secondary or machining

process
Prepared by:
Quinto, Harold G.
 Machining process

INTRODUCTION

 Manufacturing processes can be broadly

divided into two groups and they are primary
manufacturing processes and secondary
manufacturing processes.
 Machining process

INTRODUCTION
 Secondary manufacturing processes provide
the final shape and size with tighter control on
dimension, surface characteristics etc.
Material removal processes are mainly the
secondary manufacturing processes.
 Machining process

DEFINITION
 Machining is manufacturing process that
involves removing materials using cutting
tools for getting rid of the unwanted materials
from some workpiece and converting it into
the shape you desire. A large piece of stock is
used for cutting the workpiece. The large
stock might be in any shape such as solid bar,
flat sheet, beam or even hollow tubes.
 Machining process

CLASSIFICATION OF
MACHINING PROCESS
Conventional

Non-Conventional
 Machining process

CLASSIFICATION OF MACHINING
PROCESS
Conventional
Conventional machining usually involves
changing the shape of a work piece using an
implement made of a harder material. Using
conventional methods to machine hard metals
and alloys means increased demand of time and
energy and therefore increases in costs;
 Machining process Conventional Machining

Three primary machining processes:

Turning

Milling
Drilling
 Machining process Conventional Machining
Primary machining processes

Three primary machining processes

1. Turning
Turning is a machining process performed by a
device called a lathe; the lathe spins the given
product as the blades cut and scrape away the
desired areas. The cutting tools work along two
axes of motion to create cuts with precise depth
and diameter.
 Machining process Conventional Machining
Primary machining processes

Lathe Machines & Its parts:

 Machining process Conventional Machining
Primary machining processes

Common Types of Lathe Cutting Tools:

1. Right-Hand Tool

2. Left-Hand Tool 3. Round Hand Tool

 Machining process Conventional Machining
Primary machining processes

Different Types of Tooling

1. high speed steel (HSS) toolbits

Indexable carbide tooling 

3. Indexable carbide tooling 

2. Brazed carbide toolbits
 Machining process Conventional Machining
Primary machining processes

Basic turning operations: Facing

Straight

Boring Drilling
 Machining process Conventional Machining
Primary machining processes

Basic turning operations: Tapering

Threading

Knurling
Shouldering
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Straight turning

Turning is the operation when the metal removal

takes place from the surface of the cylindrical
work piece. In this process the tool is fed along
the axis of the spindle. Turning is the removal of
metal from the outer diameter of a rotating
cylindrical work piece.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Facing
Facing is the process of making flat surfaces on a
lathe. The job is held on a faceplate or chuck and the
tool is fed at right angles to the bed to obtain flat
surfaces. Most often, the work piece is cylindrical, but
using a 4- jaw chuck you can face rectangular or odd-
shaped work to form cubes and other non-cylindrical
shapes.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Boring

The process of removal of stock from a hole in

the workpiece is called boring. Holes are bored
by single point cutting tools. The cutting tool
shaves off a thin layer of material to an accurate
size.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Drilling

This is the process of making holes in the

workpiece with the help of drills. The drill is
held in the tailstock and the drilling
operation is carried out by advancing the
drill in the workpiece by rotating the handle
of the tail stock.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Threading
Threading is the process of creating a screw thread.
There are many methods of generating threads.
Thread cutting on lathe is an operation that uses a
single-point tool to produce a thread form on a
cylinder or cone. The tool moves linearly while the
precise rotation of the work piece determines the
lead of the thread.

Knurling
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Tapering
An operation performed on a lathe that feeds a tool at an
angle to the length of the work piece in order to create a
conical shape. Taper turning falls  into three categories,
short tapers of relatively obtuse angles generally turned
with the top-slide, longer tapers of a more acute angle
produced either by setting the tailstock over or by use of
a taper turning attachment, and internal taper.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Shouldering

A shoulder is a point at which the

diameter of the work piece changes
with no taper from one diameter to the
other.
 Machining process Conventional Machining
Primary machining processes

Basic turning operations:

Knurling

The process of rendering rough the

surface of a work piece by making a
series of indentations or depressions on it
is known as knurling. The knurling tool
which is held in the tool post is pressed
against the job to carry out the operation.
 Machining process Conventional Machining
Primary machining processes

Three primary machining processes

2. Milling
Milling is a process that uses rotating cutters to
remove material, but the difference lies in how the
equipment works. A milling machine features a
moveable table on which the material is mounted.
In most milling machines, the cutting tools are
stationary and the table moves the material so that
the desired cuts can be made.
 Machining process Conventional Machining

Parts of Milling Machine:

 Machining process Conventional Machining

Common Types of Milling Machines

Horizontal milling machine
Vertical milling machine Universal milling machine
 Machining process Conventional Machining
Primary machining processes

Common Types of Milling Cutting Tools:

2. Slab Mill
1. End mill 3. Fly Cutter

4. Woodruff Cutter 5. Shell mill 6. Involute gear cutter

 Machining process Conventional Machining
Primary machining processes

Basic milling operations:

 Machining process Conventional Machining
Primary machining processes

Basic milling operations:

Face milling
 Machining process Conventional Machining

Three primary machining processes:

3. Drilling
Drilling occurs when cylindrical holes are
produced in a piece of solid material using a drill
bit. It is one of the most important machining
processes as the holes that are created are often
intended to aid in assembly. To ensure stability and
precision, a drill press is often used.
 Machining process Conventional Machining

Drilling machine
& Its parts:
 Machining process Conventional Machining

Common Types of Milling Machines

Upright Drilling Machine

Sensitive Drilling Machine Radial Drilling Machine
 Machining process Conventional Machining
Primary machining processes

Common types of drill:

Flat or Spade Drill Straight Fluted Drill

Twist Drill

Reamer Drill Taper Shank Core Drill Centre Drill

 Machining process Conventional Machining
Primary machining processes

Basic drilling machine operations:

 Machining process Conventional Machining
Primary machining processes

CNC Lathe Machines & Its parts:

 Machining process Conventional Machining
Primary machining processes

CNC Milling Machines & Its parts:

 Machining process Conventional Machining
Primary machining processes

CNC Machines Advantages:

•Reduced development time

•Improved stock management
•Higher quality end products
•Cost savings
•Surplus productivity
•Increased profits
 Machining process Conventional Machining
Primary machining processes

CNC Machines Disadvantages:

• They are costly

• Trained operator is required to operate
the machine
• In case of breakdown a highly skilled
professional is required to solve the
problem
 Machining process

CLASSIFICATION OF MACHINING
PROCESS
 Non Conventional
Non-conventional machining utilizes other
forms of energy
Its uses a Machines which are fully
automated in which there is no need of human
resource to control the functions of the
machines. These may be controlled by an pre-
programmed computer or a robot. 
 Machining process Non-Conventional Machining

Basic types of Non-traditional machining processes:

Abrasive Jet Electrochemical

Electrical Discharge

Laser Beam
 Machining process Non-Conventional Machining

Basic types of Non-traditional machining processes:

Electron Beam

Abrasive Water Jet

Ultrasonic
 Machining process Non-Conventional Machining
Basic types of non-traditional

Electrical Discharge
 In this machining process an electric spark used as tool
for machining. It is same as removal of metal burr from
the metal surface in presence of electric spark. In this
process, an electric spark generated between work piece
and tool. This spark used as cutting tool to cut the metal
work piece into desire shape. Both tool and work piece
placed into a dielectric fluid, which accelerate the spark
and remove chips particles between them.  The metal
removal takes place due to spark erosion and
vaporization.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Electro chemical
 It is non-traditional machining process in which metal is
removed by electrochemical dissolution. It is inverse of
electroplating. In this process, both tool and work piece
is placed into electrolyte solution. Generally NaCl into
water take as electrolyte. The tool is act as cathode and
work piece as anode. When high voltage DC current
applied across them, metal will be depleted from anode
and plated at cathode. Generally hydrogen plated at
cathode and the metal removed from anode makes a slag
by combine with Cl- ions. This slag is removed from
electrolyte by some cleaning system.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Abrasive Jet

 In this machining process, a high stream of abrasive

particles forced towards work piece, this will remove
metal from striking surface due to erosion. The metal
removal process takes place due to brittle fracture and
micro cutting action of abrasive particles. The abrasive
particles carried by high velocity gas which act as
transportation medium for abrasive particles. This
machining is mostly used for machining hard material.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Laser Beam

 This machining process uses laser or light energy for

metal removal. In this process a high concentrated laser
beams impinging on work piece, which produces heat
energy at striking surface. This heat energy use to
remove metal by melting and evaporation of metal
particles. This process can be used to machine both
metallic and non-metallic material.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Ultrasonic

 Ultrasonic machining is a machining operation in

which a vibrating tool oscillating at ultrasonic
frequencies is used to remove material from the
work piece, aided by abrasive slurry that flows
freely between the work piece and the tool.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Electron Beam

 Electron beam machining (EBM) is one of

several industrial processes that use electron
beams. Electron beam machining uses a high-
velocity stream of electrons focused on the work
piece surface to remove material by melting and
vaporization.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Water Jet and Abrasive Water Jet

 Water jet machining is an environment friendly, non-

traditional machining process. In this process, a high
velocity water jet is used to machining work piece.  In
this process, high velocity water jet strikes at working
surface and metal removed due to erosion by water
particle.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Advantages

• It provides high accuracy and surface finish.

• No physical tool is used hence, no tool wear occur.
• They do not generate chips or generate microscopic
chips.
• These are quieter in operation.
• It can be easily automated.
• It can machine any complex shape.
 Machining process Non-Conventional Machining
Basic types of non-traditional

Disadvantages

• High initial or setup cost.

• High skilled labor is required.
• Lower metal removal rate.
• More power required for machining.
• It is not economical for bulk production.
“Continuous improvement is better than delayed
perfection.”

― Mark Twain

GOD BLESS YOU!!