Production Technology
EDPT 201
Presented By:
Dr.-Ing. Ahmed Yehia Shash
Assistant Professor
Mechanical Design & Production Dept.
Dr.-Ing. Ahmed Shash Production Technology
Material Removal by Machining
Operations
Machining is 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
Most versatile of all manufacturing processes
in its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
Casting can also produce a variety of
shapes, but it lacks the precision and
accuracy of machining
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Machining
Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
Figure 21.2 (a) A cross-sectional view of the machining process, (b)
tool with negative rake angle; compare with positive rake angle in (a).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Why Machining is Important
Variety of work materials can be machined
Most frequently used to cut metals
Variety of part shapes and special geometric
features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good dimensional accuracy and surface finish
Dr.-Ing. Ahmed Shash Machining Process
Disadvantages with Machining
Wasteful of material
Chips generated in machining are wasted
material, at least in the unit operation
Time consuming
A machining operation generally takes more
time to shape a given part than alternative
shaping processes, such as casting, powder
metallurgy, or forming
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Machining in Manufacturing Sequence
Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
Other processes create the general shape
of the starting workpart
Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot create
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Classification of Machined Parts
Rotational - cylindrical or disk-like shape
Nonrotational (also called prismatic) -
block-like or plate-like
Figure 22.1 Machined parts are classified as: (a) rotational, or (b)
nonrotational, shown here by block and flat parts.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Machining Operations and Part Geometry
Each machining operation produces a
characteristic part geometry due to two
factors:
1. Relative motions between tool and workpart
• Generating – part geometry determined
by feed trajectory of cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by
the shape of the cutting tool
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Generating Shape
Figure 22.2 Generating shape: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, (e) profile milling.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Forming to Create Shape
Figure 22.3 Forming to create shape: (a) form turning, (b) drilling, and
(c) broaching.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Forming and Generating
Figure 22.4 Combination of forming and generating to create shape:
(a) thread cutting on a lathe, and (b) slot milling.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Machining Operations
Most important machining operations:
Turning
Drilling
Milling
Other machining operations:
Shaping and planing
Broaching
Sawing
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Turning
Single point cutting tool removes material from a
rotating workpiece to generate a cylinder
Performed on a machine tool called a lathe
Variations of turning performed on a lathe:
Facing
Contour turning
Chamfering
Cutoff
Threading
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Turning
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
Figure 21.3 Three most common machining processes: (a) turning,
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Cutting Conditions for Turning
Figure 21.5 Speed, feed, and depth of cut in turning.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Turning
Figure 22.5 Turning operation.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Facing
Tool is fed
radially inward
Figure 22.6 (a) facing
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Chamfering
Cutting edge cuts an angle on the corner
of the cylinder, forming a "chamfer"
Figure 22.6
(e) chamfering
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Tapering
Dr.-Ing. Ahmed Shash Machining Process
Cutoff
Tool is fed radially into rotating work at
some location to cut off end of part
Figure 22.6 (f) cutoff
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
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
Figure 22.6 (g) threading
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Knurling
Dr.-Ing. Ahmed Shash Machining Process
Types of Chips
Dr.-Ing. Ahmed Shash Machining Process
Engine Lathe
Figure 22.7
Diagram of an
engine lathe,
showing its
principal
components
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Work Piece Fixation: Chucks, between centres
Dr.-Ing. Ahmed Shash Machining Process
Work Piece Fixation: Chucks, between centres
Dr.-Ing. Ahmed Shash Machining Process
Work Piece Fixation: Chucks, between centres
Dr.-Ing. Ahmed Shash Machining Process
Cutting Parameters
Dr.-Ing. Ahmed Shash Machining Process
Important Parameters for Process Planning
Optimized cutting speed
• Low speeds and feeds low production rate
• Excessive speeds and feeds short tool life
Tool life depends on cutting speed and shear
stress or hardness of the workpiece material
Cutting speeds and feeds decreases with
increasing hardness
Cutting fluids
Dr.-Ing. Ahmed Shash Machining Process
Important Parameters for Process Planning
Machinability of the workpiece material
Shape, dimension, dimensional tolerances,
surface finish of the product
Characteristics of the machining process
Availability of machine tools
Economics aspects of production
Roughning cuts vs finishing cuts
Dr.-Ing. Ahmed Shash Machining Process
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
Figure 21.3 (b) drilling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Drilling
Dr.-Ing. Ahmed Shash Machining Process
Through Holes vs. Blind Holes
Through-holes - drill exits opposite side of work
Blind-holes – does not exit work opposite side
Figure 22.13 Two hole types: (a) through-hole, and (b) blind hole.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Types of Drilling and Reaming Operations
Dr.-Ing. Ahmed Shash Machining Process
Tapping
Used to provide
internal screw
threads on an
existing hole
Tool called a tap
Figure 22.14 (b) tapping
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Trepanning
Dr.-Ing. Ahmed Shash Machining Process
Drill Press
Upright drill press
stands on the floor
Bench drill similar
but smaller and
mounted on a
table or bench
Figure 22.15 Upright drill press
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Milling
Dr.-Ing. Ahmed Shash Machining Process
Milling Cutters & Operations
Dr.-Ing. Ahmed Shash Machining Process
Milling Cutters & Operations
Dr.-Ing. Ahmed Shash Machining Process
Side Milling Cutters
Dr.-Ing. Ahmed Shash Machining Process
Different Types of Milling
Dr.-Ing. Ahmed Shash Machining Process
Milling Machine
Dr.-Ing. Ahmed Shash Machining Process
Basic Components of Milling Machine
Dr.-Ing. Ahmed Shash Machining Process
Basic Components of Milling Machine
Dr.-Ing. Ahmed Shash Machining Process
Vertical Milling Machine
Dr.-Ing. Ahmed Shash Machining Process
Universal Milling Machine
Dr.-Ing. Ahmed Shash Machining Process
Shaping and Planing
Similar operations
Both use a single point cutting tool moved
linearly relative to the workpart
Figure 22.29 (a) Shaping, and (b) Planing.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Shaping and Planing
A straight, flat surface is created in both
operations
Interrupted cutting
Subjects tool to impact loading when
entering work
Low cutting speeds due to start-and-stop
motion
Typical tooling: single point high speed steel
tools
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Shaper
Figure 22.30 Components of a shaper.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Planer
Figure 22.31 Open side planer.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Cutting Tool Technology
Three principal aspects:
1. Cutting temperature
2. Tool Life
3. Tool Materials
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Cutting Tool Classification
1. Single-Point Tools
One dominant cutting edge
Point is usually rounded to form a nose
radius
Turning uses single point tools
2. Multiple Cutting Edge Tools
More than one cutting edge
Motion relative to work achieved by rotating
Drilling and milling use rotating multiple
cutting edge tools
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Cutting Tools
Figure 21.4 (a) A single-point tool showing rake face, flank, and tool
point; and (b) a helical milling cutter, representative of tools with
multiple cutting edges.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
Three Modes of Tool Failure
1. Fracture failure
Cutting force becomes excessive and/or
dynamic, leading to brittle fracture
2. Temperature failure
Cutting temperature is too high for the tool
material
3. Gradual wear
Gradual wearing of the cutting tool
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Dr.-Ing. Ahmed Shash Machining Process
