Machine Tool and Machining (Lecture 1)

Dr. Saad Nawaz

COURSE OUTLINE
• Introduction to machining
• Tool geometry
• Tool defects and materials
• Machining processes
• Milling processes
• Shaping processes
• Non-conventional machining processes
• Introduction to CNC
• Sheet metal forming
• Laser manufacturing
COURSE BOOKS AND REFERENCE
MATERIAL
a) Textbook
• Fundamentals of Modern Manufacturing:
Materials, Processes, and Systems. Mikell P.
Groover, 2nd, Edition, ISBN 81-265-1266-0,
Wiley, 2010.
• Technology of Machine Tools by Krar, Gill, Smid
• Manufacturing and Machine Tool operation by:
Pollack.
Machining Background
• What is machining?
• Why machining is important?
 Manufacturing Process
• A sequence of operations and processes designed to create a
specific product.
• The process of turning materials into a products.
Products and Manufacturing
Product Creation Cycle
Design → Material Selection → Process
Selection → Manufacture → Inspection →
Feedback
Typical product
cost breakdown
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 shape.
• 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
Machining process
• The machining is the most broad technological process used in
manufacturing.
• Generally, in the field of manufacturing, the term of Machining
means removal of material from a raw material, by cutting small
chips, in order to obtain the desired shape and dimensions for final
part.
• The machining is strictly necessary when finished part has to have
very tight tolerances of dimensions or when the roughness of
surfaces need to be very smooth.
Machining processes
• Removal of chips, from a raw material, is performed by a cutting
tool that need a motion relative to raw material. This motion,
named cutting motion, could be practically a rotation one or a
translation one.
motion (cutting motion) and to assure the
process continuity the tool performs a
translation motion (feeding motion) The
raw material performs a rotation motion
(cutting motion) and to assure the process
continuity the tool performs a translation
motion (feeding motion).
Machining
Cutting action involves shear deformation of work material
to form a chip
• As chip is removed, a new surface is exposed

(a) A cross‑sectional view of the machining process, (b) tool with

negative rake angle; compare with positive rake angle in (a)
Why Machining is Important

• Variety of work materials can be machined

• Most frequently applied to metals
• Variety of part shapes and special geometry features possible,
such as:
• Screw threads
• Accurate round holes
• Very straight edges and surfaces
• Good dimensional accuracy and surface finish
Conventional Machining
• Cutting processes
– Single point: e.g. shaping, planing, turning, boring, etc.
– Multiple point: e.g. milling, drilling, etc.
• Abrasive processes
• Grinding, honing, etc.
NONTRADITIONAL MACHINING AND
THERMAL CUTTING PROCESSES
• Mechanical Energy Processes (Ultrasonic machining, Water jet
cutting, Abrasive water jet cutting, Abrasive jet machining)
• Electrochemical Machining Processes (Electrochemical machining (ECM),
Electrochemical deburring (ECD), Electrochemical grinding (ECG) )
• Thermal Energy Processes (Electric discharge machining, Electric
discharge wire cutting, Electron beam machining, Laser beam
machining, Plasma arc machining)
• Chemical Machining (Chemical milling, Chemical blanking, Chemical
engraving, Photochemical machining)
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
Machining Operations
• Most important machining operations:
• Turning
• Drilling
• Milling
• Other machining operations:
• Shaping and planing
• Broaching
• Sawing
Turning
Single point cutting tool removes material from a rotating
workpiece to form a cylindrical shape

(a) turning
Turning

turning taper profile cut groove cut cut-off thread cut

knurling
facing face groove boring, internal groove drilling
Drilling
Used to create a round hole, usually by means of a
rotating tool (drill bit) that has two cutting edges

The three most common

types of machining process:
(b) drilling
Milling
Rotating multiple-cutting-edge tool is moved slowly relative
to work to generate plane or straight surface
• Two forms: peripheral milling and face milling

(c) peripheral milling, and (d) face milling

Tool geometry

Shank is that part of the tool bit which is not ground to form cutting edge. Shank
is rectangular in cross-section and is the portion of the tool bit which is held in
the tool holder.
Base is the bottom surface of tool and takes the tangential pressure of the cut.
Face is that surface against which the chip slides.
Flank: The flanks are the surfaces below and adjacent to the cutting edges. These
are the surfaces of the tool facing the work.
Main cutting edge
Side cutting edge
Tool geometry

Cutting Edge: It is the edge on face of the tool which removes the
material from work piece. The cutting edge usually comprises the nose
radius, the side cutting edge, and the end cutting edge.
The Side (Auxiliary) Cutting Edge: This is the edge formed by intersection
of the tool face and side flank. It is mainly responsible for shearing of the
work material during cutting.
The End (main) Cutting Edge: This is the edge formed by intersection of
the tool face and end flank.
Nose: The nose of a tool is the conjunction of the side and end cutting
edges
Tool geometry

Rake angle: is the angle of the cutting face relative to the work.
positive rake angles:
• Make the tool more sharp and pointed. This reduces the strength of the tool,
as the small included angle in the tip may cause it to chip away.
• Reduce cutting forces and power requirements.
• Helps in the formation of continuous chips in ductile materials.
• Can help avoid the formation of a built-up edge.
Tool geometry

Negative rake angles, by contrast:

• Make the tool more blunt, increasing the strength of the cutting edge.
• Increase the cutting forces.
• Can increase friction, resulting in high temperatures.
• Can improve surface finish.
A zero rake angle is the easiest to manufacture, but has a larger crater wear
when compared to positive rake angle as the chip slides over the rake face.
 Tool Signature
Convenient way to specify tool angles by use of a standardized
abbreviated system is known as tool signature or tool
nomenclature.

The seven elements that comprise the signature of a single point

cutting tool can be stated in the following order:

Tool signature 0-7-6-8-15-16-0.8

1. Back rake angle (0°)
2. Side rake angle (7°)
3. End relief angle (6°)
4. Side relief angle (8°)
5. End cutting edge angle (15°)
6. Side cutting edge angle (16°)
7. Nose radius (0.8 mm)
26
The side relief (clearance) angle is the angle ground on
the side flank of the tool below the side cutting edge.
This angle is generally 6 to 10.
The side clearance on the tool bit permits the cutting
tool to advance lengthwise into the rotating work and
prevents the flank from rubbing against the work
piece.
The side rake angle is the angle at which the face
is ground away from the side cutting edge.
For general purpose tool bits, the side rake is
generally 14. Side rake creates a keener cutting
edge and allows the chips to flow away quickly.
For softer materials, the side rake angle is generally
increased.
The back rake angle is the backward slope of the
tool face away from the nose.
The back rake angle is generally about 20.
Back rake permits the chips to flow away from the
point of cutting tool.
The end relief (clearance) angle is the angle ground
on the end flank below the end cutting edge and it
permits the cutting tool to be fed into the work.
It is generally 10 to 15 for general purpose tools.
The end relief angle varies with the hardness and the
type of material and the type of cut. The end relief
angle is smaller for harder materials, providing
support under the cutting edge.
End cutting edge angle
It is the angle between the end cutting edge and a line perpendicular to
the shank of the tool.

It provides clearance between tool cutting edge and work piece.

Side cutting edge angle

It is the angle between straight cutting edge on the side of tool and the
side of the shank.

It is also known as lead angle.

It is responsible for turning the chip away from the finished surface.