operations

Plain milling operation

Face milling operation
Side milling operation
Straddle milling operation
Angular milling operation
Gang milling operation
Form milling operation
Profile milling operation
End milling operation
Saw milling operation
Slot milling operation
Gear cutting operation
Helical milling operation
Milling cutter nomenclature
 Types of Milling Operations

• There are two basic types of milling operations

(a) peripheral milling and (b) face milling.
 Peripheral Milling
• In peripheral milling, also called 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.
• The primary motion is the rotation of the cutter. The feed is imparted to the
work piece.

(a) slab milling, (b)slotting, (c) side milling, (d) straddle milling, and (e) form
milling
 Peripheral Milling

 Slab milling, the basic form of peripheral milling in which the cutter
width extends beyond the work piece on both sides.
 Slotting, also called slot milling, in which the width of the cutter is less
than the work piece width, creating a slot in the work when the cutter is
very thin, this operation can be used to mill narrow slots or cut a work
part in two, called saw milling.
 Side milling, in which the cutter machines the side of the work piece.
 Straddle milling, the same as side milling, only 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.
 Face Milling

 Conventional face milling, in which the diameter of the cutter is greater than
the work part 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, so a slot
is cut into the part.
 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.
 Types of milling cutter

Plane milling cutter

Face milling cutter
End milling cutter
T slot milling cutter
Side milling cutter
Double angle cutter
Types of milling cutter