Various

Conventional Machining
Mahros Darsin
Universitas Jember

TKM1261 Proses Manufaktur 1

 Mengingat kembali

Introduction

• What is conventional machining?

• Various machining operations

TKM1261 Proses Manufaktur 1

 Mengingat kembali

Basic Process

TKM1261 Proses Manufaktur 1 Image courtesy - Wiki

 Turning

Fig-2 Basic scheme of Turning

• To produce rotational, axis-symmetric parts.

• Feed motion
• Feed relative to work piece.

TKM1261 Proses Manufaktur 1 Image Courtesy:- Ghosh and Mallik; Manufacturing Science
 Turning
Operations

• Facing
• Parting
• Grooving
• Drilling
• Screw cutting

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
TKM1261 Proses Manufaktur 1 Ref: Manufacturing Science - Ghosh and Mallik
 Tool Designs

TKM1261 Proses Manufaktur 1

 Designations for a Right-Hand Cutting
Tool

TKM1261 Proses Manufaktur 1

 Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel

TKM1261 Proses Manufaktur 1

Effect of Turning on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials

• Physical
• Little effect

• Chemical
• Little effect

TKM1261 Proses Manufaktur 1 Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

 • Advantages
• Increased production with medium and high turret lathes.

• Disadvantages
• Limited to rotational parts.
• High equipment cost.
• Significant tool wear.
• Low production rate.
• Large amount of scrap.

TKM1261 Proses Manufaktur 1 Ref: Manufacturing Science - Ghosh and Mallik

 Turning Calculation
•  
• Vc = cutting speed
(m/min)
• D = average diameter of
workpiece

• Do = diameter awal (mm)

• Df = diameter akhir (mm) D = depth of cut/DoC = kedalaman
potong
Untuk diameter besar atau
kedlamanan potong rendah, D = Do

TKM1261 Proses Manufaktur 1

 Example
A 150mm long, 12.5mm-diameter 304 stainless
steel rod is being reduced in diameter to 12.0
mm by turning on a lathe. The spindle rotates at
n = 400 rpm, and the tool is traveling at an axial
speed of 200 mm/min. Calculate the cutting
speed
Material Removal Rate (MRR)
 Material Removal Rate (MRR)

𝑀𝑅𝑅=π𝐷𝑑𝑓
•  
 Workpiece Material
• Aluminum alloys
• Magnesium alloys
• Copper alloys
• Stainless steels
• Cast iron
• Plastics
 Drilling

• Drilling Operations
• Reaming
• Tapping
• Counterboring Fig-3 Basic scheme of Drilling
• Countersinking
• Centering
• Spot facing
Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid

TKM1261 Proses Manufaktur 1 Image Courtesy:- Ghosh and Mallik; Manufacturing Science
 Effect of Drilling on Work Material Properties
• Mechanical
• Very thin layer of highly stressed and disturbed material on new surface.

• Physical
• Little effect

• Chemical
• Increased probability of corrosion at stressed surface

TKM1261 Proses Manufaktur 1 Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

 Advantages
• High production rate.

Disadvantages
• Skilled labor is required according to the hole location and
accuracy.

TKM1261 Proses Manufaktur 1

 Milling

Fig-4 Basic scheme of Milling

TKM1261 Proses Manufaktur 1 Image Courtesy:- Ghosh and Mallik; Manufacturing Science
 Milling Operations
• Slab Milling
• Face Milling
• End Milling

Fig-5 Slab Milling Fig-6 Face Milling

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

 Workpiece Materials
• Aluminum
• Brass
• Magnesium
• Nickel
• Steel
• Thermostat plastics
• Titanium
• Zinc

TKM1261 Proses Manufaktur 1 Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

Advantages
• Variety of shapes can be obtained

Disadvantages
• Skilled labor is required
• Low to medium production rate
• Limited shape complexity
• High equipment cost
• Significant tool wear
• Large amount of scrap

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
 Boring

Fig-7 Boring operation

TKM1261 Proses Manufaktur 1 Image Courtesy:- http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm

 Boring Operations
• Single-Edge Boring
• Multi-Edge Boring
• Step Boring
• Reaming

Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel
Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alting

TKM1261 Proses Manufaktur 1 Ref: www.coromant.sandvik.com/boring

 Effect of Boring on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials
• Physical
• Little effect
• Chemical
• Little effect

Advantages
• Finish machining of cylindrical surfaces on very large workpieces.

Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alting
TKM1261 Proses Manufaktur 1
 Broaching

Fig-8 Broaching Tool

Broaching Operations
• Surface Broaching
• Pull down Broaching
• Push Broaching
• Pot Broaching
Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux

TKM1261 Proses Manufaktur 1 Image Courtesy:- wiki

 Workpiece Materials
• Aluminum
• Brass
• Bronze
• Plastic
• Malleable Iron

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux

TKM1261 Proses Manufaktur 1

Advantages
• External and internal flat surfaces
• Good surface finish
• High production rate
• Less skilled labor is required
• Reduced cycle times
• Increased tool life
• Reduced maintenance
• Complex and irregular shapes.

Disadvantages
• Costly tooling

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
 Shaping

Fig-9 Basic scheme of Shaping

TKM1261 Proses Manufaktur 1 Image Courtesy:- Ghosh and Mallik; Manufacturing Science
 Fig-10 Shaper Mechanism

TKM1261 Proses Manufaktur 1 Image Courtesy:- http://www.roymech.co.uk/images9/shaper_mechanism_6.gif

 Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on
relatively small surfaces.

Disadvantages
• Complex parts require skilled labor.

TKM1261 Proses Manufaktur 1 Ref: Manufacturing Science - Ghosh and Mallik

 Planing

Fig-11 Basic scheme of Planing

TKM1261 Proses Manufaktur 1 Image Courtesy:- Ghosh and Mallik; Manufacturing Science
 Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on large
surfaces.

Disadvantages
• Complex parts require skilled labor.

TKM1261 Proses Manufaktur 1 Ref: Manufacturing Science - Ghosh and Mallik

 References
• Books
• Manufacturing Science by Amitabha Ghosh and Asok Kumar Mallik, East-
West Press Pvt Ltd.
• Tool and Manufacturing Engineers Handbook, Volume 1 – Machining by
Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux, Society
of Manufacturing Engineers Publications Committee
• Troubleshooting Manufacturing Processes by Laroux K. Gillespie, Society
of Manufacturing Engineers Publications Committee
• Manufacturing Engineering and Technology by Serope Kalpakjian and
Steven R. Schimid, Pearson Education
• Manufacturing Processes Reference Guide by Robert H. Tadd, Dell K. Allen
and Leo Alting, Industrial Press
• Websites
• http://www.roymech.co.uk/images9/shaper_mechanism_6.gif
• http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm
• http://www.coromant.sandvik.com/boring
Thank you