MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

WEEK 1
Machining and Principles,
Basic Concepts in Cutting
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Weekly Subjects and Related Preparation Studies

Week Subjects Related Preparation

1 Machining and Principles, Basic Concepts in Cutting Lecture Notes Chapter 1

2 Parameters effecting cutting Lecture Notes Chapter 2
3 Machinability and parameters effecting machinability Lecture Notes Chapter 3
4 Machinability and tool life Lecture Notes Chapter 3
5 Machinability and cutting forces, cutting power Lecture Notes Chapter 3
6 Machinability and chip control Lecture Notes Chapter 3
7 Machinability and surface integrity Lecture Notes Chapter 3
8 Midterm 1
9 Machining ferrous materials ---
10 Machining of non- ferrous materials Lecture Notes Chapter 4
11 Machining of plastics Lecture Notes Chapter 5
12 Machining of composites Lecture Notes Chapter 6
13 Machining of ceramics Lecture Notes Chapter 7
14 Industrial applications Lecture notes Part 8 ve Current articles
15 Final
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Evaluation
Quizzes/Studio Critics 2 20
Homework Assignments 1 10
Presentations/Jury
Project
Seminar/Workshop
Mid-Terms 1 30
Final 1 40
Percentage of In-Term Studies 60
Percentage of Final Examination 40
TOTAL 100
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

REFERENCE BOOKS
Lecture Notes of Prof. Dr. Erhan ALTAN

Advanced Machining Processes of Metallic Materials, Theory Modelling and

Applications, Wit Grezesik

Basic Machining Reference Handbook, Arthur R.Meyers, Thomas J. Slattery,İndustrial

Pres İnc., New York, 2001

Handbook of Machining and Metalworking Calculations, Ronald A. Walsh, Mc Graw-

Hill, New York, 2001
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REFERENCE BOOKS
Salak M Selecka, M Selecka, H Danninger
Machinability of Powder Metallurgy Steels
Cambridge International Science Publishing, 2005, 551 pages

B. Mills, A. H. Redford, Machinability of Engineering Materials [1 ed.]

Springer Netherlands, 1983, 174 pages

Nanjappan Natarajan, Vijayan Krishnaraj, J. Paulo Davim

Metal Matrix Composites: Synthesis, Wear Characteristics, Machinability Study of MMC Brake Drum
Springer International Publishing, 2015, 85 pages

Davim, J. Paulo, Machinability of Advanced Materials [1 ed.], Wiley-ISTE, 2014, 247 pages

Davim, J. Paulo , Machinability of fibre-reinforced plastics, De Gruyter, 2015, 210 pages

Mohamed Thariq Hameed Sultan; Azwan Iskandar Azmi; Mohd Shukry Abd Majid; Mohd Ridzuan Mohd Jamir; Naheed Saba
Machining and Machinability of Fiber Reinforced Polymer Composites
Springer, 2021, 417 pages
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There are several reasons for developing a rational approach to

material removal:

1. to improve cutting techniques—even minor improvements in productivity are of

major importance in high volume production
2. to produce products of greater precision and of greater useful life
3. to increase the rate of production and produce a greater number and variety of
products with the tools available
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

The material removal processes (machining processes)

are a family of shaping operations in which excess
material is removed from a starting work part so that
what remains is the desired final geometry.

CHIP REMOVAL PROCESSES

MAK3472 - MACHINING OF INDUSTRIAL MATERIALS
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

The most important branch of the family is conventional machining, in which a sharp
cutting tool is used to mechanically cut the material to achieve the desired geometry.
The three most common machining processes are turning, drilling, and milling. The
“other machining operations” are shaping, planing, broaching, and sawing.
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Another group of material removal processes is the abrasive processes, which

mechanically remove material by the action of hard, abrasive particles.

This process group, which includes grinding, and the “other abrasive processes” in
include honing, lapping, and superfinishing.

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 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

There are the nontraditional

processes, which use various
energy forms other than a sharp
cutting tool or abrasive particles
to remove material. The energy
forms include mechanical,
electrochemical, thermal, and
chemical (corrosion).
MAK3472 - MACHINING OF INDUSTRIAL MATERIALS
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

MACHINING

It is a manufacturing process in which a sharp cutting tool is used to cut away material
to leave the desired part shape. The predominant cutting action in machining involves
shear deformation of the work material to form a chip; as the chip is removed, a new
surface is exposed. Machining is most frequently applied to shape metals.
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Workpiece - cutting tool contact

A cross-sectional view of the machining process

MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Cutting tool

Tool with negative rake angle

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Importance of Machining
Importance of Machining (commercially and technologically):
➢ Variety of work materials. Machining can be applied to a wide variety of work materials. All solid metals can be machined. Plastics and plastic
composites can also be cut by machining. Ceramics pose difficulties because of their high hardness and brittleness; however, most ceramics can be
successfully cut by the abrasive machining processes.

➢ Variety of part shapes and geometric features. Machining can be used to shape any regular geometries, such as flat planes, round holes, and
cylinders. By introducing variations in tool shapes and tool paths, irregular geometries can be obtained, such as screw threads and T-slots. By
combining several machining operations in sequence, shapes of almost unlimited complexity and variety can be produced.

➢ Dimensional accuracy. Machining can produce dimensions to very close tolerances. Some machining processes can achieve tolerances of 0.025
mm, much more accurate than most other processes.

➢ Good surface fi nishes. Machining is capable of creating very smooth surface

finishes. Roughness values less than 0.4 microns can be achieved in conventional machining operations. Some abrasive processes can achieve even
better finishes.

➢ Surface integrity. Surface integrity is the surface condition of a workpiece after being modified by a manufacturing process. Manufacturing
processes have five main variables: the workpiece, the tool, the machine tool, the environment, and process variables. All of these variables can
affect the surface integrity of the workpiece by producing
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Types of Machining Operations

Machining is not just one process; it is a group of processes. The common feature is
the use of a cutting tool to form a chip that is removed from the work part. To
perform the operation, relative motion is required between the tool and work. This
relative motion is achieved in most machining operations by means of a primary
motion, called the cutting speed, and a secondary motion, called the feed. The shape
of the tool and its penetration into the work surface, combined with these motions,
produces the desired geometry of the resulting work surface.
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

MACHINING PROCESSES/METHODS
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The Cutting Tool

A cutting tool has one or more sharp cutting edges and is made of a material that is harder than the
work material. The cutting edge serves to separate a chip from the parent work material. Connected to
the cutting edge are two surfaces of the tool: the rake face and the flank. The rake face, which directs
the flow of the newly formed chip, is oriented at a certain angle called the rake angle a. It is measured
relative to a plane perpendicular to the work surface.
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The Cutting Tool

(a) – Positive rake angle
(b) – Negative rake angle

The flank of the tool provides a

clearance between the tool and the
newly generated work surface, thus
protecting the surface from
abrasion, which would degrade the
finish. This flank surface is oriented
at an angle called the relief angle.
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The cutting tool

A cross-sectional view of the machining process

Tool with negative rake angle

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The cutting tool

Most cutting tools in practice have more complex geometries. There are two basic types:
(a) single-point tools
(b) multiple-cutting-edge tools

A single-point tool has one cutting edge and is used for operations such as turning. There is one tool point from
which the name of this cutting tool is derived. During machining, the point of the tool penetrates below the
original work surface of the part. The point is usually rounded to a certain radius, called
the nose radius.
Multiple-cutting-edge tools have more than one cutting edge and usually achieve their motion relative to the
work part by rotating. Drilling and milling use rotating multiple-cutting-edge tools. in peripheral milling. Although
the shape is quite different from a single-point tool, many elements of tool geometry are similar.
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Machining Conditions

Relative motion is required between the tool and work to perform a machining operation. The primary
motion is accomplished at a certain cutting speed v. In addition, the tool must be moved laterally
across the work. This is a much slower motion, called the feed f. The remaining dimension of the cut is
the penetration of the cutting tool below the original work surface, called the depth of cut d.
Collectively, speed, feed, and depth of cut are called the cutting conditions. They form the three
dimensions of the machining process, and for certain operations (e.g., most single-point tool
operations) they can be used to calculate the material
removal rate for the process:

RMR material removal rate, mm3/s (in3/min);

v cutting speed, m/s (ft/min), [which must be converted to mm/s (in/min)];
f feed, mm (in);
d depth of cut, mm (in).
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Machining (turning)
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Machining
The machining conditions for a turning operation are depicted in figure.
Typical units used for cutting speed are m/s (ft/min). Feed in turning is
expressed in mm/rev (in/rev), and depth of cut is expressed in mm (in). In
other machining operations, interpretations of the cutting conditions
may differ. For example, in a drilling operation, depth is interpreted as the
depth of the drilled hole.
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Machining

İmalatta, parçada genellikle birkaç kaba paso ve ardından bir veya iki bitirme pasosu uygulanır.

Kaba paso–başlangıç parçasından büyük miktarda malzeme uzaklaştırır.

Şekli istenen geometriye yaklaştırır, ancak bitirme pasoları için biraz malzeme bırakır.
Yüksek ilerleme ve derinlikler, düşük kesme hızları

Bitirme pasosu–parça geometrisini tamamlar

Son boyutlar, toleranslar ve bitirme
Düşük ilerleme ve derinlikler, yüksek kesme hızları
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Machining
Machining operations usually divide into two categories, distinguished by purpose
and cutting conditions: rough machining and finish machining.

Rough machining is used to remove large amounts of material from the starting work
part as rapidly as possible, in order to produce a shape close to the desired form, but
leaving some material on the piece for a subsequent finishing operation.

Finish machining is used to complete the part and achieve the final dimensions,
tolerances, and surface finish.
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Machining
In production machining jobs, one or more rough cuts are usually performed on the
work, followed by one or two finishing cuts. Roughing operations are performed at
high feeds and depths—feeds of 0.4–1.25 mm/rev (0.015–0.050 in/rev) and depths of
2.5–20 mm (0.100–0.750 in) are typical. Finishing operations are carried out at low
feeds and depths—feeds of 0.125–0.4 mm (0.005–0.015 in/rev) and depths of 0.75–
2.0 mm (0.030–0.075 in) are typical. Cutting speeds are lower in rough machining
than in finish machining.
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Machining
Cutting fluid

It is often applied to the machining operation to cool and lubricate the cutting tool.
Determining whether a cutting fluid should be used, and, if so, choosing the proper
cutting fluid, is usually included within the scope of cutting conditions. Given the
work material and tooling, the selection of these conditions is very influential in
determining the success of a machining operation.
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Machining
Machine Tools

Machine tools are used to hold the work part, position the tool relative to the work, and provide power for the machining
process at the speed, feed, and depth that have been set. By controlling the tool, work, and cutting conditions, machine tools
permit parts to be made with great accuracy and repeatability, to tolerances of 0.025 mm (0.001 in) and better. The term
machine tool applies to any power-driven machine that performs a machining operation, including grinding. The term is also
applied to machines that perform metal forming and pressworking operations.

Conventional machine tools are usually tended by a human operator, who loads and unloads the work parts, changes cutting
tools, and sets the cutting conditions. Many modern machine tools are designed to accomplish their operations with a form of
automation called computer numerical control
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Machining
The understanding of what happens in each of the three major regions of the cutting process involves
a knowledge of several fields of engineering and science including:

• 1. solid state physics

• 2. engineering mechanics
• 3. materials science
• 4. engineering plasticity and fracture mechanics
• 5. fundamentals of lubrication, friction, and wear
• 6. basic concepts of chemistry and physics
• 7. principles of physical metallurgy
• 8. thermodynamics and heat transfer
 MAK3472 - MACHINING OF INDUSTRIAL MATERIALS

Machining
There are three regions of interest in the cutting
process.

The first area shown in figure extends along the

shear plane and is the boundary between the
deformed and undeformed material or the chip and
the work.

The second area includes the interface between the

chip and the tool face, while the third area includes
the finished or machined surface and the material
adjacent to that surface. We are primarily interested
in the plastic deformation characteristics of the
material cut in the first area, the friction and wear
characteristics of the tool–work combination in the
second area, and the surface roughness and integrity
of the finished surface constituting the third area.

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Machining
The operational characteristics of a cutting tool are generally described by a single word — machinability. There
are three main aspects of machinability:
• 1. tool life
• 2. surface finish
• 3. power required

We must say something about the case «operational characteristics of a

cutting tool are generally described by a single word — machinability»

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