Industrial Engineering Department

Experiment Name: Machining

Date: 11/13/2019

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 Objectives:
1- To learn about Machining different methods and machines.
2- To learn about the different types of cutting tools, how did they were evaluated, and the
advantaged and disadvantaged for each one.
3- To study each machine and learn what it does.
4- To learn some safety tips while doing any machining operations.

 Introduction:
Machining are group of different manufacturing processes with several machines for these
processes. Where a thin layer is meant to be taken from a metallic workpiece.

Shaping, surface grinding, drilling, cutting, milling, and lathing are all methods of shaping
reducing the thickness of the workpiece. There is machine for each one of these machining
processes. And some machines can do more than one machining process. All these processes can
be automatically operated by special machines called CNC machines (for example CNC milling
does automated milling … etc.).

There are different types of cutting tools. They are sorted based on their material, function,
strength and flexibility, and heat resistance. Carbon steel, High speed steel (HSS), Ceramics,
Diamonds, and Carbides.

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 Tools:
Cutting tools:

1- Carbon steel: the oldest and worst cutting tool. It could handle just less than 250 C°.

2- High speed steel (HSS): when was discovered (around 1950s), a huge advancement in the
whole industrial world. Where the strength of the HSS is much harder than the carbon steel. And
one of its amazing advantages that it can handle vibration. And around 600 C° with cooling.

3- Carbides: are the material which discovered after HSS with 900 C° handling temperature.

4- Ceramics: the ceramics are stronger than HSS and Carbide and can handle more than 900 C°.
But brittle in an unbelievable way.

5- Diamonds: are much stronger than even ceramics. But at the same time unbelievably
expensive. And can handle 2000 C°.

6- Cubic boron Nitrate (CBN): this is the next huge advancement in the industrial world, where
its at the strength of diamond but costs 1/10th of its price.

Machines:

1- Shading machine: this machine reduces the dimensions of the workpiece by relative motion
between the cutter and the workpiece (back and forth motion). The speed is by the cutter and
the feed is by the workpiece.

2- Grinding machine (service machine): this machine is similar to the shading machine but it has
better surface finish and higher accuracy. It reduces the dimensions of the workpiece for very
high accuracy and surface finish which makes it suitable to be final machining process. The speed
is by the cutter and the feed is by the workpiece.

3- Lathe machine: this machine just works with cylindrical shapes. Where the workpiece is
centered and starts rotating (workpiece speed). while the cutting tool is movable to start cutting
(cutter feed). Lathe machine can reduce lengths, reduce diameters, make chamfers, holes, curvy
lines, and even threading.

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4- Milling machine: this machine can cut lines and even write letters on the workpiece. There are
two types of milling machines: vertical and horizontal milling machines. The vertical milling
machine cut vertical lines on the workpiece. Where the speed is by the cutter and the feed is by
the workpiece. While the horizontal milling machine is applying its cuts in horizontal lines.
Mostly this machine is what can cut letters on the workpiece. It applies both speed and feed by
the cutter.

5- Drilling machine: this machine cuts holes in the workpiece. Where the cutter has a V-shape tip
blade for drilling through the depth. And helical blade on its side for side cutting of the
workpiece. It applies both speed and feed by the cutter. A dynamometer ca be added (contains
load cells) for measurement purposes.

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 Pictures:

1- Shading machine 2- Grinding machine (service machine)

3- Lathe machine 4- Milling machine 5- Drilling machine

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 Discussion & Results:

Rotational
Cutting Speed Cutting Feed Torque Axial Force
Speed
N [rpm] V [m/min] fr [mm/rev] f [mm/min] T [N.cm] F [N]
0.113 16.95 650 1350

150 4.712 0.152 22.8 800 1600

0.254 38.1 1500 2900

0.113 22.6 1900 3400

200 6.283 0.152 30.4 2100 3700
0.254 50.8 2300 4200
0.113 33.9 2600 4800
300 9.424 0.152 45.6 2900 5000
0.254 76.2 3100 5200

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 Conclusion:
1- Increasing the cutting speed results increases the torque at constant cutting feed.

2- Increasing the cutting speed results increases the axial force at constant rotational speed.

3- Increasing the cutting feed results increases the torque at constant cutting feed.

4- Increasing the cutting feed results increases the axial force at constant rotational speed.

5- HSS and CBN where a very huge developments at their time.

 Safety:
1- Warning signs (big, clear and better to be with pictures).

2- Wear Lab coat can handle sharp tools.

3- Avoid dangerous parts of the machine while working.

4- Wear safety eye glasses and welding protective glasses (while welding).

5- Don’t take off the swarf by bare hands. Is could make deep wounds easily.

 References:
1- Manufacture Process Manual.

2- Records from the lecture.