COLLEGE OF TECHNOLOGY

City Campus
BACHELOR OF MECHANICAL ENGINEERING TECHNOLOGY
MECHANICAL TECHNOLOGY

MT 411 – Manufacturing Processes

First Semester, Academic Year 2022-2023

 
MODULE #6

TITLE: MATERIAL REMOVAL PROCESSES

Sub-Topics: 6.1 MACHINING

6.2 CUTTING TOOLS
6.3 GRINDING & ABRASIVE
6.4 NON-TRADITIONAL MACHINING

Objectives: 1. Define material removal processes

2. Identify material removal processes
3.Give the basic examples of material removal processes
4.Learn how this process effectively helps in the field of manufacturing as
material removal processes

Introduction:
Material removal process is a type of manufacturing process in which
the final product is obtained by removing excess metal from the stock. The best
example of a machining process is generating a cylindrical surface from a metal
stock with the help of a lathe.

Metal removal processes use a metal cutting tool that moves

relative to the workpiece, and removes metal chips from it. Efficient metal
removal is only possible, if the tool has the optimum rake and clearance (or relief)
angles as shown for a lathe tool.

In the machining process of material removal, the cutting tool

removes the unwanted materials from the workpiece to produce the desired
shape. The workpiece can be from a variety of stock materials such as
aluminum, steel, titanium, wood, stone, ceramic, glass, etc., as well as from
forged or casted materials.

Presentation of the Reports:

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.
 Machining is a technical and detail-oriented process in which material is cut
into a final shape and size to create parts, tools, and instruments. Machining is
typically used to shape metals, though it can also be used on a variety of other
raw materials. Machine shops utilize equipment and tools like mills, lathes, and
drill presses to cut material and 3D printers to add material.

Machining is most commonly used to manufacture metal objects, parts, and

tools. Metals that can be machined are stainless steel, aluminum, brass, titanium,
and copper. Stainless steel is commonly used for precision machining, offering
the advantages of strength and resistance to corrosion. Aluminum is lightweight,
easy to work with, and inexpensive. Brass is another economical material used
for machining, but should not be used in semiconductor products because of the
zinc and tin in the material.

Titanium is strong, lightweight, and resistant to corroding, however, it is

more expensive than other materials and difficult to work with. Copper is a
versatile and strong metal and works well as an electrical conductor. Plastics are
also used in machining as they are inexpensive and non-conductive. They are
commonly used in medical, electrical, and scientific industries.

Machining is the process of removing material on a workpiece in order to

create a precise object or part. The following are the primary processes used to
cut and subtract material in a machine shop by machinist.
Turning
Turning is a process that rotates the workpiece as the primary method of moving metal
against the cutting tool. Lathes are the principal machine tool used in turning.

Milling
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.

Drilling
Drilling creates a new hole or refines an existing hole using a rotating cutter. Drilling is most
commonly done using drill presses, but sometimes drilling tools will be attached to compatible lathes
or mills to create holes.

Boring
Boring is one of the most widely used techniques in machining, as it is one of the most reliable
ways to finish and enlarge pre-existing holes. This technique provides accuracy and is easily
replicated on a workpiece.

Reaming
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.
There are two main techniques when it comes to machining operations: subtractive and
additive manufacturing. These techniques are used by a machinist to either take away or add material
to a part.

1. Subtractive
Machining is a prototyping and manufacturing process that creates the desired shape by removing
unwanted material from a larger piece of material. Since a part is built by taking away material, this
process is also known as subtractive manufacturing.

2. Additive
Additive machining, also known as 3D printing, is a newer approach to production that enables the
construction of a three-dimensional object from a digital model. It allows the machinist to create
lightweight and strong parts.

CUTTING TOOLS

In the field of machining, a cutter or cutting tool is usually a hardened metal tool
used to cut, shape, and remove material from a workpiece using machining tools and abrasive
tools through shear deformation.

A cutting tool is a wedge-shaped, sharp-edged tool used to remove excess layers of

material from a workpiece by cutting during machining to obtain the desired shape, size, and
accuracy. It is firmly attached to the machine tool. The relative speed between the workpiece
and the cutting tool is also provided by various mechanical and other arrangements for the
cutting motion.

Most of these tools are designed specifically for metal. There are many different
types of single-edge cutting tools that are milled from various hardened metal alloys into
specific shapes to perform specific parts of the turning process to produce the final machined
part.

A cutting tool can have one or more primary cutting edges that simultaneously
participate in the cutting process in single pass. Cutting tools can be classified in different
ways. However, the most common method is based on the number of leading cutting edges
simultaneously participating in the cutting process. Based on this, cutting tools can be divided
into three groups as shown below.

1. Single Point Cutting Tools

A single-point cutting tool consists of only one main cutting edge that can perform material removal
operations at a time. Single point cutting tools are used in turning, shaping, planning and similar
operations.

2. Double Point Cutting Tool

A double point cutting tool consists of two cutting edges that can cut or shear at the same time in one
operation. In contrast, a single-point cutting tool contains only one main cutting edge. Drill is the only
example for this category. Note that drills can have more than two cutting edges. However,
conventional (without cutting edge modification) metal cutting drills contain two cutting edges.

3. Multi Point Cutting Tools

A multi-point cutting tool contains more than two main cutting edges that work simultaneously in one
pass. Sometimes cutters with two cutting edges are also viewed as multi-cutting tools (rather than
double-point cutters).

The following properties are required for the cutting tool:

 hardness, hot hardness and pressure resistance

 bending strength and toughness
 inner bonding strength
 wear resistance
 oxidation resistance
 small prosperity to diffusion and adhesion
 abrasion resistance
 edge strength

GRINDING AND ABRASIVE

Grinding removes material from the workpiece by abrasion, which can

generate substantial amounts of heat. To cool the workpiece so that it does not
overheat and go outside its tolerance, grinding machines incorporate a coolant.
The coolant also benefits the machinist as the heat generated may cause burns.
In high-precision grinding machines (most cylindrical and surface grinders), the
final grinding stages are usually set up so that they remove about 200 nm (less
than 1/10000 in) per pass - this generates so little heat that even with no coolant,
the temperature rise is negligible.

Grinding is used to finish workpieces that must show high surface quality
(e.g., low surface roughness) and high accuracy of shape and dimension. As the
accuracy in dimensions in grinding is of the order of 0.000025 mm, in most
applications it tends to be a finishing operation and removes comparatively little
metal, about 0.25 to 0.50 mm depth. However, there are some roughing
applications in which grinding removes high volumes of metal quite rapidly. Thus,
grinding is a diverse field.

An abrasive is a material, often a mineral, that is used to shape or finish a

workpiece through rubbing[1] which leads to part of the workpiece being worn
away by friction. While finishing a material often means polishing it to gain a
smooth, reflective surface, the process can also involve roughening as in satin,
matte or beaded finishes. In short, the ceramics which are used to cut, grind and
polish other softer materials are known as abrasives.

Abrasives are extremely commonplace and are used very extensively in a wide
variety of industrial, domestic, and technological applications. This gives rise to a
large variation in the physical and chemical composition of abrasives as well as
the shape of the abrasive. Some common uses for abrasives include grinding,
polishing, buffing, honing, cutting, drilling, sharpening, lapping, and sanding (see
abrasive machining).

Abrasive Grinding Machine

Non - Traditional Machining

Non-traditional machining, also known as “non-conventional machining” or

“modern machining method”, generally refers to the machining method of
removing or adding materials with energy of electricity, heat energy, light energy,
electrochemical energy, chemical energy, sound energy and special mechanical
energy, so as to realize materials being removed, deformed, changing properties
or being plated.
Traditional mechanical machining has a long history, it has played a great role in
human production and material civilization.

At present, most of our products are manufactured and assembled by traditional

methods, such as:

Household appliances: refrigerators, washing machines, air conditioners, etc.;

Traffic tools, such as cars, trains, planes, etc
All kinds of weapons and equipment: guns, canon, tanks, rockets, etc.
The traditional machining method is to use mechanical energy and cutting force
to remove excess metal so that the part has a certain geometric shape, size and
surface roughness.

Summary:

Machining is a technical and detail-oriented process in which material is cut

into a final shape and size to create parts, tools, and instruments. Machining is
typically used to shape metals, though it can also be used on a variety of other
raw materials. Machine shops utilize equipment and tools like mills, lathes, and
drill presses to cut material and 3D printers to add material.

In the field of machining, a cutter or cutting tool is usually a hardened metal

tool used to cut, shape, and remove material from a workpiece using machining
tools and abrasive tools through shear deformation. A cutting tool is a wedge-
shaped, sharp-edged tool used to remove excess layers of material from a
workpiece by cutting during machining to obtain the desired shape, size, and
accuracy. It is firmly attached to the machine tool. The relative speed between
the workpiece and the cutting tool is also provided by various mechanical and
other arrangements for the cutting motion.

Grinding removes material from the workpiece by abrasion, which can

generate substantial amounts of heat. To cool the workpiece so that it does not
overheat and go outside its tolerance, grinding machines incorporate a coolant.
The coolant also benefits the machinist as the heat generated may cause burns.
In high-precision grinding machines (most cylindrical and surface grinders), the
final grinding stages are usually set up so that they remove about 200 nm (less
than 1/10000 in) per pass - this generates so little heat that even with no coolant,
the temperature rise is negligible.

Non-traditional machining, also known as “non-conventional machining” or

“modern machining method”, generally refers to the machining method of
removing or adding materials with energy of electricity, heat energy, light energy,
electrochemical energy, chemical energy, sound energy and special mechanical
energy, so as to realize materials being removed, deformed, changing properties
or being plated.

References: (Used 3 Latest Reference, at least 2018 and up Edition)

1.https://clubtechnical.com/material-removal-process#:~:text=Material
%20removal%20process%20is%20a,the%20help%20of%20a%20lathe.

2. https://en.m.wikipedia.org/wiki/Cutting_tool_(machining)

3. https://en.m.wikipedia.org/wiki/Grinding_(abrasive_cutting)

4.https://www.machinemfg.com/non-traditional-machining/

List of Group Members:

1. Damacion, Joselito

2. Ligas, Vheia

3. Ellar, Leslie

4. Abe
MODULE 1 MT-411

QUIZ 1

1. What is Manufacturing Processes?

Ans: A manufacturing process is how a company builds or creates a product. It can be a

complex activity that involves a range of machinery, tools and equipment with many levels of
automation using computers, robots and cloud-based technology.

2. What are the examples of processes manufacturing products?

Ans: Food and beverage
Oil and gas
Pharmaceuticals
Personal care and cosmetics

3. It’s manufacturing involves washing, cutting, and combining ingredients to produce

edible products.
Ans: Food and beverage Manufacturing Processes

4. Is the manufacturing involves cleaning the seeds, grinding them, pressing, and
extruding the oil from them.
Ans: Oil and Gas Manufacturing Processes

5. Is the process of drug manufacturing and can be broken down into a range of unit
operations, such as blending, granulation, milling, coating, tablet pressing, filling, and
others.
Ans: Pharmaceuticals Manufacturing Processes

6. It’s the manufacturing products that applied to the human body for the purposes of
cleaning, beautifying, promoting attractiveness or changing its appearance.
Ans: Personal care and Cosmetics Manufacturing Processes

7. What is the Manufacturing Processes System?

Ans: A manufacturing system is any combination of actions and processes used throughout the
production of any goods.

8. What are most common systems used for manufacturing?

Ans: Discrete Manufacturing, Repetitive Manufacturing, Job Shop Manufacturing (Mass
Customization), Batch Manufacturing, Continuous Manufacturing, Additive Manufacturing

9. It’s a manufacturing can be similar to discrete manufacturing in that it describes the

production or assembly of distinct goods that can be broken down into its individual
components
Ans: Repetitive manufacturing

10. It’s a manufacturing processes are among the newest forms of production that have
continued to gain popularity over the past decade.

Ans: 3D printing or additive manufacturing processes

 MODULE 2
QIUZ 2

1. What is Thermal conductivity?

ANSWER:
Thermal conductivity can be defined as the rate at which heat is transferred by
conduction through a unit cross-section area of a material, when a temperature gradient exits
perpendicular to the area.

2. What is Melting Point?

ANSWER: the temperature at which a given solid material changes from a solid state to a
liquid, or melts.

3. Properties of Materials.

ANSWER:
• Density
• Melting point
• Thermal Conductivity
• Electrical Conductivity

4. What is Surfacing?

ANSWER: is a process of depositing one metal or alloy over another (base metal or
substrate) to improve its wear resisting properties like resistance to abrasion, corrosion, friction,
or for achieving dimensional control, and metallurgical needs.

5. What is Measurement?

ANSWER: refers to the numeric expression of a manufactured object's dimensions based on a

fixed reference (unit). Simply explained, dimensional measurement is the comparison of the
measurement target against a reference object.

QUIZ 3
 MODULE 3

1. Is a material in manufacturing that is typically shiny and lustrous. It is malleable and

an excellent electrical conductor.
answer: METAL

2. What are the types of Metals?

answer: Aluminum
• Copper
• Tin
• Steel
• Bronze

3. It is a metal similar to steel, brass, copper, zinc, lead or titanium. It can be melted, cast,
formed and machined in a similar way to these metals and conducts electric currents.
Answer: aluminum

4. It Is a metallic chemical element that is easily formed into sheets and wires and is one
of the best conductors of heat and electricity.
Answer: Copper

5. Is a silvery- white, soft metal that is light and easy to melt.

Answer: Tin

6. It is clay fired at relatively low temperatures of between 1,000 to 1,150 degrees.

Answer: Earthenware

7. What is a polymer?
answer: The polymers, a word that we hear about it a lot, is very vital and one cannot imagine
the life without it.

8. What are examples of synthetic polymers?

Answer: nylon, polyethylene, polyester, Teflon, and epoxy

9. What are Examples of naturally occurring polymers?

Answer: silk, wool, DNA, cellulose and proteins.

10.What is composites?
Answer: A composite material is a combination of two materials with different physical
and chemical properties.

QUIZ 4
 MODULE 4 MT 411

1. Define of maintenance of management?

Ans.

Maintenance management is the process of maintaining a company's assets and resources. The
purpose is to ensure that production proceeds efficiently and that resources are used effectively.
Maintenance management is one of those aspects of managing a company that is usually not explored
in depth.

2. Importance of maintenance management?

Ans.
Maintenance management is an important component of a well-functioning production. It helps
companies maintain their resources while controlling time and costs to ensure maximum efficiency of
the manufacturing process, the utilities and related facilities.

3. Objective of maintenance management?

Ans.

1. Control Facility and Operational Costs

2. Reduce Equipment Failures and Downtime
3. Extend the Useful Life of Equipment and Machinery
4. Ensure Equipment is Ready and Available
5. Conform to Safety and Regulatory Requirements
6. Maximize Facility Performance
QUIZ 5
MODULE 5

1. WHAT IS METAL SHAPING/FORMING PROCESSES?

Answer: Metal forming is a process where materials are subjected to plastic deformation to
obtain the required size, shape, and/or change the physical and chemical properties.

2. WHAT IS PLATE METALS

Answer: Plate Metal: is a flat piece of steel which has a thickness of 6mm inches and is widely
used for industrial applications.

3. WHAT IS SHEET METALS

Answer: Sheet metal is a flat piece of metal which thickness does not exceed more than 6mm.
The thickness of the metal starts from 0.5mm and goes up to 6mm. Anything above that is a
metal plate.

4. WHAT IS STRECH FORMING

Answer: is a metal forming process in which a piece of sheet metal is stretched and bent
simultaneously over a die in order to form large contoured parts. Stretch forming is performed
on a stretch press, in which a piece of sheet metal is securely gripped along its edges by
gripping jaws.

5. WHAT IS DEEP DRAWING

Answer: is a sheet metal forming process in which a sheet metal blank is radially drawn into a
forming die by the mechanical action of a punch. It is thus a shape transformation process with
material retention. The process is considered "deep" drawing when the depth of the drawn part
exceeds its diameter.

6. The principle of this procedure consists of reducing the thickness of a pointed,

tapered wire by drawing it through a conical opening in a tool made of a hard material.
Answer: Rolling and Drawing

7.-10 WHAT ARE THE FOUR TYPES OF EXTRUSION?

ANSWER: Direct Extrusion

Indirect Extrusion
Tubular Extrusion
Hyrdostatic Extrusion
Quiz #6
MODULE 6 MT411

1. What process that use a metal cutting tool that moves relative to the work piece?

Answer: metal removal process.

2. It is the process used to removed materials, typically metal to create parts for machines,
tools, transportation, and more.

Answer: machining.

3-4. What are the two main techniques when it comes to machining operation?
Answer: 3. subtractive
4. Additive

5-7. Give the 3 groups of cutting tool.

Answer: 5. Single point cutting tools.
6. Double point cutting tools.
7. Multi point cutting tools.

8. It is also known as conventional machining or modern machining method.

Answer: Non-traditional machining

9. It removes material from the work piece by abrasion.

Answer: abrasive machine removal using abrasives such as aluminium oxide, silicon carbide, resin
bond and many other abrasives either natural or synthetic.

10. Give 1 machining process definition.

Answer: -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.

-Machining is a technical and detail-oriented process in which material is cut into a final shape and size
to create parts, tools, and instruments. Machining is typically used to shape metals, though it can also
be used on a variety of other raw materials. Machine shops utilize equipment and tools like mills,
lathes, and drill presses to cut material and 3D printers to add material.

-Machining is most commonly used to manufacture metal objects, parts, and tools. Metals that can be
machined are stainless steel, aluminum, brass, titanium, and copper. Stainless steel is commonly used
for precision machining, offering the advantages of strength and resistance to corrosion. Aluminum is
lightweight, easy to work with, and inexpensive. Brass is another economical material used for
machining, but should not be used in semiconductor products because of the zinc and tin in the
material.
QUIZ 7
MODULE 7

GROUP 7 (MT411-MANUFACTURING)
TEST QUESTIONS

1. What is Heat Treating?

ANSWER: (or heat treatment) is a group of industrial, thermal and metalworking processes
used to alter the physical, and sometimes chemical, properties of a material.

2. What is a heat treatment process and why it is important?

ANSWER: Heat treating is a process where heat is applied to a material and then cooled to
improve its performance, durability, and properties. Heat treating can be used to soften metal to
improve formability. It can be used to harden parts, to improve their strength.

3. Purpose of Heat-Treatment Process?

ANSWER: Heat treating can soften metal, to improve formability. It can make parts harder, to
improve strength.

4. What is Surface treatment process?

ANSWER: Surface treatment is an additional process applied to the surface of a material for the
purpose of adding functions such as rust and wear resistance or improving the decorative
properties to enhance its appearance.

5. Difference between heat treatment and surface treatment?

ANSWER: Heat treatment is a type of surface treatment that includes hardening and thermal
diffusion. Both use heating to apply the surface treatments to the work piece.

6. It is to be controlled to the desired temperature using a good insulated proper heating

furnance under a suitable atmosphere to prevent the heat dissipation and the oxidation
process.
Answer: Heating

7. Is the process for softening materials or to bring about required changes in properties,
such as machinability , mechanical or electrical properties, or dimensional stability.
Answer: Annealing

8. What is surface treatment process?

ANSWER: Surface treatment means altering the molecular constitution of a surface to make it
interact with an adhesive, ink, coating, paint or another surface to create a strong bond between
the two.

9-10.) Give at least 5 types of Surface Treatment Processes?

ANSWER;
1. Micro Arc Oxidation
2. Metal Wire Drawing
3. Bluing
4. Shot Blasting
5. Sand Blasting
QUIZ 8
MODULE 8

1. What are the four main types of welding?

Answer:

Gas metal Arc Welding (GMAW)

Gas Tungsten Arc Welding (GTAW)
Shielded Metal Arc Welding (SMAW)
Flux Cored Arc Welding (FCAW)

2. What are the 3 types of soldering?

Answer:
Soft soldering
Hard soldering
Brazing

3. What is Brazing?
Answer:

Brazing is a process in which metals are joined by melting a filler metal into the joint to
create strong permanent bonds.

4. A metal working process that uses a similar process of rolling sheet metal over and
into itself, except it uses a seam to join the two layers.
Answer:
Seaming

5. What is Mechanical Fasteners?

Answer:
A mechanical fastener is a device that is used to mechanically join
(or fasten) two or more objects together.
QUIZ 9
MODULE 9

1. Non Destructive Testing

Answer: The process of determining the characteristics of the materials, components or

system where we can detect and locate the discontinuities and harmful defects without reducing
the usefulness of such materials, components or system.

2. What is Quality Assurance?

Answer: According to WHO, quality assurance is a wide-ranging concept covering all matters
that individually or collectively influence the quality of a product. With regard to pharmaceuticals,
quality assurance can be divided into major areas development, quality control, production,
distribution, and inspections.

3. What Is the Main Purpose of Quality Improvement?

Answer: Quality improvement aims to create efficiencies and address the needs of customers.
In healthcare, the main purpose of quality improvement is to improve outcomes. In healthcare
settings, quality improvement may be associated with continuous quality improvement, the
method used to identify problems and implement, monitor, and provide corrective action.

4. Give five examples of Non Destructive Testing.?

Answer:
*Acoustic emission
*Eddy Current Testing
*Radiographic Testing
*Visual NDT
*Ultrasonic NDT

5. What are the 3 major Benefits of good quality assurance?

Answer:
*Cost saving
*Efficiency Boost
*Improvements in costumer satisfaction

rte, Dave