ME231: Materials and Manufacturing

II

Muhammad Abubakar
MED/IEFR/FSD
 Course Contents
2 credits (2 hrs a week)
 Course
detail
Mid term exam: 30 Marks

End term exam: 40 Marks

02 Quizzes: 5 Marks each

Assignments/classwork/ Presentation: 10 Marks

Complex Engineering Problem: 10 Marks

 What is
• Machining?
Machining is the process of removing unwanted material from a workpiece in the
form of chips.
• If the workpiece is metal, the process is often called metal cutting or metal removal.
• Machining undoubtedly is the most important of the basic manufacturing processes.
 Material Removal
Processes

The material removal processes are a family of

shaping operations in which excess material is
removed from a starting work-part so that what
remains is the desired final geometry.
 Basic Elements in
• A block of metalMachining
(work piece)
• Cutting Tool
• Machine Tool
• Cutting Fluid
• Cutting speed (Primary Motion)
• Feed (Secondary Motion)
• Chips
• Work holding and Fixturing
• Force and Energy Dissipated
• Surface Finish
 Overview of machining
technology It is the speed at which material remove in one
minute by cutting tool from a linear distance of
Cutting speed workpiece. It is express as mm/min or m/min.
𝜋𝐷𝑁
Cutting speed (V) = m/min
1000
Where N is spindle speed in RPM, D is uncut
workpiece diameter in mm.

It is the distance the cutting tool advances along

Feed the length of the work for every revolution of the
spindle. It is expressed in mm/rev.
In turning, it is the distance the tool is plunged into
Depth of cut the surface. It is expressed in mm.

𝑴𝑹𝑹 = 𝑽𝒇𝒕 𝑚𝑚3/𝑠𝑒𝑐 𝑑. 𝑜. 𝑐. (𝑡) = 𝐷 − 𝑑

2

Where MRR is material removal rate, V is cutting speed (mm/min), f is feed rate (mm/rev) and t is depth of cut (mm).
 Class
task
A steel shaft of 25mm diameter is turned at a cutting speed of 50 metres
per minute. Find the r.p.m. of the shaft.
 Class
task
A steel shaft of 25mm diameter is turned at a cutting speed of 50 metres
per minute. Find the r.p.m. of the shaft.
 Class
task
A steel shaft of 25mm diameter is turned at a cutting speed of 50 metres
per minute to a diameter of 19 mm in a single pass turning operation. Find
depth of cut.
 Class
task
A steel shaft of 25mm diameter is turned at a cutting speed of 50 metres
per minute to a diameter of 19 mm in a single pass turning operation. Find
depth of cut.

𝐷−𝑑 25 − 19
𝑡= = = 3 𝑚𝑚
2 2
 The Cutting
• Tool
A cutting tool has one or more sharp cutting edges and is made of a material that is
harder than the work material.
• The cutting edge serves to separate a chip from the parent work material.
• Connected to the cutting edge are two surfaces of the tool: the rake face and the flank

(a) A single-point tool (b) A helical milling cutter

 Types of Machining
Methods
1. Orthogonal machining
In orthogonal machining, the cutting edge and the cutting motion are perpendicular to
each other. In orthogonal machining, the tool geometry is simplified from the three-
dimensional geometry, to a two-force geometry.
2. Oblique machining
In oblique machining, the cutting edge and the cutting motion are not perpendicular to
each other.
 Types of
chips

associated with certain

When relatively When ductile work When machining
difficult-to-machine
brittle materials materials are cut at ductile materials at
metals such as titanium
(e.g., cast irons) are high speeds and low-to-medium cutting
alloys, nickel-base
machined at low relatively small feeds and speeds, friction
super alloys, and
cutting speeds. High depths. Fine surface between tool and chip.
finish. austenitic stainless
tool–chip friction and Rough surface.
steels whenthey are
large feed and depth
machined at higher
of cut promote it.
cutting speeds.
Rough surface finish
Lathe
Machine
 Components of Lathe
• Machine
Bed: The bed supports all major components of the lathe; it has a large mass and is built rigidly, usually
from gray or nodular cast iron.
• Carriage: The carriage, or carriage assembly, slides along the ways and consists of the cross-slide, tool
post, and apron. The cutting tool is mounted on the tool post, usually with a compound rest that swivels
for tool positioning and adjustment.
• Headstock: The headstock is fixed to the bed and is equipped with motors, pulleys, and V-belts that
supply power to a spindle and at various rotational speeds, which can be set through manually
controlled selectors or by electrical controls.
• Tailstock: The tailstock, which can slide along the ways and be clamped at any position, supports the
other end of the workpiece. It is equipped with a center, which may be fixed (called dead center) or it
may be free to rotate with the workpiece itself (live center).
• Feed Rod and Lead Screw: The feed rod is powered by a set of gears through the headstock. It rotates
during the lathe operation, and provides movement to the carriage and the cross-slide by means of gears,
a friction clutch, and a keyway along the length of the rod.
 Turning
•
•
Process
Turning is a single-point tool process and is very commonly used machining process.
It is used to produce symmetrical and cylindrical parts.
Processes Performed on Lathe Machine
Processes Performed on Lathe Machine
 Class Task
Name the lathe machine operations to achieve this shape from a starting workpiece
of cylindrical shape.