Faculty of Engineering, Technology, Applied Design and Fine Art

Department of Mechanical Engineering

BME3201 Production Engineering

Lecture 1: Overview of Machining Processes

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Course content
1. Mechanics of Machine tools
2. Kinematics of Machine Tools
3. Principles of Metal Cutting
4. Mechanics of Cutting (Orthogonal and Oblique Cutting Processes),
5. Cutting Economics
6. Chip-less Machining Processes (Electrical Beam Machining (EBM),
7. Laser Beam Machining (LBM),
8. Ultrasonic Machining (USM),
9. Electro-Chemical Machining (ECM))
10.Super-finishing processes
11.Design of Jigs & Fixtures
12.Machine Tool Vibrations
13.Tool Life and Tool Wear
14.Cutting fluids and surface Roughness
15.Nomenclature of cutting Tools
16.Modeling of Chip formation
• Practical work
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 Lecture Outline
▪ Introduction
▪ Classification of machining processes
▪ Variables of machining processes
▪ Machining process selection
▪ Course outline

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 Introduction
▪ Parts are manufactured by primary process i.e. casting, forming, joining and
shaping processes
▪ Parts often require secondary and finishing operations before the product is
ready for use.
▪ Machining processes involves both secondary and finishing operations.
▪ Machining is the removal of material and modification of the surfaces of a
workpiece.

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 Introduction

Raw materials

Bulk forming Casting

Manufacturing

Sintering
processes

Sheet metal forming Molding

Machining

Assembly or use

Manufacturing processes

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 Introduction

▪ Reasons that make machining processes an obligatory solution as compared

with other manufacturing techniques are:
1. If closer dimensional control and tighter tolerances are required than are
2. available by casting and forming.
3. If special surface quality is required for proper functioning of a part.
4. If the part has external and internal geometric features that cannot be
produced by other manufacturing/production operations.
5. If it is more economical to machine the part than to produce it by other
manufacturing operations.

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 Classification of Machining Processes
▪ It covers several processes, which are usually divided into the following
categories:
▪ Conventional Machining (Cutting) – materials removal by a sharp cutting tool
which generally involves single – point or multipoint cutting tools and processes,
e.g., turning, milling, drilling
▪ Abrasive processes – material removal by hard abrasive particles, e.g. grinding,
honing
▪ Nontraditional processes – various energy forms other than sharp cutting tool
to remove material (which use electric, chemical, thermal, hydrodynamic and
optical sources of energy, as well as the combinations of these energy sources,
to remove material from workpiece surface)

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 Classification of Machining Processes

Classification of machining processes

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 Variables of Machining Processes

Variables of a machining process

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 Variables of Machining Processes
A. Input (independent) variables
▪ Workpiece material, like composition and metallurgical features.
▪ Starting geometry of the workpiece, including preceding processes.
▪ Selection of process, which may be conventional or nonconventional processes.
▪ Tool material.
▪ Machining parameters.
▪ Work-holding devices ranging from vises to specially designed jigs and fixtures.
▪ Cutting fluids.
B. Output (dependent) variables
▪ Cutting force and power. Cutting force influences deflection and chattering; both
affect part size and accuracy. The power influences heat generation and
consequently tool wear.
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 Variables of Machining Processes
B. Output (dependent) variables cont.
▪ Geometry of finished product, thus obtaining a machined surface of desired
shape, tolerance, and mechanical properties.
▪ Surface finish. It may be necessary to specify multiple cuts to achieve a desired
surface finish.
▪ Tool failure due to the increased power consumption.
▪ Economy of the machining process is governed by cutting speed and other
variables, as well as cost and economic factors. Machining economy represents
an important aspect.
▪ Ecological aspects and health hazards must be considered and eliminated by
undertaking necessary measures.

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 Machining Process Selection

▪ Part shape
▪ Part size
▪ Part material
▪ Dimensional and geometric features
▪ Surface texture
▪ Production quantity
▪ Production cost
▪ Environmental impacts

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 Course Outline
Cutting Tools and Fluids
Geometry of single-point tools; Geometry of multipoint cutting tools; Tool
materials and Cutting fluids
Fundamentals of Machining
Mechanics of Cutting; Cutting forces and power; Temperatures in cutting; Tool life:
wear and failure; Surface finish and integrity; Machinability and Economics of
metal cutting
Machining Centers, Machine-tool Structures, and Machining Economics
Machining centers; Machine-tool structures; Vibration and chatter in machining
operations; High-speed machining; Hard machining ; Ultraprecision machining;
and Machining economics

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 Course Outline
Abrasive Machining and Finishing Operations
Abrasives and bonded abrasives; The grinding process; Grinding operations and
machines; Design considerations for grinding; Ultrasonic machining; Finishing
operations; Deburring operations; and Economics of abrasive machining and
finishing operations
Introduction to Non-traditional Machining and Equipment
Chemical machining; Electrochemical machining; Electrochemical grinding;
Electrical-discharge machining; Laser-beam machining; Electron-beam machining;
Water-jet machining; Abrasive-jet machining; Hybrid machining systems; and
Economics of advanced machining processes

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