Chapter 23

Machining Processes Used to Produce Round

Shapes: Turning and Hole Making
 Material Removal Processes

A family of shaping operations, the common feature of

which is removal of material from a starting workpart so
the remaining part has the desired geometry
• Machining – material removal by a sharp cutting tool,
e.g., turning, milling, drilling
• Abrasive processes – material removal by hard,
abrasive particles, e.g., grinding
• Nontraditional processes - various energy forms other
than sharp cutting tool to remove material
 MACHINING OPERATIONS AND MACHINE
TOOLS

1. Turning and Related Operations

2. Drilling and Related Operations
3. Milling
 Lathe Cutting
Operations

Figure 23.1 Miscellaneous cutting

operations that can be performed
on a lathe. Note that all parts are
circular – a property known as
axisymmetry. The tools used, their
shape, and the processing
parameters are described
throughout this chapter.
5
Lathe Cutting Operations and Lathe Tools
 Designations for a Right-Hand Cutting Tool

Figure 23.4 Designations for a right-hand cutting tool. Right-hand means the tool
travels form right to left, as shown in Fig. 23.3.
 Turning Operation
Turning may be performed
at various speeds, dep and
feeds ƒ (Fig. 22.3),
depending on:
• workpiece and tool
materials
• surface finish and
dimensional accuracy
required
• characteristics of the
machine tool. Figure 23.3 Schematic illustration of the basic turning
operation, showing depth-of-cut, d; feed, f; and spindle
rotational speed, N in rev/min. Cutting speed is the
surface speed of the workpiece at the tool tip.
 Lathe Components

Figure 23.2 General view of a typical lathe, showing various components.

Source: Courtesy of Heidenreich & Harbeck.
 LATHES AND LATHE OPERATIONS
Lathe Components

1. Bed: The bed supports all major components of the lathe.

Beds have a large mass and are built rigidly, usually from
gray or nodular cast iron. The top portion of the bed has two
ways
2. Carriage: Consists of an assembly of cross-slide, tool post,
and apron
 The tool post, usually with a compound rest that swivels for
tool positioning and adjustment.
 The cross-slide moves radially in and out
 The apron is equipped with mechanisms for both manual and
mechanized movement of carriage and cross-slide by means
of the lead screw.
 LATHES AND LATHE OPERATIONS
Lathe Components
3. Headstock: have a hollow spindle to which Workholding
devices, such as chucks and collets, are attached, and long bars or
tubing can be fed through for various turning operations.
4. Tailstock: It is equipped with a center that may be fixed (dead
center) or may be free to rotate with the workpiece (live center).
• Drills and reamers can be mounted on tailstock quill to drill axial
holes in the workpiece
• A quill is a hollow cylindrical part with a tapered hole
5. The feed rod and Lead Screw: is powered by a set of gears
from the headstock. It rotates during the operation of the lathe
and provides movement to the carriage and the cross-slide by
means of gears
 LATHES AND LATHE OPERATIONS
Lathe Specifications

A lathe generally is specified by the following parameters:

• Swing: the max diameter of the workpiece that can be
machined
• The max distance between the headstock and tailstock centers
(distance between centers)
• The length of the bed
• For example, a lathe may have the following size: 360-mm
swing by 760 mm between centers by 1830-mm length of bed.
• Maximum workpiece diameters may be as much as 2 m.
 Lathe Centers

• A lathe center hold the end of the work piece, providing

support to preventing the work piece from deflecting
during machining
• Lather centers can be mounted in the spindle hole, or in
the tailstock quill
• Lathe centers fall into two categories
– Dead Center: solid steel tip that work piece
spins against
– Live Center: centers contact point is mounted
on bearings and allowed to spin with work
piece
 Lathe Centers

FIGURE 22-20 Live lathe

center can rotate with the part.

FIGURE 22-20 Work being

turned between centers in a
lathe, showing the use of a
dog and dog plate.
(Courtesy of South Bend
Lathe.)
 Holding the Work Between Centers
- Work is held between
head-stock and tail
stock centers
- Tail-stock center can
be live or dead center
- Live center is held in
a bearing so rotates
- Dead center is fixed
on tailstock shaft,
does not rotate:
Result is friction.
- Used for holding
parts having a large
length to diameter
ratio (a) mounting the work between centers using a "dog”
 Holding the Work in a Chuck
- Used when length to
diameter ratio of w/p is low.
- Can be used with and
without support of tail-
stock center
- Two types: 3 jaws/ 4 jaws
- 3 jaws is self centering
chuck
- For 4 jaws, w/p centering
along

(b) three-jaw chuck

 Lathe Chucks

• Lathe Chucks are adjustable mechanical vises that hold

the work piece and transfer rotation motion from the
drive motor to the work piece
• Lathe Chucks come in two basic types
– Three-jaw self-centering chucks
• Used to center round or hexagonal stock
– Four-jaw independent chucks
• Each jaw moves independently to accommodate
various work piece shapes
 Lathe Chucks

FIGURE 22-23 Hydraulically

FIGURE 22-22 The jaws on actuated through-hole three-jaw
chucks for lathes (four-jaw power chuck shown in section
independent or three-jaw selfcentering) view and in the spindle of
can be removed and the lathe above connected to
reversed. the actuator.
 Forces Acting on a Cutting Tool in Turning

Figure 23.5 Forces acting on a cuttin tool in turning, Fc is the cutting force, Ft is the thrust of
feed force (in the direction of feed), and Fr is the radial force that tends to push the tool away
from the workpiece being machined.
 THE TURNING PROCESS
Material Removal Rate (MRR)
 THE TURNING PROCESS
Material Removal Rate (MRR)
 THE TURNING PROCESS
Summary of Turning Parameters and Formulas
• N = Rotational speed of workpiece, rpm
• ƒ = Feed, mm/rev
• υ = Feed rate, or linear speed of tool along workpiece length, mm/min =
ƒN
• V = Surface speed of workpiece, m/min = π DoN (for max speed)= π
DavgN (for average speed)
• l = Length of cut, mm
• Do = Original diameter of workpiece, mm
• Dƒ = Final diameter of workpiece, mm
• Davg = Average diameter of workpiece, mm= (Do + Dƒ)/2
• d = Depth of cut, mm= (Do - Dƒ)/2
• t = Cutting time, s or min = L/ƒN
• MRR = mm3/min= π Davg d ƒN
• Torque = N. m = (Fc) (Davg/2)
• Power = k W or hp = (Torque) (ω), where ω = 2 πN radians/min
 POWER AND ENERGY RELATIONSHIPS IN
MACHINING

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 POWER AND ENERGY RELATIONSHIPS IN
MACHINING

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
• EXAMPLE Material-removal Rate and Cutting Force in Turning
A 150mm long, 12.5mm-diameter 304 stainless steel rod is being reduced in
diameter to 12.0 mm by turning on a lathe. The spindle rotates at N = 400 rpm, and
the tool is traveling at feeding rate of 200 mm/min. Calculate the cutting speed,
material-removal rate, cutting time, power dissipated, and cutting force.
Solution:
V = πDON
= (3.14*12.5*400)/1000 = 15.7 m/min
The cutting speed at the machined diameter is
V = πDON
= (3.14*12.0*400)/1000 = 15.1 m/min
the depth of cut is d = (12.5-12) / 2 = 0.25mm
the feed is f = 200/400 = 0.5 mm/rev.

-6
MRR = π DavgdƒN = 3.14*12.25*0.25*0.5*400 = 1924 mm3/min = 2*10 m3/min
• The actual time to cut is t = L / fN = 150 / 0.5*400 = 0.75 min
• The specific energy for stainless steel from table 21.3 is 4
w.s/mm3

• The power needed is P = U * MRR

= (4 * 1924) / 60 = 128 watt
So, the power P= 128*60 = 7680 N.m/min

Power = (Torque) (ω), Torque = 7680/(2*3.14*400)= 3.1 N.m

Torque = Fc * (Davg/2)

Fc = (2*torque) / Davg = 2 * 3.1 / (12.25/1000) = 506 N

 Example
• In a production turning operation, the foreman has
decided that a single pass must be completed on a
cylindrical workpiece in 5.0 min. The piece is 400 mm
long and 150 mm in diameter. Using a feed = 0.30
mm/rev and a depth of cut = 4.0 mm, what cutting speed
must be used to meet this machining time requirement?
Estimate the material removal rate in this operation.

t = L / fN

MRR = π DavgdƒN

29
 Example
• In a turning operation on stainless steel with hardness =
200 HB, the cutting speed = 200 m/min, feed = 0.25
mm/rev, and depth of cut = 7.5 mm. How much power will
the lathe draw in performing this operation if its mechanical
efficiency = 90%.
- Take U = 2.8 N-m/mm3 = 2.8 J/mm3

Pc
Pu 
MRR

30
 Example: Solution

• MRR = vfd
= (200 m/min)(103 mm/m)(0.25 mm)(7.5 mm)
= 375,000 mm3/min = 6250 mm3/s

• Pc = (6250 mm3/s)(2.8 J/mm3) = 17,500 J/s

= 17,500 W = 17.5 kW

• Accounting for mechanical efficiency, Pg

= 17.5/0.90 = 19.44 kW

31
 Boring and Boring Mill
Figure 23.17 (a) Schematic
illustration of a steel boring bar
with a carbide insert. Note the
passageway in the bar for cutting
fluid application. (b) Schematic
illustration of a boring bar with
tungsten-alloy “inertia disks”
sealed in the bar to counteract
vibration and chatter during
boring. This system is effective
for boring bar length-to-diameter
ratios of up to 6.

Figure 23.18 Schematic illustration of a vertical

boring mill. Such a machine can accommodate
workpiece sizes as large as 2.5m (98 in.) in
diameter.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Drilling

• Creates a round hole in

a workpart
• Compare to boring
which can only enlarge
an existing hole
• Cutting tool called a drill
or drill bit
• Machine tool: drill press
 Vertical Drill Press and Radial Drilling Machine

Figure 23.24 (a) Schematic illustration of the components of a vertical drill press. (b) A radial
drilling machine.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Chisel-Point
Drill and
Crankshaft
Drill

Figure 23.19 Two common types of drills: (a) Chisel-point drill. The function of the pair of margins is to provide a
bearing surface for the drill against walls of the hole as it penetrates into the workpiece. Drills with four margins (double-
margin) are available for improved drill guidance and accuracy. Drills with chip-breaker features also are available. (b)
Crankshaft drills. These drills have good centering ability, and because chips tend to break up easily, these drills are
suitable for producing deep holes.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Machining Calculations: Drilling

• Spindle Speed - N v (rpm)

• v = cutting speed N
• D = tool diameter πD
• Feed Rate - fr (mm/min)
• f = feed per rev fr  N f
• Machining Time - Tm (min)
– Through Hole : t  D tan 90 
1 

• t = thickness Tm  2 2

•  = tip angle
fr
– Blind Hole : d
Tm 
• d = depth fr
• Material Removal Rate π D 2 fr (mm3/min)
MRR 
4
36
• Example: A drilling operation is to be performed with a 12.7 mm
diameter twist drill in a steel workpart. The hole is a blind hole at a
depth of 60 mm and the point angle is 118°. The cutting speed is 25
m/min and the feed is 0.30 mm/rev. Determine (a) the cutting time to
complete the drilling operation, and (b) metal removal rate during the
operation, after the drill bit reaches full diameter.

• Solution:

• (a) N = v/πD = 25(103) / (12.7π) = 626.6 rev/min

• fr = Nf = 626.6(0.30) = 188 mm/min

• A = 0.5D tan (90 – θ/2) = 0.5(12.7)tan(90 – 118/2) = 3.82 mm

• Tm = (d + A)/fr = (60 + 3.82)/188 = 0.339 min

• (b) RMR = 0.25πD2fr = 0.25π(12.7)2(188) = 23,800 mm3/min

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Operations Related To Drilling: Reaming

• Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish
 Operations Related To Drilling: Tapping

• Used to provide internal screw

threads on an existing hole
• Tool called a tap
 General Capabilities of Drilling

Various types of drills and drilling and reaming operations.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Types of Drills

Figure 23.21 Various types of drills.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Three-Axis Computer Numerical-Control Drilling
Machine

Figure 23.25 A three-axis computer

numerical-control drilling machine. The
turret holds as many as eight different
tools, such as drills, taps, and reamers.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Helical Reamer and Inserted-Blade Adjustable Reamer

Figure 23.26 (a) Terminology for a helical reamer.

(b) Inserted-blade adjustable reamer.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Characteristics of Machining Processes and Typical
Dimensional Tolerances