Department of Mechanical Engineering

University of Central Punjab

Machining Operations
(Turning and Related Operations)

COURSE TITLE: MANUFACTURING PROCESSES II (MEN3143)

Chapter 22 Course Instructor: Umer Hayat

 Summary of Last Lecture
2

 Forces Acting on Chip

 The Merchant Equation

 Power in Machining
 Why Cutting Temperatures are Important?
 reduce tool life
 produce hot chips (safety hazards to operator)
 inaccuracies in work part dimensions due to thermal expansion
 Overview of Chapter
3

 Turning and Related Operations

 Drilling and Related Operations
 Milling
 Machining Centers and Turning Centers
 Other Machining Operations
 High Speed Machining
 Machining
4

 A material removal process in which a sharp cutting tool is used to

mechanically cut away material so that the desired part geometry
remains

 Most common application: to shape metal parts

 Machining is the most versatile and accurate of all manufacturing

processes in its capability to produce a diversity of part geometries
and geometric features (e.g. screw threads, gear teeth, flat surfaces)
 Castingcan also produce a variety of shapes, but it lacks the precision and
accuracy of machining
 Classification of Machined Parts
5

 Rotational - cylindrical or disk-like shape. Achieved by rotation motion

of the workpart. Ex. turning and boring

 Nonrotational (also called prismatic) - block-like or plate-like.

Achieved by linear motion of the workpart. Ex. Milling, shaping,
planing and sawing

Figure 22.1 - Machined parts are classified as: (a) rotational, or (b)
nonrotational, shown here by block and flat parts
 Machining Operations and Part Geometry
6

Each machining operation produces a characteristic part geometry due

to two factors:
1. Relative motions between the tool and the workpart
• Generating – part geometry is determined by the feed
trajectory of the cutting tool. Feed motion creates shape. Ex.
Straight turning, taper turning, and profile milling
2. Shape of the cutting tool
• Forming – part geometry is created by the shape of the
cutting tool. Cutting edge has the reverse of the shape to be
produced on the part surface. Ex. Form turning, drilling and
broaching
 Forming and generating are sometimes combined in one operation,
such as in thread cutting on a lathe and slot milling
 Generating
7

Straight turning Taper turning Contour turning

Profile milling
Plain milling
 Forming
8

Form Turning Drilling Broaching

 Forming and Generating Combination
9

Threading Slot milling

 Turning and Related Operations
10

 A single point cutting tool removes material from a rotating workpiece

to generate a cylindrical shape

 The tool is fed linearly in a direction parallel to the axis of rotation

 Performed on a machine tool called a lathe

 Variations of turning that are performed on a lathe:

 Facing
 Taper turning
 Contour turning  Form turning
 Chamfering
 Boring
 Cutoff
 Drilling
 Threading
 Knurling
 Cutting Conditions in Turning
11

 Rotational speed N = rotational speed, rev/min

 Final Diameter of Workpiece
 Linear Travel rate
 Machining Time
 or
V = cutting speed
Do = origional dia.
Df = final dia. after cut
d = depth of cut
fr = feed rate, mm/min
f = feed
L = length of work piece

 Material Removal Rate

 RMR = v f d
 Example
12

 A turning operation is performed on a cylindrical work part whose

diameter=120 mm and length=450 mm. Cutting speed=2.0 m/s,
feed=0.25 mm/rev, and depth of cut=2.2 mm. Determine (a) cutting
time and (b) material removal rate
 Problem 22.3
13

 A facing operation is performed on an engine lathe. The diameter of the

cylindrical part is 6 in and the length is 15 in. The spindle rotates at a
speed of 180 rev/min. Depth of cut = 0.110 in, and feed= 0.008
in/rev. Assume the cutting tool moves from the outer diameter of the
workpiece to exactly the center at a constant velocity. Determine (a) the
velocity of the tool as it moves from the outer diameter towards the
center and (b) the cutting time

 a) fr = fN = (0.008 in/rev)(180 rev/min) = 1.44 in/min

 L = distance from outside to center of part = D/2
 Tm = L/fr = D/(2fr) = 6/(2 x 1.44) = 2.083 min
 Turning Related Operations
14

 Facing
 Tool is fed radially inward
to create a flat surface

 Taper Turning
 Toolis fed at an angle creating a
tapered cylinder or conical shape
 Turning Related Operations
15

 Contour Turning
 Instead of feeding the tool parallel to the
axis of rotation, tool follows a contour that
is other than straight, thus creating a contoured
form

 Form Turning
❑ Tool shape is imparted to work
❑ Not a single point tool
 Turning Related Operations
16

 Chamfering
 Toolcut the edge of the part at
an angle called chamfer

 Cutoff
 Tool is fed radially into rotating
work at some location to cut off end
of part
 Turning Related Operations
17

 Threading
 Pointed form tool is fed linearly across
surface of rotating workpart parallel to
axis of rotation at a large feed rate, thus
creating threads

 Boring
 Single point tool is fed linearly, parallel
to the axis of rotation, on inside of an
existing hole
 Turning Related Operations
18

 Drilling
 Drill along the axis
 Not a single point tool

 Knurling
 Produce a regular cross-hatched section
 Metal forming process instead of

machining process
19
 The Engine Lathe
20
 The Engine Lathe
21

 Most lathe machines are horizontal but vertical lathe machines are also
used for jobs with large diameter relative to the length and for heavy
work

 The size of the lathe is designated by swing and maximum distance

between centers
 Swing is the maximum workpart diameter that can be rotated in the
spindle
 Maximum distance between centers indicate the maximum length of a
workpiece that can be mounted between headstock and tailstock centers

 350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance

between centers of 1.2 m