Lecture 5-Machining Operations

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).
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

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
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
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.
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
Generating Shape
Figure 22.2 Generating shape: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, (e) profile milling.
Forming to Create Shape
Figure 22.3 Forming to create shape: (a) form turning, (b) drilling, and
(c) broaching.
Forming and Generating
Figure 22.4 Combination of forming and generating to create shape:

(a) thread cutting on a lathe, and (b) slot milling.
Machining Operations
 Most important machining operations:
 Turning
 Drilling
 Milling
 Other machining operations:
 Shaping and planing
 Broaching
 Sawing
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
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,
Cutting Conditions for Turning
Figure 21.5 Speed, feed, and depth of cut in turning.
Turning
Figure 22.5 Turning operation.
Facing
Tool is fed
radially inward
Figure 22.6 (a) facing
Chamfering
 Cutting edge cuts an angle on the corner

of the cylinder, forming a "chamfer"
Figure 22.6
(e) chamfering
Tapering

Cutoff
 Tool is fed radially into rotating work at

some location to cut off end of part
Figure 22.6 (f) cutoff
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
Knurling

Types of Chips

Engine Lathe
Figure 22.7
Diagram of an
engine lathe,
showing its
principal
components
Work Piece Fixation: Chucks, between centres



Cutting Parameters

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

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

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
Drilling

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.
Types of Drilling and Reaming Operations

Tapping
 Used to provide
internal screw
threads on an
existing hole
 Tool called a tap
Figure 22.14 (b) tapping
Trepanning

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
Milling

Milling Cutters & Operations

Milling Cutters & Operations

Side Milling Cutters

Different Types of Milling

Milling Machine

Basic Components of Milling Machine

Basic Components of Milling Machine

Vertical Milling Machine

Universal Milling Machine

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.

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
Shaper
Figure 22.30 Components of a shaper.
Planer
Figure 22.31 Open side planer.
Cutting Tool Technology
Three principal aspects:
1. Cutting temperature
2. Tool Life
3. Tool Materials
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
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.
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

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Production Technology

Dr.-Ing. Ahmed Yehia Shash

Dr.-Ing. Ahmed Shash Production Technology

Figure 21.2 (a) A cross-sectional view of the machining process, (b)

Dr.-Ing. Ahmed Shash Machining Process

 Rotational - cylindrical or disk-like shape

Figure 22.4 Combination of forming and generating to create shape:

Single point cutting tool removes material from a

Figure 21.3 Three most common machining processes: (a) turning,

Figure 21.5 Speed, feed, and depth of cut in turning.

Figure 22.5 Turning operation.

Figure 22.6 (a) facing

 Cutting edge cuts an angle on the corner

Dr.-Ing. Ahmed Shash Machining Process

 Tool is fed radially into rotating work at

Figure 22.6 (f) cutoff

Figure 22.6 (g) threading

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

 Optimized cutting speed

Dr.-Ing. Ahmed Shash Machining Process

 Machinability of the workpiece material

Dr.-Ing. Ahmed Shash Machining Process

Figure 21.3 (b) drilling

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Figure 22.14 (b) tapping

Dr.-Ing. Ahmed Shash Machining Process

 Upright drill press

 Bench drill similar

Figure 22.15 Upright drill press

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Dr.-Ing. Ahmed Shash Machining Process

Figure 22.29 (a) Shaping, and (b) Planing.

Figure 22.30 Components of a shaper.

Figure 22.31 Open side planer.

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