Manufacturing Processes (ME F219)

Prof Amrita Priyadarshini

Associate Professor
Department of Mechanical Engineering
 BITS Pilani
Hyderabad Campus

Machining 2
 Manufacturing Processes

Component 1
Casting

Joining Finishing
Raw material

Assembly
Component 2 Machining Finished
product
Forming
Component 3
Machining
• Why?

• What?

• How?
Types
Turning

Drilling

Milling
 Types of motions
• Primary or cutting motion
– Generatrix
• Feed motion
– Directrix
 Drilling

Turning

Milling
Cutting parameters in turning
Mechanics of basic machining operation
Basic machining operation and important parameters
 Orthogonal vs Oblique
There are two basic methods of metal cutting based
on cutting edge and direction of relative motion
between tool and work:
• Orthogonal cutting process (Two Dimensional)
– In orthogonal cutting process, the cutting edge is
perpendicular (90 degree) to the direction of feed.
– The chip flows in a direction normal to cutting edge of the
tool. A perfectly sharp tool will cut the metal on rack surface.
• Oblique cutting process (Three Dimensional)
– In oblique cutting process, the cutting edge is inclined at
an acute angle (less than 90 degree) to the direction of
feed. The chip flows sideway in a long curl.
– The chip flows in a direction at an angle with normal to
Orthogonal vs Oblique Cutting
 Orthogonal vs Oblique

Orthogonal cutting process (Two Dimensional)

• In orthogonal cutting process, the cutting edge is perpendicular (90 degree) to the
relative velocity.
• The chip flows in a direction normal to cutting edge of the tool. A perfectly sharp
tool will cut the metal on rack surface.
Oblique cutting process (Three Dimensional)
• In oblique cutting process, the cutting edge is inclined at an acute angle (less than
90 degree) to the relative velocity. The chip flows sideway in a long curl.
• The chip flows in a direction at an angle with normal to the cutting edge of the tool.
Comparative Features
Pipe turning
Chip Formation Mechanism
 Factors Influencing Metal Cutting Process
Independent Variables:

• Cutting tool material, shape, geometry, angles.

• Work piece material, condition, temperature.

• Cutting parameters, such as speed, feed, and depth of cut.

• Cutting fluids.

• Machine tool specifications.

• Work holding and Fixturing.

 Factors Influencing Metal Cutting Process
Dependent Variables:
• Dependent variables are influenced by changes in
independent variables

The major dependent variables are:

• Types of chips formed.
• Temperature zone at work tool interface.
• Tool wear and failures.
• Surface finish.
• Force and energy in cutting process.
Factors Influencing Metal Cutting Process
Types of chips
 Continuous chips
• Ductile work materials
• High cutting speed
• High rake angles, sharp cutting
edge
• Small feed and depth of cut
• Low tool chip friction
• Good surface finish
• Tend to get tangled around the
tool
• Formation of very lengthy chips
are hazardous to machining
process and operator Failure to understand and control ductility and its effects on
our chips can result in safety hazards to machine operators
Discontinuous chips
Continuous chips with BUE
• Ductile materials
• Low to medium cutting speeds
• Tool chip friction causes portions of chip to adhere to rake face
• BUE forms, then break off, cyclically