Material Removal Processes: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Material Removal Processes
A family of shaping operations in which the

material is removed from a starting work part
so the remaining part has the desired geometry
 Machining – material removal by a sharp
cutting tool, e.g., turning, milling, drilling
 Abrasive processes – material removal by
hard, abrasive particles, e.g., grinding
 Nontraditional processes - various energy
forms other than sharp cutting tool to remove
material
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Machining
Cutting action involves shear deformation of work

material to form a chip
 As chip is removed, new surface is exposed
Figure 1 (a) A cross‑sectional view of the machining

process, (b) tool with negative rake angle; compare
with positive rake angle in (a).
Why Machining is Important
 Variety of work materials can be machined
 Most frequently used to cut metals
 Variety of part shapes and special geometric
features possible, such as:
 Screw threads
 Accurate round holes
 Very straight edges and surfaces
 Good dimensional accuracy and surface finish
Disadvantages with Machining
 Wasteful of material
 Chips generated in machining are wasted
material, at least in the unit operation
 Time consuming
 A machining operation generally takes more
time to shape a given part than alternative
shaping processes, such as casting, powder
metallurgy, or forming
Machining in Manufacturing Sequence
 Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
 Other processes create the general shape
of the starting workpart
 Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot create
Machining Operations
 Most important machining operations:
 Turning
 Drilling
 Milling
 Other machining operations:
 Shaping and planing
 Broaching
 Sawing
Turning
 Single point cutting tool removes material from

a rotating workpiece to form a cylindrical shape
Figure 2 Three most common machining processes:

(a) turning,
Drilling
 Used to create a round hole, usually by means

of a rotating tool (drill bit) with two cutting
edges
Figure 3 (b) drilling,
Cutting Tool Classification
1. Single-Point Tools
 One dominant cutting edge
 Point is usually rounded to form a nose
radius
 Turning uses single point tools
2. Multiple Cutting Edge Tools
 More than one cutting edge
 Motion relative to work achieved by rotating
 Drilling and milling use rotating multiple
cutting edge tools
Cutting Tools
Figure 5 (a) A single‑point tool showing rake face,

flank, and tool point; and (b) a helical milling cutter,
representative of tools with multiple cutting edges.
MACHINING OPERATIONS AND
MACHINE TOOLS
1. Turning and Related Operations
2. Drilling and Related Operations
3. Milling
4. Machining Centers and Turning Centers
5. Other Machining Operations
6. High Speed Machining
Machining
A material removal process in which a sharp
cutting tool is used to mechanically cut away
material so that the desired part geometry
remains
 Most common application: to shape metal parts
 Most versatile of all manufacturing processes
in its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
 Casting can also produce a variety of
shapes, but it lacks the precision and
accuracy of machining
Turning
Single point cutting tool removes material from a
rotating workpiece to generate a cylinder
 Performed on a machine tool called a lathe
 Variations of turning performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading
Turning
Figure 6 Turning operation.
Turning Operation
Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert (photo
courtesy of Kennametal
Inc.)
Facing
Tool is fed
radially inward
Figure 7 (a) facing
Chamfering
 Cutting edge cuts an angle on the corner
of the cylinder, forming a "chamfer"
Figure8 (e)
chamfering
Cutoff
 Tool is fed radially into rotating work at

some location to cut off end of part
Figure 9 (f) cutoff
Threading
 Pointed form tool is fed linearly across surface
of rotating workpart parallel to axis of rotation
at a large feed rate, thus creating threads
Figure 10 (g) threading
Engine Lathe
Figure 11 Diagram of an engine lathe, showing its principal

components
Lathe Machine
 Lathe is the oldest machine tool. The entire machine

tools are developed from the lathe, therefore, it is also
known as the mother of machine tools.
 A number of cutting operations can be performed on a
lathe with or without some attachments.
https://www.youtube.com/watch?v=ccYPxgen5hI
https://www.youtube.com/watch?v=HmP3Qy7n2eI
Typical Lathe and Its Various
Components
Lathe Components
 Bed: Usually made of cast iron. Provides a heavy
rigid frame on which all the main components are
mounted.
• Ways: Inner and outer guide rails that are
precision machined parallel to assure accuracy of
movement.
• Headstock: mounted in a fixed position on the
inner ways, usually at the left end. Using a chuck, it
rotates the work.
• Gearbox: inside the headstock, providing multiple
speeds with a geometric ratio by moving levers.
• Spindle: Hole through the headstock to which bar stock
can be fed.
• Chuck: 3-jaw (self centering) or 4-jaw (independent) to
clamp part being machined.
• Tailstock: Fits on the inner ways of the bed and can slide
towards any position the headstock to fit the length of the
work piece. An optional taper turning attachment would
be mounted to it.
• Tailstock Quill: Has a Morse taper to hold a lathe center,
drill bit or other tool.
• Carriage: Moves on the outer ways. Used for mounting
and moving most the cutting tools.
• Cross Slide: Mounted on the traverse slide of the
carriage, and uses a handwheel to feed tools into the
workpiece.
• Tool Post: To mount tool holders in which the cutting bits
are clamped.
• Compound Rest: Mounted to the cross slide, it pivots
around the tool post.
• Apron: Attached to the front of the carriage, it has the
mechanism and controls for moving the carriage and
cross slide.
• Feed Rod: Has a keyway, with two reversing pinion gears,
either of which can be meshed with the mating bevel gear
to forward or reverse the carriage using a clutch.
• Lead Screw: For cutting threads.
• Split Nut: When closed around the lead screw, the
carriage is driven along by direct drive without using a
clutch.
• Quick Change Gearbox: Controls the movement of
the carriage using levers.
• Steady Rest: Clamped to the lathe ways, it uses
adjustable fingers to contact the workpiece and align
it. Can be used in place of tailstock to support long
or unstable parts being machined.
• Follow Rest: Bolted to the lathe carriage, it uses
adjustable fingers to bear against the workpiece
opposite the cutting tool to prevent deflection.
https://www.youtube.com/watch?v=tI5KPc4rcps
Boring
 Difference between boring and turning:
 Boring is performed on the inside
diameter of an existing hole
 Turning is performed on the outside
diameter of an existing cylinder
 In effect, boring is internal turning operation
 Boring machines
 Horizontal or vertical - refers to the
orientation of the axis of rotation of
machine spindle
Vertical Boring Mill
Figure 16 A vertical boring mill – for large, heavy workparts.

Drilling
 Creates a round
hole in a workpart
 Compare to boring
which can only
enlarge an existing
hole
 Cutting tool called
a drill or drill bit
 Machine tool: drill
press
Figure 17 (b) drilling
Through Holes vs. Blind Holes
Through‑holes - drill exits opposite side of work
Blind‑holes – does not exit work opposite side
Figure 18 Two hole types: (a) through‑hole, and (b) blind hole.
Reaming
 Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish
Figure 19 Machining operations

related to drilling: (a) reaming
What is Reaming
 An operation used to make an existing hole
dimensionally more accurate and/or to improve
surface finish
 For further accuracy and surface finish, holes
may be burnished, ground or honed.
Tapping
 Used to provide
internal screw
threads on an
existing hole
 Tool called a tap
Figure 20 (b) tapping
Tapping
 Produces threads
 May be done by hand
or machine
 Chipless tapping is a
process of internal
thread rolling
Counterboring
 Provides a stepped
hole, in which a
larger diameter
follows smaller
diameter partially
into the hole
Figure 21 (c) counterboring

Material Removal Processes: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

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Material Removal Processes: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

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Material Removal Processes

A family of shaping operations in which the

Cutting action involves shear deformation of work

Figure 1 (a) A cross‑sectional view of the machining

 Single point cutting tool removes material from

Figure 2 Three most common machining processes:

 Used to create a round hole, usually by means

Figure 3 (b) drilling,

Figure 5 (a) A single‑point tool showing rake face,

Figure 6 Turning operation.

Figure 7 (a) facing

 Tool is fed radially into rotating work at

Figure 9 (f) cutoff

Figure 10 (g) threading

Figure 11 Diagram of an engine lathe, showing its principal

 Lathe is the oldest machine tool. The entire machine

Figure 16 A vertical boring mill – for large, heavy workparts.

Figure 17 (b) drilling

Figure 19 Machining operations

Figure 20 (b) tapping

Figure 21 (c) counterboring

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