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,
Milling
Rotating multiple-cutting-edge tool is moved
across work to cut a plane or straight surface
 Two forms: peripheral milling and face milling
Figure 4 (c) peripheral milling, and (d) face

milling.
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
Methods of Holding the Work in a Lathe
 Holding the work between centers
 Chuck
 Collet
 Face plate
Holding the Work Between Centers
Figure 12 (a) mounting the work between centers using a "dog”
Chuck
Figure 13 (b) three‑jaw chuck
Collet
Figure 14 (c) collet
Face Plate
Figure 15 (d) face plate for non‑cylindrical workparts
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
Tapping
 Used to provide
internal screw
threads on an
existing hole
 Tool called a tap
Figure 20 (b) tapping
Counterboring
 Provides a stepped
hole, in which a
larger diameter
follows smaller
diameter partially
into the hole
Figure 21 (c) counterboring
Drill Press
 Upright drill press
stands on the floor
 Bench drill similar

but smaller and
mounted on a
table or bench
Figure 22 Upright drill press
Milling
Machining operation in which work is fed past a
rotating tool with multiple cutting edges
 Axis of tool rotation is perpendicular to feed
 Creates a planar surface
 Other geometries possible either by cutter
path or shape
 Other factors and terms:
 Interrupted cutting operation
 Cutting tool called a milling cutter, cutting
edges called "teeth"
 Machine tool called a milling machine
Two Forms of Milling
Figure 23 Two forms of milling: (a) peripheral milling, and (b)

face milling.
Peripheral Milling vs. Face Milling
 Peripheral milling
 Cutter axis parallel to surface being
machined
 Cutting edges on outside periphery of cutter
 Face milling
 Cutter axis perpendicular to surface being
milled
 Cutting edges on both the end and outside
periphery of the cutter
Slab Milling
 Basic form of peripheral milling in which the
cutter width extends beyond the workpiece
on both sides
Figure 24 (a) slab

milling
Slotting
 Width of cutter is less than workpiece
width, creating a slot in the work
Figure 25 (b) slotting
Conventional Face Milling
Cutter overhangs work
on both sides
Figure 26 (a) conventional face milling
High speed face
milling using
indexable inserts
(photo courtesy
of Kennametal
Inc.).
End Milling
 Cutter diameter is
less than work
width, so a slot is
cut into part
Figure 27 (c) end milling
Profile Milling
Form of end milling
in which the
outside periphery
of a flat part is cut
Figure 28 (d) profile milling
Pocket Milling
 Another form of
end milling used
to mill shallow
pockets into flat
parts
Figure 29 (e) pocket

milling
Surface Contouring
 Ball‑nose cutter fed
back and forth
across work along a
curvilinear path at
close intervals to
create a three
dimensional surface
form
Figure 30 (f) surface

contouring
Horizontal Milling Machine
Figure 31 (a) horizontal knee-and-column milling machine.
Vertical Milling Machine
Figure 32 (b) vertical knee‑and‑column milling machine
Shaping and Planing
 Similar operations
 Both use a single point cutting tool moved
linearly relative to the workpart
Figure 33 (a) Shaping, and (b) planing.

Shaping and Planing
 A straight, flat surface is created in both
operations
 Interrupted cutting
 Subjects tool to impact loading when
entering work
 Low cutting speeds due to start‑and‑stop
motion
 Typical tooling: single point high speed steel
tools
Shaper
Figure 34 Components of a shaper.
Planer
Figure 35 Open side planer.

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 4 (c) peripheral milling, and (d) face

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

Figure 12 (a) mounting the work between centers using a "dog”

Figure 13 (b) three‑jaw chuck

Figure 14 (c) collet

Figure 15 (d) face plate for non‑cylindrical workparts

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

 Bench drill similar

Figure 22 Upright drill press

Figure 23 Two forms of milling: (a) peripheral milling, and (b)

Figure 24 (a) slab

Figure 25 (b) slotting

Figure 26 (a) conventional face milling

Figure 27 (c) end milling

Figure 28 (d) profile milling

Figure 29 (e) pocket

Figure 30 (f) surface

Figure 31 (a) horizontal knee-and-column milling machine.

Figure 32 (b) vertical knee‑and‑column milling machine

Figure 33 (a) Shaping, and (b) planing.

Figure 34 Components of a shaper.

Figure 35 Open side planer.

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