METERIAL

REMOVAL PROCESS

S.M.I.B.GUNASINGHE
GAL/ME/2017/F/259
CONTENT
• WHAT IS METAL REMOVING PROCESS
• CLASSIFICATION
• Advantages of Material Removal Process
• Limitations of material removal process
• Applications of material removal process
• Conventional Machining
• Abrasive machining
• Non conventional Machining
• Advantages , Disadvantages of NTM
What is Metal Removing Process?
• Material removal process is a type of manufacturing process in
which the final product is obtained by removing excess metal
from the stock
Advantages of material removal process

• Very high dimensional accuracy

• Sharp corners can be obtained

• Versatile in operation

• Setup is in as costly as compared to casting or forming

processes
Limitations of material removal process

• Size of component is generally limited

• Process is very costly as mentioned earlier, hence should only be used

as a secondary manufacturing process

• In manual machining highly skilled operator is required

• Generally, time consuming

Applications of material removal process
• In making automotive parts

• Making parts of custom specifications

• Making of gears, shafts and other mechanical parts

1.Conventional Machining

Conventional Machining Processes mostly remove material

in the form of chips by applying forces on the work material
with a wedge shaped cutting tool that is harder than the work
material under machining condition

• Smooth surface finish

• Close tolerance
• Repeatable’ regular geometries
common machining processes
• Turning and Related Operations –Lathe
• Drilling and Related Operations-–Drill press
• Milling -Milling Machine
Cutting Tool
(1) single-point tools,
used in operations such as turning and boring
(2) multiple-edge cutting tools, used in operations such as milling and
drilling

Ex ;Drilling tools
Cutting condition

• Relative motion between tool and work

• Cutting conditions –Cutting speed, v(m/s) –Surface speed –Feed f(m):
the lateral distance traveled by the tool during one revolution. –Depth
of cut d(m)
•Material Removal Rate : MRR = v f d
–Roughing -removes large amounts of material, at high feeds and
depths, low speeds
–Finishing -Achieves final dimensions, tolerances, and finish, Low feeds
and depths, high cutting speed
Machine Tools
• What is a machine tool?
A machine tool can be defined as a power-driven machine that positions
and moves a tool relative to the work to accomplish machining or
other metal shaping process.

• A power-driven machine that performs a machining operation

–Holds work part
–Positions tool relative to work
–Provides power and controls speed, feed, and depth.
–Pumps a Cutting fluid
Theory of Chip Formation
Chip formation is part of the process of cutting materials by
mechanical means , using such as saws , lathes and milling cutters
 2. Abrasive Machining Processes

• Abrasive machining involves material removal by the action of hard , abrasive

particles
• The use of abrasives to shape parts is probably the oldest material removal
process

*The importance of Abrasive Machining

• They can be use do n all types of materials ranging from soft metal to
hardened steel sand hard non metallic materials such as ceramic sand silicon.
• Extremely fine surface finishes(0.025µm).
• For certain abrasive processes, dimensions can be held to extremely close
tolerances.
The importance of Abrasive Machining

They can be used on all types of materials ranging from

Soft metals to hardened steels and hard nonmetallic
materials such as ceramics and silicon. Extremely fine surface
finishes(0.025µm). For certain abrasive processes , dimensions
can be held to extremely close tolerances.
Abrasive Materials
• General Properties
Hardness, wear resistance, toughness, friability
• examples-
Aluminum oxide
Silicon Carbide
Cubic Boron Nitride
Diamond
Types of Abrasive Machining Processes

• Grinding
• Honing
• Lapping
• Super finishing
• Polishing
• Polishing
• Buffing
• Abrasive water jet machining
• Ultra sonic machining
Surface Grinding
3.Nontraditional machining process

• What is non traditional machining

Non-conventional manufacturing processes is defined as a
group of processes that remove excess material by various
techniques involving mechanical, thermal, electrical or
chemical energy or combinations of these energies but do not
use a sharp cutting tools as it needs to be used for
traditional manufacturing processes
 Classification of NTM processes
classification of NTM processes is carried out depending on the nature of
energy used for material removal.

1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)

2. Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
• 3. Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)

• 4. Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)
Advantages of non traditional Process
• materials of any hardness can be machined
• No burrs are left in machined surface
• thin and fragile/brittle components can be machined without
distortion
• Complex internal shapes can be machined
Limitations of NTM
• This process can only be employed in electrically conductive materials
• Material removal rate is low and the process overall is slow
compared to conventional machining processes
• Unwanted erosion and over cutting of material can occur
• Rough surface finish when at high rates of material removal
THANK YOU