Machining operations

DR / ASMAA SAAD
 Machining operations

1- Introduction
Machining is the manufacturing process by which parts can be produced to
the desired dimensions and surface finish from a blank by gradual removal
of the excess material in the form of chips with the help of a sharp cutting
tool. Almost 90% of the all engineering components are subjected to some
kind of machining during manufacture.

1- Machining classification.

Machining can be classified as shown in Fig.1:-

2- Classifications of Machined Parts

1. Rotational - cylindrical shape

2. Non-rotational (also called prismatic) – block or plate

Machined parts are classified as: (a) rotational, or (b) non-rotational,

2-1 Part Geometry

Each machining operation produces a characteristic part

geometry due to two factors:
1. Relative motions between the tool and the workpart.
• Generating – part geometry is determined by the feed
trajectory of the cutting tool.
2. Shape of the cutting tool.
• Forming – part geometry is created by the shape of the
cutting tool.

Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling

Forming to create shape: (a) form turning, (b) drilling,

Combination of forming and generating to create shape:
(a) thread cutting on a lathe, and (b) slot milling

3- Concept of rake and clearance angles of cutting tools.

The word tool geometry is basically referred to some specific angles or
slope of the salient faces and edges of the tools at their cutting point.
Rake angle and clearance angle are the most significant for all the
cutting tools.
The concept of rake angle and clearance angle will be clear from some
simple operations shown in Fig

Rake and clearance angles of cutting tools

 Rake angle (γ): Angle of inclination of rake surface from reference
plane
 clearance angle (α): Angle of inclination of clearance or flank surface
from the finished
surface
 Rake angle is provided for ease of chip flow and overall machining.
4- Machine Tool Motions
• Primary motion that causes cutting to take place.
• Feed motion that causes more of the part surface to be machined
• Rotations and/or translations of the workpiece or cutting tool

4-1 Planing Machine

• Primary motion is translation of the workpiece
• Feed motion is translation of the tool incrementally between cuts

4-2 Shaping Machine

• Primary motion is translation of the tool
• Feed motion is translation of the workpiece between cuts
4-3 Turning Operations
Primary motion is rotation of the workpiece Feed motion is translation
of the cutting tool – continuous driven by spindle rotation

5- Overview of Major Machining Processes

5-1- Turning
A single point cutting tool removes material from a rotating workpiece
to generate a cylindrical shape.
Lathe Parts
A simple lathe comprises of a bed made of grey cast iron on which
headstock, tailstock, carriage and other components of lathe are
mounted.
Different types of Turning Operations

The following fig illustrates various types of Turning Operations.

Methods of Holding the Work in a Lathe

• Holding the work between centers

• Chuck

• Collet
• Face plate

Operating/Cutting Conditions

Feed f

Fed (f) – the distance the tool advances for every rotation of workpiece
(mm/rev)
Fed rate (fr) – linear travel rate (mm/min)
fr = f N

3. Depth of Cut d

Depth of cut (d) perpendicular distance between machined surface and

uncut surface of the Workpiece
d = (D1 – D2)/2 (mm)
Metal-Removal Rate

For turning, the chip width is , where and are outer and inner workpiece
diameters, respectively. The crosssectional area is . Therefore, the metal
removal rate is

Cutting tool types

MILLING

A milling machine is a machine tool that removes metal as the work is

fed against a rotating multipoint cutter. The milling cutter rotates at high
speed and it removes metal at a very fast rate with the help of multiple
cutting edges. One or more number of cutters can be mounted
simultaneously on the arbor of milling machine. This is the reason that a
milling machine finds wide application in production work.

MILLING METHODS

There are two distinct methods of milling classified as follows:

1. Up-milling or conventional milling, and

2. Down milling or climb milling.

UP-Milling

In the up-milling, as shown in the Fig, the metal is removed in form of

small chips by a cutter rotating against the direction of travel of the
workpiece. In this type of milling, the chip thickness is minimum at the
start of the cut and maximum at the end of cut. As a result the cutting
force also varies from zero to the maximum value per tooth movement of
the milling cutter.

Down-Milling

Down milling is shown in the Fig.. In this method, the metal is removed by
a cutter rotating in the same direction of feed of the workpiece. The effect
of this is that the teeth cut downward instead of upwards. Chip thickness
is maximum at the start of the cut and minimum in the end.
TYPES OF MILLING CUTTERS

TYPES OF MILLING MACHINES

The main types of milling machines are:

a- Horizontal milling machine

b- Vertical milling machine

OPERATIONS PERFORMED ON MILLING MACHINE

Many different kinds of operations can be performed on a milling

machine.
Operating/Cutting Conditions
General Safety Precautions while Working in Machine Shop

The following safety precautions or guidelines are generally adopted for

every metal cutting or machining shop. They must be strictly followed
for safety. Specific safety guidelines for some of the machine process like
lathe, drilling, shaping, planning slotting, grinding, milling, and finishing
operations are also described in the following sections.
1. One should use the correct tools and work holding devices
recommended for the process.
2. One should hold the work piece and tool securely on the machine.
3. One should clamp the tool correctly. An overhanging tool may cause
catastrophic failure of the tool, work piece or the machine tool.
4. One should not try to remove chips from the machine with your
hands.
5. Never use compressed air from mouth. Use brush.
6. One should not touch a job-piece with bare hands while doing
inspection or removing it from the machine. Use gloves always.
7. One should operate the machine at recommended operating
conditions based on work material and tool material combination and
other cutting conditions specified.
8. One should use recommended coolant depending upon work-tool
material combination.
9. During machining ductile materials, use chip breakers and chip guards.
10. One should re-sharp the tools immediately when it starts producing
rough surfaces on the job-piece or produces chatter.
11. One should not run the machines at speed higher than
recommended. It may produce vibrations and chatter and damage job-
piece, tool, or both.
12. Provide sufficient approach and over travel distances wherever
necessary.
13. In case of power failures, switch off the machine and retrieve tool
from the workpiece.
14. One should wear goggles to protect eyes from flying chips.
15. Machines are governed by the old clinch garbage input, garbage
output. The skill of the operator is often the limiting factor for the
machining operation.
16. Stop machine before attempting to clean, removing tool or
workpiece.