MECH 262 –

MANUFACTURING
ENGINEERING
MATERIAL REMOVAL
PROCESSES

THEORY OF METAL
MACHINING

Mr Bright Osafo Adunu

 MATERIAL REMOVAL PROCESSES
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 The material removal processes are a family of shaping operations in

which excess material is removed from a starting workpart so that what
remains is the desired final geometry.
 The most important branch of the family is conventional machining, in
which a sharp cutting tool is used to mechanically cut the material to
achieve the desired geometry.
 The three principal machining processes are turning, drilling, and milling.
 The ‘‘other machining operations’’ in include shaping, planing, broaching,
and sawing.
CLASSIFICATION OF MATERIAL REMOVAL PROCESSES
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 MACHINING
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 Machining is the most versatile and accurate of all

manufacturing processes in its capability to produce a
diversity of part geometries and geometric features.

 Machining is the process of cutting, shaping, or

removing material from a workpiece using a machine
tool.

 Machining is classified as a secondary process.

 MACHINING
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 Cutting action involves shear deformation of work

material to form a chip

 As chip is removed, new surface is exposed

 MACHINING
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 WHY MACHINING IS IMPORTANT
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 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
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 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
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 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
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 Most important machining operations:

 Turning
 Drilling
 Milling

 Other machining operations:

 Shaping and planing
 Broaching
 Sawing
 TURNING
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 Turning is a machining process in which a single-point tool

removes material from the surface of a rotating workpiece to form
a cylindrical shape.

 The tool is fed linearly in a direction parallel to the axis of rotation

to generate a cylindrical geometry

 Turning is traditionally carried out on a machine tool called a lathe,

which provides power to turn the part at a given rotational speed
and to feed the tool at a specified rate and depth of cut.
 TURNING
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 OPERATIONS RELATED TO TURNING
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 DRILLING
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 Drilling is a machining operation used to create a round hole in

a workpart.
 Drilling is usually performed with a rotating cylindrical tool

that has two cutting edges on its working end. The tool is
called a drill or drill bit.
 DRILLING
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 OPERATIONS RELATED TO DRILLING
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 Most of the operations follow drilling; a hole must be

made first by drilling, and then the hole is modified by
one of the other operations.

 All of the operations use rotating tools.

 OPERATIONS RELATED TO DRILLING
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 Reaming: Reaming is used to slightly enlarge a hole, to

provide a better tolerance on its diameter, and to improve its
surface finish. The tool is called a reamer, and it usually has
straight flutes.
 OPERATIONS RELATED TO DRILLING
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 Tapping: This operation is performed by a tap and is

used to provide internal screw threads on an existing
hole.
 OPERATIONS RELATED TO DRILLING
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 Counterboring: Counterboring provides a stepped hole, in

which a larger diameter follows a smaller diameter partially
into the hole. A counterbored hole is used to seat bolt heads
into a hole so the heads do not protrude above the surface.
 OPERATIONS RELATED TO DRILLING
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 Countersinking: This is similar to counterboring, except that

the step in the hole is cone-shaped for flat head screws and
bolts.
 OPERATIONS RELATED TO DRILLING
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 Centering: Also called center drilling, this operation drills a

starting hole to accurately establish its location for subsequent
drilling. The tool is called a center drill.
 OPERATIONS RELATED TO DRILLING
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 Spot facing: Spot facing is similar to milling. It is used to

provide a flat machined surface on the workpart in a localized
area.
 MILLING
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 Milling is a machining operation in which a rotating multiple-

cutting-edge tool is moved across workpart to cut a plane or
straight surface
 Two forms: peripheral milling and face milling
 The conventional machine tool that performs this operation is a
milling machine.
 Milling - Peripheral Milling
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 In peripheral milling, also called plain milling, the axis of the tool
is parallel to the surface being machined, and the operation is
performed by cutting edges on the outside periphery of the cutter.
 Several types of peripheral milling

 (a) Slab milling

 (b) Slotting
 (c) Side milling
 (d) Straddle milling
 (e) Form milling
 Milling - Face Milling
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 In face milling, the axis of the cutter is perpendicular to

the surface being milled, and machining is performed by
cutting edges on both the end and outside periphery of the
cutter.
 Milling - Face Milling
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 Several types of face milling

 (a) conventional face milling
 (b) partial face milling
 (c) end milling
 (d) profile milling
 (e) pocket milling
 (f) surface contouring
 SOME MILLING OPERATIONS
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 CUTTING TOOL CLASSIFICATION
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 Single-Point Tools
 One dominant cutting edge
 Point is usually rounded to form a nose radius
 Turning uses single point tools
 CUTTING TOOL CLASSIFICATION
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 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 CONDITIONS IN MACHINING
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 Three dimensions of a machining process:

 Cutting speed (v) – primary motion

 Feed (f) – secondary motion

 Depth of cut (d) – penetration of tool below original work

surface
 For certain operations, material removal rate can be computed as

 Where, = cutting speed; = feed; = depth of cut

 CUTTING CONDITIONS FOR TURNING
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 Roughing vs. Finishing
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 In production, several roughing cuts are usually taken on the

part, followed by one or two finishing cuts
 Roughing - removes large amounts of material from starting

workpart
 Creates shape close to desired geometry, but leaves some material for
finish cutting
 High feeds and depths, low speeds
 Finishing - completes part geometry
 Final dimensions, tolerances, and finish
 Low feeds and depths, high cutting speeds
 MACHINE TOOLS
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 A power-driven machine that performs a machining

operation, including grinding
 Functions of machine tools in machining:
 Holds workpart
 Positions tool relative to work
 Provides power at speed, feed, and depth that have been set

 The term is also applied to machines that perform metal

forming operations
 ORTHOGONAL CUTTING MODEL
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 Simplified 2-D model of machining that describes the

mechanics of machining fairly accurately
 SHAPING AND PLANING
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 Shaping and planing are similar operations, both involving the use
of a single-point cutting tool moved linearly relative to the
workpart. In conventional shaping and planing, a straight, flat
surface is created by this action.

 In shaping, the speed motion is accomplished by moving the

cutting tool.

 In planing, the speed motion is accomplished by moving the

workpart.
 SHAPING AND PLANING
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 Types of shapes that can cut by shaping and planing
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 (a) V-groove
 (b) Square groove

 (c) T-slot

 (d) Dovetail slot

 (e) Gear Teeth

 BROACHING
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 Broaching is performed using a multiple-teeth cutting tool by

moving the tool linearly relative to the work in the direction of
the tool axis
 The machine tool is called a broaching machine, and the cutting

tool is called a broach.

 TYPES OF BROACHING
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 There are two principal types of broaching: external (also called

surface broaching) and internal.

 External broaching is performed on the outside surface of the work

to create a certain cross-sectional shape on the surface.

 Internal broaching is accomplished on the internal surface of a hole

in the part. Accordingly, a starting hole must be present in the part
so as to insert the broach at the beginning of the broaching stroke.
 WORK SHAPES CUT BY BROACHING
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 SAWING
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 Sawing is a process in which a narrow slit is cut into the

work by a tool consisting of a series of narrowly spaced
teeth.

 Sawing is normally used to separate a workpart into two

pieces, or to cut off an unwanted portion of a part.

 These operations are often referred to as cutoff operations.

 BASIC TYPES OF SAWING
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 HACKSAWING, involves a linear reciprocating motion of the saw

against the work. This method of sawing is often used in cutoff operations.
 Cutting is accomplished only on the forward stroke of the saw blade.
 The hacksaw blade is a thin straight tool with cutting teeth on one edge.
 Hacksawing can be done either manually or with a power hacksaw.
 A power hacksaw provides a drive mechanism to operate the saw blade at
a desired speed; it also applies a given feed rate or sawing pressure.
 HACKSAWING
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 BASIC TYPES OF SAWING
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 BANDSAWING involves a linear continuous motion, using a

bandsaw blade made in the form of an endless flexible loop with
teeth on one edge.

 The sawing machine is a bandsaw, which provides a pulley-like

drive mechanism to continuously move and guide the bandsaw
blade past the work.

 Bandsaws are classified as vertical or horizontal. The designation

refers to the direction of saw blade motion during cutting.
 BANDSAWING
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Horizontal Bandsawing

Vertical Bandsawing
 BASIC TYPES OF SAWING
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 CIRCULAR SAWING, uses a rotating saw blade to provide a

continuous motion of the tool past the work.

 Circular sawing is often used to cut long bars, tubes, and similar
shapes to specified length.

 Circular sawing machines have powered spindles to rotate the

saw blade and a feeding mechanism to drive the rotating blade
into the work.
 CIRCULAR SAWING
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 Questions
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 MID – SEMESTER EXAMINATION
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DATE:


……………,2023