Department of Mechanical Engineering

University of Central Punjab

Machining Operations
(Machining Special geometries + High
Speed Machining)

COURSE TITLE: MANUFACTURING PROCESSES II (MEN3143)

Chapter 22 Course Instructor: Umer Hayat

 Summary of Last Lecture
2

Machine Centers Shaping and Planing

Broaching Sawing
 Screw Threads
3

 Threaded hardware components are widely used as

 fasteners in assembly e.g screws, bolts, and nuts
 for transmission of motion in machinery e.g., lead screws in
positioning systems

 Threads - grooves that form a spiral around the outside of a cylinder

(external threads) or the inside of a round hole (internal threads)

 Comparison of thread rolling and thread making using machining?

 Methods for Making Screw Threads
4

External Threads Internal Threads

 Single-Point Threading
 Threading Die  Tapping
 Thread Milling
 Thread Grinding
 Single Point Threading
5

 Simplest and most versatile method

 Uses single-point cutting tool on a lathe

 Starting diameter of the workpiece = major diameter of the screwthread

 Lathe’s lead screw is used to cut a constant spiral

 More than one passes required

 Each ensuing pass traces the same

spiral using ever greater depths of cut

until the desired form of the thread
groove is established

Suitable for low to medium

production
 Threading Die
6

 Die is rotated around the starting cylindrical stock of the proper

diameter, beginning at one end and proceeding to the other end

 Cutting teeth at the opening of the die are tapered

 so that starting depth of cut is less
 finally reaching full thread depth at the trailing side of the die

 Pitch of die = Pitch of screw

 Slit – allows size of opening to
be adjusted

 Cut threads in single pass

 Thread Milling
7

 Form milling cutter is used to shape the threads of a screw

 Shape of cutter = Shape of thread groove

 In this operation, cutter is oriented at an angle equal to the helix

angle of the thread and fed longitudinally as the workpiece is slowly
rotated

 Reasons for preferring thread milling

 Thread size is too large to be cut with die
 Produce more accurate and smoother
threads
 Thread Grinding
8

 Similar to thread milling except

 the cutter is a grinding wheel with the shape of the thread groove
 rotational speed of the grinding wheel is much greater than in milling

 Can be used to completely form threads or to finish threads which

are formed by one of previous processes

 Especially used for threads which are hardened by heat treatment

 Internal Threads - Tapping
9

 Most common process for creating internal threads

 Cylindrical tool with cutting teeth arranged in a spiral is simultaneously

rotated and fed into a pre-existing hole

 Pitch of tool threads = Pitch of threads formed

 Cutting tool is called a tap

 In the simplest version of the process, tapping is performed on a drill

press equipped with a tapping head, which allows penetration into the
hole at a rate that corresponds to the screwpitch
 At the end of the operation, the spindle

rotation is reversed so the tap can be

unscrewed from the hole
 Gears
10

 Gears are machinery components used to transmit motion and power

between rotating shafts
 Various gear types are
 Spur Gear – teeth are parallel to axis of rotation
 Helical Gear – teeth form an angle relative to axis

 Bevel gears – provides motion between shafts which are at angle to each other

 Rack and pinion – converts rotational motion to linear or vise versa

 Methods of Gear Formation
11

Shape Processing Operations Machining Operations

 Investment casting
 Form milling
 Die casting
 Gear hobbing
 Plastic injection molding
 Gear shaping
 Powder metallurgy
 Gear broaching
 Forging

 Gear rollling
Finishing processes for gear teeth
 Gear shaving

 Gear grinding

 Burnishing
 Form Milling
12

 Teeth on a gear blank are machined individually by a form-milling

cutter
 Machining operation is classified as forming

 Disadvantages – Low Production rates, Time consuming

 Eachteeth is created one at a time
 Gear blank needs indexing

 Advantage – Milling cutter is less expensive

 Used for low production rates

 Gear Hobbing
13

 Also a milling operation

 Motions used in gear hobbing
 Rotary motions of the hob and workpiece
 A straight-line motion to feed the hob relative

to the gear blank

 Disadvantage
 Tooling is expensive
 Special machines are required to establish

relative motion
 Advantage
 Several teeth are cut simultaneously
 Used for medium and high production
 Gear Shaping
14

 In gear shaping, a reciprocating cutting tool motion is used

 The cutter has the general shape of a gear

 Cutter is fed into the blank after each stroke until the required depth

has been reached

 After each pass, both cutter

and blank are indexed to

maintain same tooth spacing
on each
 Gear Broaching
15

 For internal gears, tool consists of a series of gear-shaped cutting

teeth of increasing size to form the gear teeth as the broach is drawn
through the work blank

 To produce external gears, the broach is tubular with inward-facing

teeth

 Short production cycle time

 Used for high production
 Finishing Operations for Gears
16

 Gears are usually heat treated to harden the teeth for maximum
wear resistance
 Heat treatment often results in distortion of workpiece

 Finishing operations are also required to improve surface finish and

dimensional accuracy

 Some of the finishing operations are

 Gear shaving
 Gear burnishing

 Gear grinding – Honing, Laping

 High Speed Machining (HSM)
17

 Cutting at speeds significantly higher than those used in conventional

machining operations

 A persistent trend throughout history of machining is higher and higher

cutting speeds

 At present there is a renewed interest in HSM due to potential for

faster production rates, shorter lead times, and reduced costs

 Typical HSM spindle velocities range between 8000 - 35,000 rpm,

although some spindles today are designed to rotate at 100,000 rpm
 Comparison of Cutting Speeds
18
 Requirements for High Speed Machining
19

 Special bearings designed for high rpm

 High feed rate capability (e.g., 50 m/min)
 CNC motion controls with “look-ahead” features to avoid
“undershooting” or “overshooting” tool path
 Balanced cutting tools, toolholders, and spindles to minimize vibration
 Coolant delivery systems that provide higher pressures than
conventional machining
 Chip control and removal systems to cope with much larger metal
removal rates
 High Speed Machining Applications
20

 Aircraft industry, machining of large airframe components from large

aluminum blocks
 Much metal removal, mostly by milling

 Multiple machining operations on aluminum to produce automotive,

computer, and medical components
 Quick tool changes and tool path control important

 Die and mold industry

 Fabricating complex geometries from hard materials