Course Code: ME305A Course Title: Manufacturing Process - 2: Lecture No. 1 Lecture Delivered By: Dr. Suresh R

Course Code: ME305A
Course Title: Manufacturing Process -2
Lecture No. 1
Introduction To Material Removal Operations
Lecture delivered by:
Dr. Suresh R
1
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
Lecture Objectives
At the end of this lecture, the students should be able to:
• Explain the importance of Machining

• Illustrate the applications of Machining processes
• Classify various machine tools used in manufacturing
2
Introduction
• The process of converting raw materials, components or parts into

finished goods that meet a customer's expectations or
specifications
• Manufacturing commonly employs a man-machine setup with
division of labor in a large scale production
• Process in which a sequence of operations are performed on the
raw work piece so as to convert it into desired product
Fig.1 Manufacturing as an input-output system 3

Classification of Manufacturing Process
• Process type manufacturing

– It involves continuous flow of materials
through a series of processing steps to obtain
finished product, like Chemicals, Oil and Gas
industries, Textile industries
• Fabrication type Manufacturing
– It involves manufacturing of individual parts or
components by series of operations , such as
machining, forming and welding
• Assembly type of Manufacturing

– The parts or components are put together to
get a complete product such as machines,
automobiles, aircrafts, ship building, etc.
4
Machining Applications
• It is a process by which parts can be produced to the desired
dimensions and surface finish from a blank by gradual removal of
the excess material in the form of chips with the help of a sharp
cutting tool
• Manufacturing industries for making the various types of jobs for
automobiles, machine tools, energy generation sectors
• Machine tool parts, Press tools, tool and dies making applications
• Aircraft, space craft, surgical and orthopedic components
Connecting rods Cam Shaft Turbine 5

Aerospace Applications
Landing gear beam
Landing Gear
Aerospace Components
6
Automobile Applications
Camshaft
Engine block
Bearing
7
Press Tool Applications
Figure: Press tool dies
8
Industrial Applications
Industrial components
9
Machine Tool Applications
Tool Adapter for Machine tool spindle Machine tool bed

machine tools
10
Surgical Applications
Ti alloys and stainless steels used to Joint

replacement, bone plates and screws
11
Power Generation Applications
Machining of turbine blades
12
Selection of Suitable Process
Following factors influence the selection of a suitable machining

process, namely
• Material of work piece
• Shape and size of the work piece
• Degree of dimensional accuracy and geometrical tolerances
• Surface finish required
• Number of products to be produced
• Cost consideration
13
Classification of Manufacturing Process
14
Classification of Machine Tools
15
Metal Removal/Machining Process
The machining process involves removal of extra material from a given
work piece to get it to desired shape and dimensions with better
surface finish.
The machining process are classified as
• Metal cutting
– Single point cutting, Turning, shaping, Planing and Boring
– Multipoint cutting, Milling, drilling, tapping, broaching
• Grinding and finishing
– Surface Grinding, Cylindrical Grinding and Centre-less Grinding
– Lapping, Honing, Super-finishing
• Unconventional machining
– Ultrasonic machining, Electric Discharge Machining, Abrasive Jet Machining,
Laser Beam Machining, etc.
16
Metal Removal Process
• Produce a desired shape, size and finish of a component by
removing excess material in the form of chips
• Chips may constitute more than 50% of initial work piece
• Machining processes are performed on metal cutting machines,

using various types of cutting tools
• Metal cutting process carried out at high speeds and feeds with
least cutting effort at minimum cost
17
Metal Cutting process (cont..)
• Removing unwanted material: Cutting/chipping/machining/metal
cutting
• To get desired Shape, Size and Surface finish
Figure: Typical machining example
18
Why Machining is Important?
• Variety of work materials can be machined
- Most frequently applied to metal processing
• Variety of part shapes and special geometry features possible,
such as:
- Screw threads
- Accurate round holes
- Very straight edges and contour surfaces
• Good dimensional accuracy and surface finish
• Shearing process in which excess materials is removed by cutting
tools
19
Advantages of Machining Process
• A variety of work materials
• ‘Repeatable’ regular geometries
• Close tolerance (<0.05μm)
• Smooth surface finish (0.8μm)
• Other processes such as casting, forging, and bar drawing
create the general shape
• Provides the final shape, dimensions, finish, and special
geometric details that other processes cannot create
20
Disadvantages of Machining Process
 Wastage 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,
forging, extrusion and other forming process
21
Machining Operations
 Most important machining operations:

• Turning
• Drilling
• Milling
 Other machining operations:
• Shaping and Planing
• Broaching
• Sawing
22
Turning
 Using single point cutting tool removes material from a rotating
workpiece to form a cylindrical shape
Fig.: Turning operation
23
Turning Operations
Turning Facing Grooving Forming Threading
External
Internal
Figure: Different types of turning operations
24
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
Figure: Peripheral milling and Face milling

25
Milling Operations
Figure: Different types of milling operations
26
Drilling
 Drilling is used to create a round hole, usually by means of a
rotating tool (drill bit) that has two cutting edges
Figure: Drilling Process

27
Shaping and Planing
 A single point tool moves linearly relative to the work part
• Shaping –A tool moves
• Planing –A work part moves
Figure: (a) Shaping and (b) Planing

28
Broaching and Sawing
 Broaching
- Performed by a multiple tooth cutting tool by moving linearly
relative to the work in the direction of the tool axis
 Sawing
-Hacksawing, bands awing and circular sawing
Figure: Broaching tools Figure: Broached components

29
Abrasive Machining Processes
• Abrasive machining: Material is removed from a work piece using a
multitude of small abrasive particles; Eg.,
Grinding
Honing
Lapping
Polishing
• Different types of grinding
• Surface grinding
• Cylindrical grinding and
• Centerless grinding
30
Grinding Operations
Figure: Surface grinding Figure: Cylindrical grinding
Figure: Centerless grinding

31
Honing
• Honing: Produces a precision surface on a metal work piece by
scrubbing an abrasive stone against it along a controlled path
• Applications: Finishing of cylinders for internal combustion engines,
air bearing spindle and gears
Figure Honing Tool

Figure: Honing Process
32
Factors Affecting Metal Cutting
• Properties of Work material

• Properties of the tool material & geometry of cutting tool
• Interaction between tool and workpiece
• Cutting parameters like cutting speed, feed rate and depth of cut
• Insufficient lubrication between tool and workpiece (cutting
environment)
• Machine tool rigidity
33
Summary
• Machine tools are classified based on the applications as general

purpose, production and special purpose
• Applications of machine tools in various fields as automobile,

aerospace, medical and power generation industries
• Types of machining operations, turning, milling, grinding,

broaching honing etc.
34

Course Code: ME305A Course Title: Manufacturing Process - 2: Lecture No. 1 Lecture Delivered By: Dr. Suresh R

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Course Code: ME305A Course Title: Manufacturing Process - 2: Lecture No. 1 Lecture Delivered By: Dr. Suresh R

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Course Code: ME305A

Course Title: Manufacturing Process -2

At the end of this lecture, the students should be able to:

• Explain the importance of Machining

• The process of converting raw materials, components or parts into

Fig.1 Manufacturing as an input-output system 3

• Process type manufacturing

• Assembly type of Manufacturing

Connecting rods Cam Shaft Turbine 5

Landing gear beam

Figure: Press tool dies

Tool Adapter for Machine tool spindle Machine tool bed

Ti alloys and stainless steels used to Joint

Machining of turbine blades

Following factors influence the selection of a suitable machining

• Machining processes are performed on metal cutting machines,

Figure: Typical machining example

 Most important machining operations:

Fig.: Turning operation

Turning Facing Grooving Forming Threading

Figure: Different types of turning operations

Figure: Peripheral milling and Face milling

Figure: Different types of milling operations

Figure: Drilling Process

Figure: (a) Shaping and (b) Planing

Figure: Broaching tools Figure: Broached components

Figure: Surface grinding Figure: Cylindrical grinding

Figure: Centerless grinding

Figure Honing Tool

• Properties of Work material

• Machine tools are classified based on the applications as general

• Applications of machine tools in various fields as automobile,

• Types of machining operations, turning, milling, grinding,

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