Metal cutting is a process of removing metal material by applying a

cutting force with a sharp edge. The metal cutting process can be
accomplished using various techniques, including mechanical,
thermal, and chemical. These techniques are used in many
manufacturing industries, including aerospace, automotive,
construction, and shipbuilding, to produce various metal products.
Metal Cutting
Metal cutting aims to produce high-quality metal parts with precise
dimensions, smooth surfaces, and minimal waste. The selection of the
right cutting method depends on the type of metal, the shape and size
of the part, and the desired surface finish. The accuracy and
efficiency of metal cutting operations are critical to the overall
success of a manufacturing process, and cutting technology advances
continue to drive productivity and product quality improvements.
What is Metal Cutting?
Metal cutting refers to removing metal material from a workpiece to create a
desired shape or form. It involves applying a cutting force with a sharp tool,
such as a cutting blade or laser, to remove material and create a precise,
finished product. This process is crucial in many industries, including
manufacturing, construction, and fabrication.
There are various metal cutting methods, including mechanical cutting,
thermal cutting, and chemical cutting. The choice of method is dependent on
the type of metal being cut, the desired final product, and the equipment
available. Regardless of the method, metal cutting requires precision and
accuracy to ensure that the final product meets specific dimensional and
surface quality requirements. The continued advancements in cutting
technology are driving improvements in productivity and product quality in
metal-cutting operations.

Classification of the Metal Cutting Process

Classification of the metal cutting process can be done based on the type of
tool used, such as single-point cutting tools and multi-point cutting tools, or
based on the nature of the cutting operation, such as orthogonal cutting,
oblique cutting, and curved cutting. Additionally, it can also be classified
based on the energy source used, such as mechanical cutting, thermal cutting,
and electric cutting. Metal cutting processes can be classified into several
categories based on the type of cutting force used, including:
 1. Mechanical cutting: This category includes traditional cutting methods
that rely on a sharp tool to physically remove material, such as turning,
milling, drilling, and grinding.
2. Thermal cutting: This category involves using heat to melt or burn
away material, such as oxy-fuel cutting, plasma cutting, and laser
cutting.
3. Chemical cutting: This category utilizes chemical reactions to remove
metal, such as electrochemical machining and water jet cutting.
4. Abrasive cutting: This category involves using abrasive particles to
remove metal, such as abrasive water jet cutting and abrasive wire
cutting.
Each category has its own set of advantages and disadvantages, and the choice
of method depends on the job's specific requirements, such as material type,
part size and shape, and desired surface finish.

Types of Metal Cutting Process

Metal cutting processes include a variety of methods for removing material
from a workpiece, including turning, milling, drilling, grinding, sawing,
shearing, punching, and stamping. The choice of process depends on the job's
specific requirements, such as material type, part size and shape, and desired
surface finish. There are several types of metal-cutting processes, including:
1. Turning: A process where a single-point cutting tool moves along the
surface of a rotating workpiece to remove material and produce a desired
shape.
2. Milling: A process where a multi-point cutting tool moves perpendicular
to the surface of a workpiece to remove material and produce a desired
shape.
3. Drilling: A process where a rotary cutting tool is used to create a
cylindrical hole in a workpiece.
4. Grinding: A rotating abrasive wheel removes material from a
workpiece to produce a desired surface finish.
5. Sawing: A continuous or reciprocating blade cuts a workpiece into
desired lengths.
6. Shearing: A process where a sharp blade is used to cut a workpiece
along a straight line.
7. Punching: A sharp tool is used to remove a portion of a workpiece to
create a hole or notch.
8. Stamping: A process where a punch and die set is used to deform a
workpiece into a desired shape.
Each metal-cutting process has its own set of advantages and disadvantages,
and the choice of process depends on the job's specific requirements, such as
material type, part size and shape, and desired surface finish.\
LATHE OPERATIONS
A standard machine is that which is able to deal with a variety of work and a wide
range of operations can be performed on it. Special purpose machine is that which
has been designed for specific purpose and only performs one or limited range
of operations.

A centre lathe is an example of standard lathe because on this machine we can

perform the following operations :
Turning

It is the removal of material from the outside diameter of a cylindrical job to

obtain one or more finished diameter. Usually, there are three types of turning
which are given below :

(a) Plain or straight or parallel turning.

(b) Stepped turning.
(c) Taper turning.

In plain turning machining is done in this way that after removal of material,
finished diameter at both the ends of length remains equal.
Turning operation where the entire length is divided in steps of different diameter
but each step individually finished by using plain turning is known as stepped
turning. Taper turning is the operation in which the material is removed from the
job to produce a conical shape. All the three types of turning are shown in Figure
7.13.

turning operation

Plain Turning and Stepped Turning

In plain turning, the workpiece is turned straight throughout the entire length
when it is made to rotate about the lathe axis, and the cutting tool is fed along the
lathe axis. The plain or straight turning produces a cylindrical surface after
machining.

In stepped turning, the workpiece is turned in such a way that throughout the
turning length it forms the steps of different diameters.
After facing and centering at both ends faces, the job is mounted between the
centres using a dog carrier attached to the workpiece, the bent tail of dog carrier
is fitted into the slot provided on the driven plate. If the workpiece is mounted on
a chuck, care should be taken to centre it accurately with the lathe axis. The
trueness of the workpiece held on a chuck is tested by holding a scriber or a dial
indicator against the rotating workpiece. Turning tool is clamped on the tool post
by keeping its cutting edge approximately at the lathe axis or slightly above it.

Taper Turning

Generally, the following methods are used for taper turning :

(a) By swivelling compound rest
(b) By setting over the tail stock
(c) By taper turning attachment
(d) By forming or broad-nose tool
By Swivelling Compound Rest

This method is used to produce short or steep tapers. The principle of this
compound rest is that axis of workpiece rotates parallel to the bed
axis and the cutting tool moves at the desired angle where the compound rest is
already swivelled.

Let the swivelled angle of compound rest with lathe axis is ‘θ’. ‘ L’ shows the
length, on which taper turning takes place. We can calculate the swivelled angle of
compound rest in respect of lathe axis

by following formula : tan θ = ( D – d) / L

where ‘ D’ and ‘d ’ are the larger and smaller diameters respectively.

Facing

It is the machining of the ends of a workpiece to make the ends smooth. For this
operation, the cutting tool is fed perpendicular to the lathe or workpiece axis by
means of cross slide.

Parting Off

This operation involves cutting the work-metal into two parts by using parting off
tool. Feed to the cutting tool is given in same manner as in case of facing
operation.

Knurling

It is the process of producing rough surface of embossing diamond shaped pattern

on a smooth surface of a cylindrical job. Knurling provides an effective gripping
surface on a job to prevent it from slipping when operated by hand. Knurling, as
shown in Figure 7.14, may be of two types :
(a) straight or parallel, and
(b) diamond type.
lathe knurling operation
Knurling is done by means of knurling tool which consists of a set of hardened
steel rollers. The teeth are cut on the steel rollers in different pattern. For knurling
operation, the knurling tool is forced with the workpiece which is already arranged
in revolving condition.

Thread Cutting

In thread cutting operation, there is a certain ratio of motion between the travel of
tool and the rotation of the spindle. This ratio is directly effected by the lead screw
which is attached to the lathe spindle through gears. General set up for thread
cutting is shown in Figure 7.15.

For cutting threads of different pitches, the stud (driver gear) and lead screw
gear (driven gear) are changed as per desired ratio of revolution between the
spindle and the lead screw. The ratio between the teeth on stud and lead screw
gear can be calculated by the given formula,
thread cutting on lathe Machine

Grooving

This operation is also denoted as necking. Usually, grooves are cut on a cylindrical
surface in narrow shape by means of grooving tool. The cutting edge of grooving
tool is kept narrow.

Drilling

For making a standard size of hole in a workpiece by means of drill is known as

drilling operation. For this operation, drill is held in tail stock spindle.

Boring

Boring is the operation of enlarging a drilled hole by means of a boring tool. The
boring tool is fitted on a boring bar which is held in tail stock spindle.

Reaming

It is the operation of finishing a drilled hole to an accurate dimension with the help
of reamer as a tool. The reamer is held on the tail stock spindle.