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MACHINING PROCESS
What is a Machine?
• A machine is a mechanically, electrically, or electronically operated
device for performing a task.
• Any physical system having arranged structural and functional
characteristics is a machine.
• It could be a molecular machine or a man-made device that uses
power to apply forces and control movement to act.
• An assembly of interconnected components arranged to transmit or
modify force in order to perform useful work.

Ex. Simple Machines

Pulley

- is a simple machine that combines a rope or cable with a wheel and

axle use to lift large objects.

Screw

- The main function of the screw is to connect the two workpieces

together and play the role of fastening.

Lever

- are the most basic machine s which are used to do some work with
minimal effort. A lever is usually used to move or lift objects.

Ex. Compound Machines

Wheelbarrow

- use to move sand, dirt, and other heavy materials.

Crane

- use to lift a heavy load from one location and to place it in another.
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Bulldozer

- used for shallow digging and ditching; short-range transportation of

material; spreading soil dumped from trucks; rough grading;
removing trees, stumps, and boulders; and c leaning and leveling
around loading equipment.

Ex. Power Tools

Cordless Drills

- used to drill holes in metal, plastics, wood, and stone, as well as drive
screws with an electric screwdriver.

Impact Wrenches

- do a great job of tightening and loosening bolts, lug nuts and rusted
fasteners.

Powered Screwdrivers

- used for driving (and removing) screws effortlessly.

What is Machining?

• Machining is the process used to remove material, typically metal, to

create parts for machines, tools, transportation, and more. Machine
shops and machinists use equipment like lathes, mills, and drill
presses to turn material into useful tools using precise cuts.
• The many processes that have this common theme, controlled
material removal, are today collectively known as subtractive
manufacturing.
• The many processes that have this common theme, controlled
material removal, are today collectively known as subtractive
manufacturing.

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Additive vs Subtractive Manufacturing

Additive Manufacturing
• Using computer aided design (CAD) or 3D object scanners, additive
manufacturing allows for the creation of objects with precise
geometric shapes.
• These are built layer by layer, as with a 3D printing process, which is
in contrast to traditional manufacturing that often requires machining
or other techniques to remove surplus material.

Additive Manufacturing Processes:

Binder Jetting

o This technique uses a 3D printing style head moving on x, y

and z axes to deposit alternating layers of powdered material
and a liquid binder as an adhesive.

Directed Energy Deposition

o can be used with a wide variety of materials including

ceramics, metals and polymers. A laser, electric arc or an
electron beam gun mounted on an arm mov es horizontally
melting wire, filament feedstock or powder to build up material
as a bed moves vertically.

Material Extrusion

o This common AM process uses spooled polymers which are

either extruded or drawn through a heated nozzle which is
mounted on a movable arm. These builds melted material
layer by layer as the nozzle moves horizontally and the bed
moves vertically. The layers adhere through temperature
control or chemical bonding agents.

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Subtractive Manufacturing
• (CNC machining) is a machining process in which solid piece of raw
material is carved into a desired 3D geometrical shape and size by
using a controlled material-removal process.
• This process relies heavily upon the use of machine tools in addition
to power and hand tools.
• CNC – Computerized Numerical Control

Subtractive Manufacturing Processes:

Water Jet Cutting

o a manufacturing process that uses high pressure jets of water

provided by pressurizing pumps that deliver a supersonic
stream of water to cut and shape various types of materials.
The water in water jet cutting is pressurized to 392 MPa and
projected using a s mall precision nozzle. As the water leaves
the nozzle, it reaches speeds that are three times the speed
of sound.

Electrical Discharge Machine (EDM)

o a non-traditional form of precision machining that uses

thermal energy instead of mechanical force to remove
material from a workpiece.

Laser Cutting

o is mainly a thermal process in which a focused laser beam is

used to melt material in a localized area. A co-axial gas jet is
used to eject the molten material and create a kerf. A
continuous cut is produced by moving the laser beam or
workpiece under CNC control.

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What is Machine Shop?

• A machine shop is a facility with equipment and supplies for

machining, a process where parts are cut, fabricated, and finished to
prepare them for use.
• Machine shops are used in the creation of new parts, as well as
repairs of existing equipment and parts.
• Machine Shops use equipment and machines to create tools and
parts.
• Machinist
o are part of a machine shop, machinist is trained tradesperson
with the skills and knowledge to create tools, parts, and
objects by operating milling and drilling machines, grinders,
and lathes in a machine shop.
o remove material from objects that are made of metal, though
machining techniques can also be used on wood, ceramic,
and plastic materials.

Common Machine Shop Areas

• Job – Shop
• A Portion of a Factory
• Production Area for Manufacturing

Materials that can be Machined

1. Stainless Steel
2. Aluminum
3. Brass
4. Titanium
5. Copper
6. Plastics
7. Carbon Steel
8. Aluminum Alloy

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Stainless Steel
- it is commonly used for precision machining, offering the
advantages of strength and resistance to corrosion.
- Stainless steel machining is popular due to its superior strength-to-
weight ratio, which allows parts to be machined from thinner
materials.

Aluminum
- it is lightweight, easy to work with, and inexpensive.
- Industry professionals employ aluminum in machining operations to
produce a variety of parts and products.
- These components find application in a wide range of industries,
including Automotive, Aerospace, Electrical and electronic products
and more.

Brass
- known for its stability and low strength, is one of the easiest and most
cost-efficient materials to machine.
- Due to brass's unique properties, it is one of the most widely used
alloys.
- Because of its versatility, there are seemingly endless industries and
products making use of this alloy.

Titanium
- it is strong, lightweight, and resistant to corroding, however, it is more
expensive than other materials and difficult to work with.

Copper
- It is a versatile and strong metal and works well a s an electrical
conductor.
- When it comes to machining, pure copper has poor machinability due
to high plasticity and toughness.
- Alloying the copper with elements such as zinc, tin, aluminum, silicon
and nickel change the materials composition and can drastically
improve machinability.
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Plastics
- They are used in machining as they are inexpensive and non-
conductive. They are commonly used in medical, electrical, and
scientific industries.
- Plastic, polymeric material that has the capability of being molded or
shaped, usually by the application of heat and pressure.

Carbon Steel
- is high in carbon that when exposed to moisture can corrode and rust
quickly.
- is stronger and more durable than stainless steel.

Aluminum Alloy
- is the most widely used non-ferrous metal structural material in
industry, and it has been widely used in aviation, aerospace,
automobile, machinery manufacturing, ship building and chemical
industries.
- has good plasticity, and can process various specifications and
formed products. Through surface treatment, it can produce different
properties and different colors of film, which has good decoration.

Primary Processes in a Machine Shop

Turning
- is a process that rotates the workpiece as the primary method of
moving metal against the cutting tool.
- use to rotate the metal while a cutting tool moves in a linear motion
to remove metal along the diameter, creating a cylindrical shape.
- use to impart an irregular shape on a workpiece using a specially
ground tool.

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Drilling
- creates a new hole or refines an existing hole using a rotating cutter.
- is most commonly done using drill presses, but sometimes drilling
tools will be attached to compatible lathes or mills to create holes.
- use to drill holes in the ground for such activities as prospecting, well
sinking (petroleum , natural gas, water, and salt), and scientific
explorations.

Boring
- is one of the most widely used techniques in machining, as it is one
of the most reliable ways to finish and enlarge pr e-existing holes.
This technique provides accuracy and is easily replicated on a work
piece.
- boring bar is a tool used in metalworking and woodworking.
- Boring is a technique used in many aspects of building.
- Woodworkers have used boring as a form of drilling for centuries. In
woodworking, the boring tool is static in size and used to form circular
plunge cuts.

Grinding
- is the process of removing metal by the application of abrasives
which are bonded to form a rotating wheel. When the moving
abrasive particles contact the work piece, they act as tiny cutting
tools, each particle cutting a tiny chip from the workpiece.
- is used for roughing and finishing flat, cylindrical, and conical
surfaces; finishing internal cylinders or bores; forming and
sharpening cutting tools; snagging or removing rough projections
from castings and stamping s; and cleaning, polishing, and buffing
surfaces.

Milling
- uses a rotating cutting tool to bring cutting edges to bear against the
workpiece.
- This is the most versatile tool and technique used in a machine shop.

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- use to machine flat and irregularly shaped surf aces and can be used
to drill, bore, and cut gears , threads, and slots.

Reaming
- is a process that uses a rotary cutting tool to smooth an existing hole
in a workpiece.
- This is a cutting process that removes material, and its primary
purpose is to even out the walls of a hole.
- Manufacturing companies perform reaming using a milling machine
or drill press.

Machining Tools
1. Cutting Tools 4. Turning Tools
2. Boring Tools 5. Grinding Tools
3. Drilling Tools 6. Milling Tools

Cutting Tools
- also known as a cutter, is often a hardened metal tool that is used
with machining tools and abrasive tools using shear deformation to
cut, shape, and remove material from a workpiece.
Examples:
• Power Saws • Coping Saw
• Lathe • Two Man Crosscut
• Japanese Saw Saw
• Jig Saw • Axe
• Planes • Pruning Saw
• Crosscut Saw • Circular Saw

Boring Tools
- used to cut tapered holes and to obtain a hole's diameter with more
accuracy.
- A machine shop may use a jig borer to accurately locate the precise
center of a hole and at horizontal boring machine to perform the cut.

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Examples:
• Boring Bars • Boring Heads

Drilling Tools
- are devices that rotate to create round holes on a workpiece by
removing material.
- are end-cutting tools designed for producing holes in a workpiece.
The shank of a drilling tool incorporates flutes, or grooves, that allow
for the entrance of fluids, along with ejecting the cut ships from the
workpiece.
Examples:
• Benchtop Drill Press • Standard Electric Drill

Turning Tools
- are used on lathes for cutting or finishing the outside diameter of a
workpiece.
- can be used to produce cylindrical parts.
Examples:
• Spindle Gouge • Round Nose Scraper

Grinding Tools
- employ a rotating wheel to create finishes on machined workpieces,
sharpen tools, or make small cuts.
- A workpiece's surface imperfections can be deburred and removed
using grinding tools to produce a smooth finish.
Examples:
• Bench Grinder • Swing Frame Grinder
• Hand Grinder • Surface Grinder
• Portable Grinder • Cylindrical Grinder
• Abrasive Belt Grinder • Internal Grinder

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Milling Tools
- remove material by their movement in the machine and from their
shape. Milling tools used to machine flat and irregularly shaped
surfaces and can be used to drill, bore, and cut gears, threads, and
slots.

Examples:
• End Mill • Face Mill

Machine Shop Safety Tips & Safety Guidelines

General Safety Tips:

• Safety glasses with side shields must be worn at all times.
• Do not wear loose clothing, loose neckwear or exposed jewelry while
operating machinery.
• Do not work alone. The buddy system is mandatory!
• Pull back and secure long hair.
• Do not wear thin fabric shoes, sandals, open-toed shoes, and high-
heeled shoes.
• A machinist's apron tied in a quick release manner should be worn
ideally.
• Always keep hands and other body parts a safe distance away from
moving machine parts, work pieces, and cutters.
• Use hand tools for their designed purposes only.
• Report defective machinery, equipment or hand tools to the lab
manager.

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Safety Guidelines:
• If guards or safety mechanisms are present do not remove or disable
them.
• Do not attempt to oil, clean, adjust, or repair any machine while it is
running. Stop the machine and lock the power switch in the "OFF"
position.
• Do not operate any machine unless authorized to do so by the policy
and procedures currently in place.
• Do not set up or operate machinery if you are not trained and familiar
with that setup.
• Even after the power is off, do not leave the machine until it has
stopped running. Someone else may not notice that it is still in motion
and be injured. Do not leave a machine until it has come to a
complete stop.
• Do not try to stop the machine with your hands or body.
• Check tools and machines before use to assure they are safe to use.
• Always see that work and cutting tools on any machine are clamped
securely before starting to work.
• All setscrews should be of the flush or recessed type. If they are not,
move with caution when near them. Projecting setscrews are very
dangerous because they may catch on sleeves or clothing. The same
goes for chuck jaws on a lathe, they are very dangerous especially
when extended near the outer limits.
• Only one person should operate a given machine and its switches.
• Do not lean against a machine.
• Concentrate on the work and do not talk unnecessarily while
operating the machine.
• Do not talk to others when they are operating a machine. A distraction
may lead to an injury.
• Do not walk behind people operating a machine; you may bump them
by accident or startle them and cause an accident.
• Always remove gloves before turning on or operating any machine.
If material is rough or sharp and gloves must be worn, place or handle
material with the machine turned off.
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