Production Engineering MEC041
Lecture 6
Machining Processes I
Dr. Amira Aly Khattab
Assistant Professor_ Alexandria University
Field of Engineering Sciences
العلمين الدولية جامعة
Production Process
Dr. Amira Aly Khattab
What is Machining?
• Machining is the removal of the unwanted material
(machining allowance) from the workpiece so as to
obtain a finished product of the desired size,
shape and surface quality.
• Machining is generally used as a final finishing
operation for parts produced by casting and
forming before they are ready for assembly or
use.
• Machining ranges from relatively rough cleaning of
casting to high precision micromachining components
Required narrow tolerances
Dr. Amira Aly Khattab
Why Machining is Important
1. Variety of work materials can be machined
2. Variety of part shapes and special geometric features
possible:
Screw threads
Accurate round holes
Very straight edges and surfaces
3. Good dimensional accuracy and surface finish
Dr. Amira Aly Khattab
Disadvantages of Machining
1. Wasteful of material
Chips generated in machining are wasted material.
2. Time consuming
A machining operation generally takes longer to shape a given
part than alternative shaping processes.
Dr. Amira Aly Khattab
Machining Processes
Mechanical Machining Bench working Machining
Dr. Amira Aly Khattab
Machining Equipments
(Center Lathe)
Dr. Amira Aly Khattab
Turning Processes
Dr. Amira Aly Khattab
Cutting Motions
• Main cutting motion (1): The work piece rotates about its axis
• Feed motion (2): The tool moves slowly at a constant speed parallel to the required
profile of work piece
• Depth of Cut (3): Before starting with the feed motion, the tool must be moved
radial to the required depth of cut 1
2 3
Dr. Amira Aly Khattab
Turning Products
• Lathes are considered the most common machine tool.
• Parts machined on these lathes are cylindrical like columns, shafts, sleeves,
screws, etc...
• To produce these parts, cutting tools of different types and shapes are
used, such as lathes cutting tools, twist drills, counterboring tools, taps,
threading dies, and others.
Screws Sleeves Shafts
Dr. Amira Aly Khattab
Center Lathe
(Turning Machine)
• Headstock, it transmits power to the different
parts of a lathe.
• Chuck, it holds the workpiece.
• Bed, it supports all components of lathe.
• Tailstock, It is used for Holding the workpiece
and Holding the tool for drilling.
• Carriage, it rests over the bed and slides on it.
• Lead Screw, it is used for thread cutting
operation in a lathe machine.
• Feed rod, is used to move the carriage and it is
used in most turning operations.
Dr. Amira Aly Khattab
Turning Machine Processes
Dr. Amira Aly Khattab
Turning Machine Processes
Dr. Amira Aly Khattab
Tool Angles
Clearance Angle (α)
➢ The angle between the flank of the tool and a tangent
to the work surface. It reduces the friction between
the cutting tool and workpiece, so heating and wear of
the cutting tool are reduced.
Depth of cut
Wedge (tool) Angle (β)
➢ It is the angle between the tool face and the flank.
Increasing tool angle increases the tool rigidity.
Rake Angle (Ƴ)
➢ It is the angle that the tool face with the normal
plane to the machined surface. It facilitates the tool
penetration in the workpiece.
Dr. Amira Aly Khattab
Basic Elements of Turning Process
Dr. Amira Aly Khattab
Turning Process Equations
Dr. Amira Aly Khattab
Dr. Amira Aly Khattab
Example 2
Dr. Amira Aly Khattab
π ∗ D1 ∗ n1
vc =
1,000 Example 2 D1= 60 mm D2=57 mm
π ∗ 60 ∗ n1
32 =
1,000
• n1 = 169.765 rpm
L 250
t1m = s∗n = 0.2∗169.765 = 7.363 min •
1
t=1.5 mm
• D2 = D1 − 2 ∗ t = 60 − 2 ∗ 1.5 = 57 mm
π∗D2 ∗n2
• vc =
1,000
π∗57∗n2 D2= 57 mm D3=54 mm
• 32 = 1,000
• n2 = 178.7 rpm
L 250
t 2m = = = 6.99 min •
s∗n2 0.2∗178.7
• 𝐭 𝐦 = 𝐭 𝟏𝐦 + 𝐭 𝟐𝐦 = 𝟕. 𝟑𝟔𝟑 + 𝟔. 𝟗𝟗 = 𝟏𝟒. 𝟑𝟓 𝐦𝐢𝐧
t=1.5 mm
Dr. Amira Aly Khattab
