Mechanical Engineering

Department; Thapar
University

Machining Processes

1
 Introduction of Machining Process
Mechanical Engineering
Department; Thapar
University

• Machining is a manufacturing process in which a

sharp cutting tool is used to cut away material to
leave the desired part shape.
• Machining is most frequently applied to shape
metals.
• Machining operations form chip; as the chip is
removed, a new surface is exposed.

2
 Different Machine Tools Use for Machining
Mechanical Engineering
Department; Thapar
University

Lathe Milling Machine

3
 Different Machine Tools Use for Machining
Mechanical Engineering
Department; Thapar
University

Shaping Machine Drilling Machine

4
 Lathe
Mechanical Engineering
Department; Thapar
University

Components of Lathe
5
 Lathe
Mechanical Engineering
Department; Thapar
University

Components of Lathe
6
 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– External

TURNING
• Reduce diameter of workpiece
• TURNING is a machining process in which a
single-point tool removes material from the
surface of a rotating workpiece.
• Turning is traditionally carried out on a machine
tool called a LATHE, which provides power to turn
the part at a given rotational speed and to feed
the tool at a specified rate and depth of cut.

7
 Turning
Mechanical Engineering
Department; Thapar
University

 Reduce diameter of workpiece

 Turning tool moves axially, along the side of the workpiece
 removing material to form steps and tapers.

8
 Taper Turning
Mechanical Engineering
Department; Thapar
University

• Instead of feeding the tool parallel to the axis of

rotation of the workpiece, the tool is fed at an
angle, thus creating a tapered cylinder or conical
shape.

9
 Contour Turning
Mechanical Engineering
Department; Thapar
University

• Instead of feeding the tool along a straight line

parallel to the axis of rotation as in turning, the
tool follows a contour that is other than straight,
thus creating a contoured form in the turned
part.

10
 Facing
Mechanical Engineering
Department; Thapar
University

 The tool is fed radially into the rotating workpiece on one end to create a flat
surface on the end.
 Reduce the length of workpiece

11
 Chamfering
Mechanical Engineering
Department; Thapar
University

• The cutting edge of the tool is used to cut an

angle on the corner of the cylinder, forming what
is called a ‘‘ chamfer. ’’

12
 Grooving
Mechanical Engineering
Department; Thapar
University

• Grooving tool moves radially, into the side of the

workpiece,
• cutting a groove equal in width to the cutting tool.

13
 Parting
Mechanical Engineering
Department; Thapar
University

• Similar to grooving, parting tool moves radially, into

the side of the workpiece,
• continues until the centre or inner diameter of the
workpiece is reached.

14
 External Threading
Mechanical Engineering
Department; Thapar
University

• A pointed tool is fed linearly across the outside surface

of the rotating workpiece in a direction parallel to the
axis of rotation at a large effective feed rate, thus
creating threads in the cylinder.

15
 Mechanical Engineering
Department; Thapar
Various Operations That Can Be Performed in Lathe
University
– Internal

Drilling
 Drilling can be performed on a lathe by feeding the drill
into the rotating work along its axis. Reaming can be
performed in a similar way.

Twist drill

Feed direction

16
 Boring
Mechanical Engineering
Department; Thapar
University

• A single-point tool is fed linearly, parallel to the axis of

rotation, on the inside diameter of an existing hole in
the part.
• Enlarge the existing hole.

Boring tool

Feed direction

17
 Tapping
Mechanical Engineering
Department; Thapar
University

• A tap enters the workpiece axially through the end

• Cuts internal threads into an existing hole.
• The existing hole is typically drilled by the required tap
drill size that will accommodate the desired tap.

Tapping tool

Feed direction

18
 Knurling
Mechanical Engineering
Department; Thapar
University

• This is not a machining operation because it does

not involve cutting of material. Instead, it is a metal
forming operation used to produce a regular cross-
hatched pattern in the work surface.

19
 Turning parameters
Mechanical Engineering
Department; Thapar
University

Df

Do

20
 Cutting Speed (v)
Mechanical Engineering
Department; Thapar
University

 Cutting speed may be defined as the rate (or speed)

that the material moves past the cutting edge of the
tool.
 It is tangential speed of the workpiece in downward
direction at cutting point.

Cutting
Speed (v)

21
 Cutting Speed (v)
Mechanical Engineering
Department; Thapar
University

Example of cutting speed values for different materials:

Rough Cut Finish Cut

Material m/min m/min

Cast iron 18 24
Bronze 27 30
Aluminum 61 93

22
 Cutting Speed (v) m/min
Mechanical Engineering
Department; Thapar
University

When cutting speed is in m/min

v = π Do N/1000

v cutting speed m/min

N rotational speed rev/min
Do original dia of the part mm

24
 Feed (f) mm/rev
Mechanical Engineering
Department; Thapar
University

Feed f:
 The relative speed at which the cutting tool is
linearly traversed over the workpiece to remove the
material.
 The cutting tool moves in a direction usually normal
to the cutting speed direction.
 It is defined as feed per revolution that states how
much a tool advances in one revolution of workpiece.

 Feed is expressed in mm/rev

25
 Feed Rate (fr) mm/min
Mechanical Engineering
Department; Thapar
University

 The feed can be converted to a linear travel

rate or linear speed (Feed Rate) ( fr ) in
mm/min by the below formulae,

fr = N f (2)

26
 Depth of Cut (d) mm
Mechanical Engineering
Department; Thapar
University

 It is defined as the depth of penetration of the tool

into the work piece during machining.
 In other words, it is the perpendicular distance
measured from the machined surface to the
unmachined surface of the work piece.
 It is usually expressed in mm.

27
 Depth of Cut (d) mm
Mechanical Engineering
Department; Thapar
University

28
 Depth of Cut (d) mm
Mechanical Engineering
Department; Thapar
University

The thickness of material removed by one pass

of the cutting tool is called Depth of Cut.

Do - Df
d = (3)
2
d depth of cut mm
Do original dia of the part mm
Df final dia of the part mm

29
 Machining Length (l) mm
Mechanical Engineering
Department; Thapar
University

l Tool pre-travel

L a

l = L + a (4)

30
Mechanical Engineering
Department; Thapar
University

Computer Numerical Control (CNC) Machine

31
 Numerical Control (NC)
Mechanical Engineering
Department; Thapar
University

 Controlling of machine tools by means of prepared program is known as

Numerical Control, or NC.
 In typical NC system the numerical data which is required for producing a
part is maintained in program and is called part program.
 The part program arrange in the form of blocks of information that
contains the numerical data required to produce one segment of
workpiece.
 Block contains the information of segment length, dimensions, its cutting
speed, feed, depth of cut etc. the programs are made according to
surface finish and tolerance requirements.
 Compare with conventional machine tools, NC system replaces the
manual action of operators.
 All thinking operations that were performed by the operators are now contained in
the part program.

32
 Numerical Control (NC)
Mechanical Engineering
Department; Thapar
University

 The part program is written manually or by using computer assisted

language such as APT.
 The part programmers must be familiar with function of NC machine tools
and machining processes and have to decide the optimal sequence of
operations.
 Basic Length Unit (BLU)= it corresponds to position resolution of axis of
motion. It is also called “incremental size”.
 In NC machine tools each axis of motion is equipped by separate driving
devices that replaces hand wheel in conventional machine. The driving
devices are a dc motor, a hydraulic actuator or a stepping motor.

33
 Computer Numerical Control (CNC)
Mechanical Engineering
Department; Thapar
University

 Controlling of machine tools by means of prepared program is known as

Numerical Control, or NC.
 The functions of machine tool are partly or fully taken over by a
dedicated computer (i.e computer controlled),
 A micro or minicomputer is assigned with machine tool,
 In typical CNC system the numerical data which is required for
producing a part is maintained in program and is called part program.
 The program may be prepared by programmer or obtained from drafting
software (i.e Autocad),
 The programs can be modified and displayed at the machine, along with
a simulated view of the process,
 Availability of small computer with large memory and program editing
capabilities popular the use of CNC systems widely.

34
 Advantages of NC System
Mechanical Engineering
Department; Thapar
University

 Accuracy is maintained through the full range of speeds and

feeds.
 A shorter production time.
 The possibility of manufacturing a part of complicated
contour. Contour cutting in three dimensions or in two
dimensions can not be performed by manual operations.
 High flexibility. Accommodate design change.
 The feature of high flexibility is substantially significant in modern
industry. The machine has capability to perform many operations and
change the sequence of operations in a short time. A part program is
needed for producing a new part.

 The need of highly skilled labour and experienced operator is

avoided.
35
 Structure of CNC System
Mechanical Engineering
Department; Thapar
University

 The CNC machine tool

system contain:
 Machine control unit (MCU)
 Machine tool itself

Numerical Control System

36