Basic Considerations in Machining Processes

MTI Faculty of Engineering – Basic Science Engineering Program
Basic Considerations in Machining Processes

A research project submitted to the Faculty of Engineering
MTI University
In partial fulfillment of the requirements
for passing the Spring semester 2020 evaluation
In
Production II
By
Mohamed Ahmed Abbas Hassan
92099
Supervised by
Prof. Dr. Taha El-Shafie
June 2020
Page |1
Table of Contents
1. Abstract……………………………………………………………………..….…….…..…3
2. Introduction………………………………………………………………………….………3
3. Theoretical part (Machining Processes and tool).……….…………..……...….4
3.1 Turning…………………………………………………………………….…………..…4
3.1.1 Long Turning…………………………………..…………………….…………….5
3.1.2 Face Turning…………………………………..…………………….…………….5
3.1.3 Threading…..…………………………………..…………………….…………….6
3.1.4 Knurling……..………………………………..…………………….……….…..…6
3.2 Milling………………………………………………………………………………..…..7
3.2.1 Vertical milling.…………………………………..…………….……..……….…8

3.2.2 Horizontal milling……………..………………….………….………….………9
3.3 Drilling……………………………………..…………………………………..………10
3.3.1 Counter Thinking.………………….……..………..…………….….….……11

3.3.2 Counter Boring……………..…..…………………..………….…………....11
3.4 Orthogonal Cutting……..…….……….……………………………..………..…....12
3.5 Properties of Tools.………………………..……….……………….………..…...13
3.6 Heat generation…….…………………………………………….………..….…….14
4. Applied part………………………………………………………………….......…..….17
4.1 Calculation of Machining Time, Force, Power………………....…………….…17

4.2 Saw tooth diagram…………………………..………………………………….…....22
5. Results and Comments………….………………………………………………..…….26
6. Conclusions…………………………..…………………………………………………....28
7. References…………………………………………………………………………………..29
Page |2
1. Abstract
In this research I will talk about the most important and used cutting processes; Turning, Milling,
Drilling; Explain their steps and the working conditions affecting them, such as, number of
revolutions (n), speed (v), depth of cut (t), and feed (s). The basics of the cutting theory is similar
or practically the same for all the processes and in order to improve our understanding of
machining; several phenomenal occur during the cutting process that we must be familiar with;
such as, the plastic deformation occurring before the separation of the chip from the work-piece,
the heat generated during the cutting, how to decrease it, and the effect of using cutting fluid. It
is very important to know the role that the cutting tool plays in the machining operations and the
required properties of the material used to design it in such a way that would lead to the increase
in efficiency of the machining process, enhancement of the tool life and reduction of the overall
cost of machining. As one of the most important and main job of the production engineering is to
ensure that all products are manufactured with the most efficiency, high quality, low cost;
Engineers must know how to calculate machining time, cutting force, power consumed during
cutting. Also know how to arithmetically and geometrically distribute the speed of the motor on
a gear box transmission, draw the saw tooth diagram for both cases, and how to select the
optimum speed for cutting work piece of specific diameter.
2. Introduction
There’s a lot that goes into machining a perfectly smooth, precise, functional work-piece. It
requires great attention to detail and experience. Turning, drilling, and milling are just a few of
the most common machining processes. They’ve been around for many, many years and played
an important role in the industrial revolution. More than 5% of the world GDP is related to
machining processes as part of manufacturing technologies. This proves that knowledge about
machining processes is strategically important and has to be further improved. Machining is the
manufacturing process by which parts and products can be produced to the desired dimensions
and surface finish from by gradual removal of the excess material in the form of chips with the
help of a sharp cutting tool. Since the majority of industrial applications are in metals; Every
Engineer must be familiar with Machining and cutting processes, because almost 90% of the field
of engineering is subjected to some kind of machining during the manufacture process.
Page |3
3. Theoretical part (Machining Processes and tool)
- Definition of Machining
Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process with a cutting tool.
There are many kinds of machining operations, each of which are capable of generating a
certain part geometry and surface texture.
3.1. Turning
- Turning is the most important machining process; it can produce

a wide variety of parts. Turning is used cylindrical parts using a
single point cutting tool on a lathes machine. In Turning, the
work-piece is rotated and a cutting tool removes a layer of
material as the tool moves to feed into the work-piece. [Fig.1]
[Fig.1: Turning]
- Lathe machine: A lathe is a machine in which the workpiece rotates about its axis and the tool
is fixed and moved to feed to produce the desired product in a cylindrical shape. Various
operations can be done on a Lathe machine, such as, cutting, sanding, knurling, drilling,
deformation, facing, and turning. (3) (4) [Fig.2]
[Fig.2: Lathe Machine]
Page |4
3.1.1 Long Turning

- Operation of removing metal from outer diameter of a rotation cylindrical work-piece; usually
by feeding the tool to the left (to the direction of the headstock of the lathe machine). [Fig.3]
[Fig.3: Long Turning]
3.1.2 Face Turning

- Operation of removing metal from outer diameter of a rotation cylindrical work-piece to
produce a flat surface at the end. [Fig.4]
[Fig.4: Face Turning]
Page |5
3.1.3 Threading
- The process of creating a screw thread, by producing a helical ridge of uniform section on
the work-piece using a threading tool, (Usually having a 60, or 55° nose angle). [Fig.5]
[Fig.5: External threading]
3.1.4 Knurling
- A manufacturing process of producing a pattern into the surface of a workpiece to
provide a better gripping surface. The process can be done on a lathe machine by
impressing a knurling tool that has patterns such as a diamond shaped or straight crossed
lines into the rotating work-piece material. [Fig.6]
[Fig.6: Knurling on Lathe]
Page |6
3.2 Milling
- Milling is a process of machining using a rotary cutter with several edges to remove
material by advancing the cutter into a work piece. Milling is usually used to machine flat
surfaces, but can also produce irregular surfaces. It can also be used to bore, drill,
produce gears, and slots. The process is done on a Milling Machine.
- Milling Machine: also known as the multi-tasking machines. The milling machine has
the cutter installed on a stationary spindles, while the work-piece is fixed on a table and
allowed to go up and down, and left and right by a feed cranks to execute the feed. There
are two main types of milling can be done on the milling machine. These are Vertical
milling and Horizontal milling. (4) (5) [Fig.7]
[Fig.7: Vertical and Horizontal milling Machines]
Page |7
3.2.1 Vertical milling

- In vertical milling, the spindle axis is aligned in a vertical manner to the machine's bed.
That means that the cutting tool is arranged vertically to the work-piece; then the work-
piece moves to make the feed. There are two basic types of vertical mills that provide
unique benefits; which are, turret and bed.
- Turret Mill: In a turret mill, the spindle remains in a fixed location, and the bed portion
of the machine that holds the material moves horizontally or vertically.
- Bed Mill: where the bed mill can only move the material along the horizontal axis.
Examples of Vertical Milling
1) U-grove by using a U cutting tool.
Page |8
3.2.2 Horizontal milling

Horizontal milling also has a fixed cutter on a spindle but their cutters are placed on a
horizontal arbor. Many horizontal mills have a built-in rotary table that helps in milling
in various angles; these tables are called the universal tables. Apart from this all the tools
that are used in a vertical mill can also be used in the horizontal mill.
Examples of Horizontal Milling
1) U-grove by using a U cutting tool.
2) V-grove by using a V cutting tool.
Page |9
3.3 Drilling
- Drilling is the Process of removing material from the inside of a work-piece and
producing a hole of circular cross-section by a tool called “drill bit”. The process can be
done by Milling machines, where the bit is rotating at rate of revolutions per minute; or
by Lathe machines, where the bit is fixed and the work-piece is rotating. In both cases the
tool is pressed against the work-piece, forcing the cutting edge of the bit to cut into the
work-piece. But As In the industry of metal work tools, shorter processing times are
always in high demand, a machine was invented later for the specific operations of
drilling.
- Drilling Machines: A single spindle vertical drilling machines, which are firmly
mounted on table tops. They are suitable for smaller holes and work pieces and have
moderate to high speeds. The work-piece is fixed on the work table, while the tool is
hanged in the rotating spindle by a chuck, and lowered to execute the feed by a hand
feed. [Fig.8]
[Fig.8: Drilling Machine]
P a g e | 10
3.3.1 Counter Thinking

- Operation of producing a tapered entrance to a hole. [Fig.9]
[Fig.8: Counter Thinking]
3.3.2 Counter Boring

- Operation of boring a second hole with a diameter larger than the first but concentric with
it. [Fig.9]
[Fig.9: Counter Boring]
P a g e | 11
3.4 Orthogonal Cutting

- Orthogonal Cutting is a method that involves the use of a wedge- shaped tool in which the
cutting edge is perpendicular to the direction of speed motion into the work material. The cutting
force acts on larger area and so tool life is more. The reason for the longer life of the tool is that
the same feed is done by less contact between the tool and the work-piece. This method of
cutting is used in almost all machining operations. [Fig.10]
[Fig.10: Orthogonal Cutting]
- Since the chip un-deformed & deformed has the same value;
From [Fig.11]
Chip un-deformed  L*t*S
Chip deformed  L1* t1* S
We get that,
L * t * S = L1* t1* S
[Fig.11]
- This relation is taken as measure for evaluation of plastic deformation accompanying the cutting
process.
P a g e | 12
3.5 Properties of Tools

- Machine Tooling: The desired form of the material will determine what type of tools
you’ll need for the job. The two basic types of cutting tools are single point and multi-
point tools. Use single point tools for turning, boring, and planning. Use multi-point tools
for milling and drilling. It is imperative to properly use and maintain the cutting tools for
quality purposes. [Fig.12]
[Fig.12]
- There’s a verity of materials that the tool can be made from. Choosing the material
required, is according to the severe working conditions that the cutting tool is subjected
to during the cutting process.
- The favorite properties for tool material:

1) High strength: The tool is subjected to stress equal to the cutting resistance R.
2) High Hardness: The tool must be able to penetrate into the work-piece.
3) High wear resist: The tool must keep its shape and geometry as long as possible.
4) High Toughness: The tool must not be brake when subjected to shocks.
5) High thermal conduct: The tool must absorb more heat to lower the temperature at
the place of cut.
6) Low price: To reach lower cost of the machining process.
7) High Machinability: To reach the required geometry shape with low cost.
8) Hot Hardness: The ability of the material to remain its cutting ability even at high
temperature (Like HSS).
P a g e | 13
3.6 Heat generation

- During machining, heat is generated at the cutting point from three sources. [Fig.13]
1) Primary shear zone
 Also known as shear zone. It is where the major part of the energy is converted
into heat due to plastic deformation of the work-piece.
2) Secondary deformation zone

 Also known as friction zone. At the area surrounding the chip-tool contact
region; where further heat is generated due to the friction and/or shear.
3) Flank wear zone

 Due to friction between the tool and the finished surface. It presents low heat
due to the built up edge of the tool
Mechanical
Face
Power
Flank
Resistance
[Fig.13: Heat generation zones]
P a g e | 14
Steady State Temperature

- Steady state in any field means that the properties being measured do not change with
time. The system has finished evolving, and now the properties, when measured at a
point, do not change with time.
- Steady State Temperature is the form of conduction that happens when the
temperature difference driving the conduction are constant and does not change any
further after an equilibration time.
T is reached when
Qa = Q g
- There are two options to decrease T:
Option 1: Lowering Qg. by:
 lower force,
 lower v, s , t,
 lower friction.
*Can’t use Option 1 due to consideration of operation economy*
Option 2: Increase Qa. by:

 Higher Qt.
 Higher Qs.
 Using cooling liquid.
P a g e | 15
Cooling Liquid
- Cooling liquid: Also known as Cutting fluid, which is a type of coolant and lubricant
designed specifically for metalworking processes, such as machining and stamping.
There are various kinds of cutting fluids, which include oils, oil-water emulsions,
pastes, gels, aerosols (mists), and air or other gases.
- The effect of using Cooling Liquid:

1) Reducing and removing the heat build-up in the cutting zone and work-piece.
2) Absorb heat.
3) Provides lubrication effect to reduce friction between the tool and removal of the
chips. Hence lowering Qg.
4) Flushes away chips and small abrasive particles from the work area.
5) Using fabrication liquids can provide flexibility and efficacy and the safe factor to
the machining process.
P a g e | 16
4. Applied part
4.1 Calculation of Machining Time, Force, Power.
Turning
- Ex1: In longitudinal turning process, it is given: Length of workpiece l = 120 mm, No.
of spindle revelations n = 200 RPM, feed S = 0.2 min/rev. Depth of cut t = 1 mm.
Calculate the time of machining.
L = 120mm n = 200 RPM S = 0.2 mm/rev.

t = 1mm
L = L + 2ⵠ
L = 120 + 2*3 = 126mm
T=N =1* = 3.15 min
- Ex2: In longitudinal turning process, it is given: Length of workpicce 1= 180 mm, DI

(initial diameter) = 58 mm, D2 (final diameter) = 56 mm, No. of spindle revelations n =
320 RPM, feed S = 0.25 mm/rev. Calculate the time of machining.
L = 180mm n = 320 RPM S = 0.25 mm/rev.
t = 1mm d1 = 58 mm d2 = 56 mm.
L = L + 2ⵠ
L = 180 + 2*3 = 186mm
T=N =1* = 2.325 min
P a g e | 17
- Ex3: In longitudinal turning process, it is given: Length of workpiece 1 = 100 mm,

Di(initial diameter) = 58 mm, D2 (final diameter) = 54 mm, No. of spindle revelations n = 320
RPM, feed S = 0.3 mm/rev. Max allowable depth of cut t = 1 mm. Calculate the time of
machining.
L = 100mm n = 320 RPM S = 0.3 mm/rev.
tmax = 1mm di = 58 mm df = 54 mm.
L = L + 2ⵠ
L = 100 + 2*3 = 106mm
( )
N= = = 2 strokes
T=N =2* = 2.208 min
- Ex4: In facing process, it is given: L1(initial length) = 120 mm, L2(final length) = 118 mm,
D(workpiece diameter) = 60 mm, No. of spindle revelations n = 320 RPM, feed S = 0.2
.mm/rev. Calculate the time of machining.
L1 = 120mm L2 = 118mm S = 0.2 mm/rev.
d= 60 mm n = 320 mm.
L= +2ⵠ
L= + 2*3 = 36mm
T=N =1* = 0.56 min
P a g e | 18
- Ex5: An facing process, it is given: 11 (initial length) = 120 mm. 12 (final length) =
117.5 mm, D (workpicce diameter) = 80 mm, MaZ allowable depth of cut t = 1 mm,
No. of spindle revelation's n = 200 RPM, feed S = 0.25 mm/rev. Calculate the total
machining time.
L1 = 120mm L2 = 117.5mm S = 0.25 mm/rev.
d= 80 mm n = 200 RPM. tmax = 1mm
L= +2ⵠ
L= + 2*3 = 46mm
( )
N= = = 2.5
T=N =3* = 2.76 min
- Ex6: Drilling process, it is given: diameter of twist drill d = 9 mm. No. of spindle
revelations, n = 320 RPM. Thickness of workpiece I = 30 mm, feed S = 0.1 min/rev.
Calculate the drilling time.
L = 30mm S = 0.1 mm/rev. dtwist= 9 mm
n = 320 RPM.
L = L + x + 2ⵠ
L = 30 + 0.3*9 + 2*3 = 38.7mm
T=N =1* = 1.2 min
P a g e | 19
Milling
- Ex7: In horizontal milling process, it is given: Length of workpiece = 100 mm. milling
cutter diameter d = 60 nun, No. of spindle revelations n = 120 RPM, feed S = 0.2
mm/rev., depth of cut t = 1.5 mm. Calculate the machining time.

n = 120 RPM.
L = L + x + 2ⵠ
L = 100 + √( ) ( ) + 2*3 = 115.36 mm
T=N =1* = 4.8 min
Ex8: In vertical milling process. It is given, Length of workpiece l = 80mm. milling

cutter diameter d = 15 mm. No. of spindle n =120 RPM, .feed S = 0.25 mm/rev.
Calculate the machining time of this groove.
n = 120 RPM.
L = L + x + 2ⵠ
L = 80 + + 2*3 = 93.5mm
T=N =1* = 3.11 min
P a g e | 20
Power and Force
- Ex9: In shaping process, it is given: Length of workpiece L1 = 120 mm. depth of cut
t1=1 mm, thickness of chip t 2 = 1.3 mm, Calculate coefficient of up sitting deformation.
RC and calculate the length of chip L2.
RC = =
RC = =
RC = 0.77 L2 = = 92.3mm
- Ex10: in longitudinal turning process, it is given: diameter of workpiece d = 100 mm.

No. of spindle r revelations n = 320 RPM, feed S = 0.25 mm/rev. Depth of cut t = 0.5
mm, specific cutting resistance of workpiece material = 1050 MPa. Calculate the
cutting force P and the power N. If 0.1 of the power is loss in friction between the
driving motor and the spindle. Calculate the power consuming by motor.
dw.p.= 100 mm n = 320 RPM. S = 0.25 mm/rev
t = 0.5mm KS= 1050 MPa.
F = KS * S * t = 1050 * 0.25 * 0.5 = 131.25 N
Neff. = =
= 1 – loss = 1 – 0.1 = 0.9
0.9 = 
P a g e | 21
4.2 Saw tooth diagram

- In a 9 speed gear-box, it is given
Vmin = 20m/min Vmax =100 m/min
dmin = 50mm dmax =120 mm

a) Calculate nmax & nmin
b) Calculate the 9 speeds of the gear-box when distributed according to:
1- Arithmetic prog.
2- Geometrical prog.
c) Draw the saw tooth diagram for both cases.
d) Write down the value of n to be adjusted for both cases when cutting a work-piece
of d =80mm.
a) Calculate nmax & nmin

nmax = = = 636.6
nmin = = = 53.05
b) Calculate the 9 speeds of the gear-box

- Athematic:
Ca = = = 73
For d = 50
n1 = nmin = 53 𝜋
V1 = = 8.3 m/min
n2 = n1 + Ca = 53 + 73 = 126 RPM 𝜋
V2 = = 19.7 m/min
n3 = n2 + Ca = 126 + 73 = 199 RPM 𝜋
V3 = = 31.25 m/min
n4 = n3 + Ca = 199 + 73 = 272 RPM 𝜋
V4 = = 42.72 m/min
n5 = n4 + Ca = 272 + 73 = 345 RPM 𝜋
V5 = = 54.19 m/min
n6 = n5 + Ca = 345 + 73 = 418 RPM 𝜋
V6 = = 65.65 m/min
n7 = n6 + Ca = 418 + 73 = 491 RPM 𝜋
V7 = = 77.12 m/min
n8 = n7 + Ca = 493 + 73 = 564 RPM 𝜋
V8 = = 88.6 m/min
n9 = nmax = 637 RPM V9 =
𝜋
= 100 m/min
P a g e | 22
Athematic Graph
P a g e | 23
- Geometrical:
Cg = ( ) ==( ) = 1.364
For d = 50
n1 = nmin = 53 𝜋
V1 = = 8.3 m/min
n2 = n1 * Cg = 53 * (1.364) = 72.3 RPM 𝜋
V2 = = 11.34 m/min
2 2 𝜋
n3 = n1 * Cg = 53 * (1.364) = 98.6 RPM V3 = = 15.48 m/min
3 3 𝜋
n4 = n1 * Cg = 53 * (1.364) = 134.49 RPM V4 = = 21.12 m/min
4 4 𝜋
n5 = n1 * Cg = 53 * (1.364) = 183.45 RPM V5 = = 28.81 m/min
5 5 𝜋
n6 = n1 * Cg = 53 * (1.364) = 250.23 RPM V6 = = 39.3 m/min
6 6 𝜋
n7 = n1 * Cg = 53 * (1.364) = 341.32 RPM V7 = = 53. m/min
7 7
n8 = n1 * Cg = 53 * (1.364) = 465.56 RPM V8 =
𝜋
= 73.13 m/min
n9 = nmax = 637 RPM V9 =
𝜋
= 100 m/min
Geometrical graph
P a g e | 24
d) Write down the value of n to be adjusted for both cases when cutting a work-piece of
d=80mm.
- Case1: Arithmetical
nopt. = = = 397.88 RPM
nopt. is between n5 = 345 & n6 = 418
So n5 = 345 is the best cutting speed for a work-piece of d = 80mm
- Case2: Geometrical
nopt. = = = 397.88 RPM
nopt. is between n7 = 341.32 & n8 = 465.56
So n7 = 341.32 is the best cutting speed for a work-piece of d = 80mm
P a g e | 25
5. Results and Comments

The results of this research are to learn about the Theory of Metal Cutting and
understanding of the cutting process.
 Machining: any of various processes in which a piece of raw material is cut into a desired
final shape and size by a controlled material-removal process.
 Most important and used cutting processes
- Turning: a machining process in which a cutting tool advancing against a rotating work-
piece to removing layers of metal from the material. The process is done on a lathe
machine and used to create cylindrical parts.
- Milling: a process of machining using a rotary cutter with several edges to remove
material by advancing the cutter into a work piece. The process has two main types;
vertical mill and horizontal mill and done on a Milling machine.
- Drilling: Process of removing material from the inside of a work-piece and producing a
hole of circular cross-section by a tool called “drill bit”. The process can be done on a
lathe or milling machine, but due to shorter processing times are always in high demand,
a machine was invented later for the specific operations of drilling.
 Orthogonal Cutting
- Cutting edge of the tool is perpendicular to the direction of tool travel.
- The direction of chip flow is perpendicular to the cutting edge.
- The chip coils in a tight flat spiral.
- The same feed and depth of cut is done by less force and less tool-material contact.
Therefore, the life of the tool is less.
- This method is generally used is lathe and other parting off operations.
P a g e | 26
 Tooling is available in a variety of materials. The most common are carbide and
high-speed steel. You may choose to use high-speed steel (HSS) for general purpose
milling. But, opt for Carbide to machine tougher and harder tool steels.
 The favorite properties for tool material

1) High strength
2) High Hardness
3) High wear resist
4) High Toughness
5) High thermal conduct
6) Low price
7) High Machinability
8) Hot Hardness (Like HSS)
 Heat generation
- During machining, heat is generated at the cutting point from three sources.
1) Primary shear zone
2) Secondary deformation zone
3) Flank wear zone
 Steady State Temperature (T)

- A temperature reached when Qa = Qg
- There are two options to decrease T:
1) Lowering Qg.
2) Increasing Qa.
 Cooling Liquid
- A type of coolant and lubricant designed specifically for metalworking
processes. Helps reducing the heat generated during the cut.
P a g e | 27
6. Conclusions
With increasing demands for the production of parts in various industries, Machining
processes such as Turning, Milling, and Drilling became an essential for manufacturing.
Knowing how to calculate machining time, cutting force, power consumed during cutting;
and the how to properly choose the required tool material for the cutting process is a must
production Engineers as one of their main job is to ensure that all products are manufactured
with utmost efficiency, high quality, and low cost. In order to do that, they must be familiar
with the several phenomenal that occur during the cutting process, and how to deal with
them. The knowledge about machining processes is a strategically important subject to all
Engineers because almost 90% of the field of engineering is subjected to some kind of
machining during the manufacture process.
P a g e | 28
7. References
(1) Dr. Taha Elshafie Lectures notes
https://drive.google.com/drive/folders/1izvYbyAr2hNPZifQ7pKGuxVyzkeJPsr0
(2) Dr. Osama Khayal; (2019) Nile Valley University. THEORY OF METAL CUTTING
UNIT.
https://www.academia.edu/43007411/UNIT_-I_THEORY_OF_METAL_CUTTING_UNIT_-
I_THEORY_OF_METAL_CUTTING
(3) Amrit Kumar, (July, 23, 2018). Lathe Machine: Definition, Introduction, Parts, Types,
Operations, and Specifications.
https://learnmechanical.com/lathe-machine
(4) Diagram of a lathe machine.
http://car-az.blogspot.com/2018/04/diagram-of-lathe-machine.html
(5) Engineering Articles. (August 7, 2015) Milling Machine Definition, Process & Types
http://www.engineeringarticles.org/milling-machine-definition-process-
types/#:~:text=Milling%20Machine,surface%20of%20the%20work%20piece.
(6) Fundamentals of Machine Tools. (Oct 29, 1996) Army Publishing Directorate.
https://armypubs.army.mil/epubs/DR_pubs/DR_a/pdf/web/tc9_524.pdf
(7) Amrit Kumar, (Sept, 28, 2018). Drilling Machine: Definition, Parts, Types, and
Operations.
https://learnmechanical.com/drilling-machine/
(8) Prof. K GOBIVEL, (KCG College of Technology). MANUFACTURING
TECHNOLOGY – II Theory of metal cutting. Orthogonal cutting.
https://www.brainkart.com/article/Orthogonal-metal-cutting_5767/
(9) TECHNICAL COMMUNICATIONS TEAM. (Sept 26, 2016). Machining Processes:
Turning, Milling, and Drilling – Trimantec.
https://trimantec.com/blogs/t/machining-processes-overview
(10) Minaprem. Difference Between Primary Shear Zone and Secondary Deformation Zone
https://www.difference.minaprem.com/machining/difference-between-primary-shear-zone-and-
secondary-deformation-zone/
(11) Thermal conduction. Wikipedia.
https://en.wikipedia.org/wiki/Thermal_conduction#Steady-state_conduction
P a g e | 29
(12) Cutting fluid. Wikipedia.

https://en.wikipedia.org/wiki/Cutting_fluid
(13) Suzi Mein (Nov, 15, 2019). The Importance of Coolants in Machining.
https://www.firetrace.com/fire-protection-blog/importance-of-coolants
P a g e | 30

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MTI Faculty of Engineering – Basic Science Engineering Program

Mohamed Ahmed Abbas Hassan

Prof. Dr. Taha El-Shafie

3.2.1 Vertical milling.…………………………………..…………….……..……….…8

3.3.1 Counter Thinking.………………….……..………..…………….….….……11

3.5 Properties of Tools.………………………..……….……………….………..…...13

3.6 Heat generation…….…………………………………………….………..….…….14

4.1 Calculation of Machining Time, Force, Power………………....…………….…17

5. Results and Comments………….………………………………………………..…….26

3. Theoretical part (Machining Processes and tool)

- Turning is the most important machining process; it can produce

[Fig.2: Lathe Machine]

3.1.1 Long Turning

[Fig.3: Long Turning]

3.1.2 Face Turning

[Fig.4: Face Turning]

[Fig.5: External threading]

[Fig.6: Knurling on Lathe]

[Fig.7: Vertical and Horizontal milling Machines]

3.2.1 Vertical milling

Examples of Vertical Milling

1) U-grove by using a U cutting tool.

3.2.2 Horizontal milling

Examples of Horizontal Milling

1) U-grove by using a U cutting tool.

2) V-grove by using a V cutting tool.

[Fig.8: Drilling Machine]

3.3.1 Counter Thinking

[Fig.8: Counter Thinking]

3.3.2 Counter Boring

[Fig.9: Counter Boring]

3.4 Orthogonal Cutting

[Fig.10: Orthogonal Cutting]

Chip deformed  L1* t1* S

3.5 Properties of Tools

- The favorite properties for tool material:

3.6 Heat generation

2) Secondary deformation zone

3) Flank wear zone

[Fig.13: Heat generation zones]

Steady State Temperature

Option 2: Increase Qa. by:

- The effect of using Cooling Liquid:

4.1 Calculation of Machining Time, Force, Power.

L = 120mm n = 200 RPM S = 0.2 mm/rev.

T=N =1* = 3.15 min

- Ex2: In longitudinal turning process, it is given: Length of workpicce 1= 180 mm, DI

T=N =1* = 2.325 min

- Ex3: In longitudinal turning process, it is given: Length of workpiece 1 = 100 mm,

T=N =2* = 2.208 min

T=N =1* = 0.56 min

T=N =3* = 2.76 min

T=N =1* = 1.2 min

L = 100mm S = 0.1 mm/rev. dtwist= 9 mm

L = 100 + √( ) ( ) + 2*3 = 115.36 mm

T=N =1* = 4.8 min

Ex8: In vertical milling process. It is given, Length of workpiece l = 80mm. milling

T=N =1* = 3.11 min

Power and Force

- Ex10: in longitudinal turning process, it is given: diameter of workpiece d = 100 mm.

F = KS * S * t = 1050 * 0.25 * 0.5 = 131.25 N

= 1 – loss = 1 – 0.1 = 0.9