Ch # 1

Traditional Machining Processes

Sep 2023
Content:
• Overview of manufacturing processes
• Machining processes:
— Definition
—Machining requirements
—Traditional machining (TM)
—Classifications of TM
—Advantages of TM
—Disadvantages of TM
—Applications of TM
• Traditional machining processes & machine tools
• Kinematics of machine tools
 1. Overview Manufacturing
Processes

Manufacturing processes alter a material’s shape, physical properties,

or appearance in order to add value.
Three categories of manufacturing processes:
1) Shaping processes - alter the geometry of the starting work
material.
2) Property-enhancing processes - improve properties without
changing shape.
3) Surface processing processes - clean, treat, coat, or deposit
material on surface of work.
i. Shaping Processes:
1) Solidification processes – starting
material is a heated liquid or
semifluid form.
2) Particulate processing - starting
material consists of powders
3) Deformation processes - starting
material is a ductile solid (commonly
metal).
4) Material removal processes - starting
material is a ductile or brittle solid.
a. Solidification Processes

# Starting material is heated sufficiently to transform it into a liquid

or highly plastic state.
# Casting process at left and casting product at right.
 b. Particulate Processing
Starting materials are metal or ceramic powders, which involve
three steps:

1) Mixing

2) Pressing/compaction and

3) Sintering.
 c. Deformation Processes

Starting workpart is shaped by application of forces that exceed the

yield strength of the material.
Examples: (a) forging and (b) extrusion
 d. Material Removal Processes
> Excess material is removed from the starting piece so what remains is the
desired geometry.
> Examples: i) Traditional Machining – Ex.: (a) turning, (b) drilling, and
(c) milling
ii) Abrasive processes – material
removal by hard, abrasive particles,
e.g., grinding
iii) Nontraditional processes -
various energy forms other
than sharp cutting tool to remove
material.
 2. Machining
2.1. What is machining?
 Machining is a metal removing process. It removes a material & decreases
the material’s mass hence this is a subtractive process.

 Machining is an essential process of

finishing by which jobs of desired dimensions
and surface finish are produced by gradually
removing the excess material from the
preformed blank in the form of chips with the
help of cutting tool(s) moved past the work
surface(s).
 These machining processes are performed on
metal cutting machines, more commonly
termed as machine tools using various types of
2.2. Machining Requirements:
 2.3. Traditional/Conventional Machining
Process
 Conventional Machining process is a machining process in which

the machining carry out with the traditional method means not using

any advanced method for the machining. Therefore this machining

process is also called as traditional machining process.

 These processes are commonly carried out in machine shops or tool

room for machining a cylindrical or flat jobs to a desired shape,

size and finish on a rough block of job material with the help of a

wedge shaped tool.

 Cont’d…

» In this process the sharp point cutting tools are used for the

machining purpose, such as the taper tool in the lathe machine for

tapering.

» The cutting tool material is harder than the work-piece material &

the cutting tool is in directly contact with the workpiece hence more

tool wear occurs.

» The cutting tool is used against rotary or stationary work-piece for

the material removal.

 Examples of traditional machining
process:

1) Turning

2) Milling

3) Drilling

4) Grinding

5) …etc
 2.4. Classification of Traditional Machining

1. Cutting processes:

 Single point: e.g. shaping, planing, turning, boring, etc.

 Multiple point: e.g. milling, drilling, etc.

2. Abrasive processes:

 Grinding, honing, etc

2.5. Advantages of traditional machining process
Variety of work materials can be machined.
> Most frequently used to cut metals.

Variety of part shapes and special geometric features possible:

> Screw threads
> Accurate round holes
> Very straight edges and surfaces.

Good dimensional accuracy and surface finish.

Less capital cost.
2.6. Disadvantages with Traditional Machining

Wasteful of material:
> Chips generated in machining are wasted material.

Time consuming;
> A machining operation generally takes longer time to
shape a given part than alternative shaping processes.
Less surface finish and dimensional accuracy as
compared to NTM
More tool wear
 2.6. Applications of traditional
machining process

— Drilling holes in workpiece using drill machine.

— Turning, Facing operations on lathe machine.

—…etc
 2.7. Difference between traditional and non
traditional machining process:

Traditional machining Nontraditional machining

A poor surface finish is obtained A better surface finish is obtained

It can’t be used for small-size machining. It can be used for small-size

machining

The problem of tool wear, hence tool life is Here there is no problem of the tool
less wear, therefore life of tool is more.

Less investment or capital cost More capital or investment cost

Direct contact between tool and workpiece. No direct contact between the tool
and workpiece

It can’t make microholes It can make microholes

 3. Traditional Machining Processes and
Machine Tools
1. Turning

— Turning operation is a machining process

and is used to produce round parts in shape

by a single point cutting tool.

— Materials are removed by traversing in a

direction parallel to the axis of rotation of

axis or along a specified path to form a

complex rotational shape.

— The tool is fed either linearly in a direction

parallel or perpendicular to the axis of

Fig. Turning operation on a round work
piece
 Cont’d…
» A machine tool used for turning is Lathe machine.
» Single point cutting tool removes material from a rotating workpiece.
» Configuration of center lathe machine:

Fig. Center lathe machine and its configuration

 Cont’d…

Other common machining operations done in centre lathes:

 Method of holding work piece in a lathe:

1) Holding the work between centers

2) Chuck
3) Collet
4) Face plate
Figure (b) three-jaw chuck

Figure (a) mounting the work between centers

using a "dog” Figure (c) collet
 Cont’d…

Fig. Face plate for holding non-cylinderical

parts
 2. Drilling

— Drilling is a hole making process for which drill is used as a

cutting tool for producing round holes of different sizes and

depths.

— Drilling machines are subjected for drilling holes, tapping,

counter boring, reaming, and general boring operations.

— Drills may be classified into a large variety of types. Twist

drills are the most common tools used in drilling and are made in

many sizes and lengths.

— Lengths range Straight-shank twist drills from 1/60 in diameter

to 11/4 in by1/64; 2in by 1/16 in increment. Taper-shank drills

range from 1/8 in diam to 13/4 in by 1/64 increments.

 Cont’d…

> Configuration of drilling machine:

Work Holding for Drill Presses

• Workpart can be clamped in a vise, fixture, or jig.

—Vise: general purpose workholder with two jaws

—Fixture: workholding device that is usually custom-

designed for the particular workpart

—Drill jig : similar to fixture but also provides a means of

guiding the tool during drilling

 Cont’d….
Through Holes vs. Blind Holes:

— Through-holes - drill exits the opposite side of work

— Blind-holes – drill does not exit work on opposite side

Figure - Two hole types: (a) through-hole, and (b) blind hole
 Cont’d….

1. Upright Drill
— Stands on the floor
3. Radial Drill
2. Bench Drill
— Large drill press
— Similar but smaller and mounted on a table
or bench designed for large parts
 3. Milling
— Through milling process flat and complex shapes are formed by

using multipoint cutting tool.

— The axis of rotation of cutting tool is perpendicular to the direction

of feed. During each revolution of cutting operation the teeth of

milling cutter enter and exit the work piece. Therefore on every

rotation the teeth are subjected to impact force and thermal

shock.
Milling Machine
Rotating multiple-cutting-edge
tool is moved across work to cut a
plane or straight surface.

Two forms: vertical milling and

horzontal milling.

Configuration of milling
machine:
 Different milling types:

Figure - Two forms of milling: (a) peripheral milling, and (b) face milling
Peripheral milling: Face milling:
— Cutter axis is parallel to surface being — Cutter axis is perpendicular to surface being milled
machined — Cutting edges on both the end and outside
— Cutting edges on outside periphery of periphery of the cutter
 Slab Milling:

• The basic form of peripheral

milling in which the cutter width

extends beyond the workpiece on

both sides
Slotting
• Width of cutter is less than workpiece
width, creating a slot in the work

End Milling
• Cutter diameter is less
than work width, so
a slot is cut into part
 4. Grinding:

» Grinding is the most common form of abrasive machining. It is a

material cutting process that engages an abrasive tool whose cutting

elements are grains of abrasive material known as grit.

» These grits are characterized by sharp cutting points, high hot

hardness, chemical stability and wear resistance.

» The grits are held together by a suitable bonding material to give

shape of an abrasive tool.

 Cont’d…
» Grinding machine is employed to obtain high accuracy along with very high

class of surface finish on the work piece. However, advent of new generation of

grinding wheels and grinding machines, characterized by their rigidity, power

and speed enables one to go for high efficiency deep grinding (often called as

abrasive milling) of not only hardened material but also ductile materials.

Fig. Cutting action of abrasive grains

 Cont’d…
• Conventional grinding machines can be broadly classified as:

a) Surface grinding machine

b) Cylindrical grinding machine

c) Internal grinding machine

d) Tool and cutter grinding machine

 Cont’d…

Advantages

— dimensional accuracy

— good surface finish

— good form and locational accuracy

— applicable to both hardened and unhardened material

Applications

— surface finishing

— slitting and parting

— descaling, deburring

— stock removal (abrasive milling) finishing of flat as well as cylindrical surface

— grinding of tools and cutters and re sharpening of the same.

4. Planer Machine
> Used for generating flat surfaces with better accuracy.
> Planer Machine is a machine in which unwanted material is cut
from the workpiece to produce a flat surface on the workpiece.
> Configuration of planer machine:

Main Parts of Planer

Machine are:
— Bed
— Column or Housing
— Table
— Cross Rail
— Tool Head
— Driving
— Feed Mechanism
 Planer Machine Working Principle:

» The worktable can be move and the tool head of the machine is in a

stationary position.

» The workpiece is fixed on the work table and the single point cutting tool

is attached to the tool head and now we switch on the machine that means

power supply to the machine and the worktable moves forward.

» Hence it cuts the material and it is called cutting stroke. The worktable

moves downward there is no cutting of material so this is called the return

stroke. The process will be continued unless you change the power supply
 Cont’d…

Advantges:
The following advantages of Planer Machine as follows:
— It has greater accuracy,

— Good surface finish,

— More than one tool can perform on the workpiece at a time and

— Low maintenance is required.

Disadvantages:
• The following disadvantages of Planer Machine as follows:

— The cost of the machine is on the higher side.

— The power consumption is quite more.

— The skilled worker required.

 Cont’d…

Applications of Planer machine:

The following application of Planer Machine as follows:

— The Planer machine is used for flat surfaces on the

workpiece.

— Cutting angular surfaces is one of the major applications.

— Cutting slots and grooves.

 Cont’d…
5. Shaper Machine
# Shaping machines are machine tools by which chip removal gives workpieces
the desired shape, dimension and surface finish. They produce mainly flat
surfaces, shoulders, grooves and similar shapes.
# The shaper machine is a reciprocating type of machine basically used for
producing the horizontal, vertical or flat surfaces. The shaper holds the single
point cutting tool in ram and workpiece is fixed in the table.
# Configuration of shaper m/c:
 Shaper Machine Working:

» As you can see the above diagram of Shaper machine, the tool is hold by

Ram and workpiece is fixed over table.

» When we switch on the power the ram reciprocates with respect to the

table that means the cutting tool cuts workpiece material in the forward

direction and when moving return there is no cut.

» The cutting process take place at low speed of ram and return stroke take

place at high speed.

» With the use of hand transverse wheel we can do up and down of the table.
 Cont’d…

Advantages:
Disadvantages:
Following Advantages of Shaper are:
— The tool (Single Point cutting tool) The following disadvantages of

cost is low. Shaper Machine:

— The workpiece can be held easily in
— The cutting speed is not much
this machine.
high.
— It produces flat or angular surfaces.
— Setup of Shaper is very easy and tool — Only one cutting tool can be

changing is also easy. fixed. There is no option for

more than one cutting tool.

Applications of shaper M/C:

The following application of Shaper Machine are:

— A shaper Machine is used to make Internal splines.

— It generates straight and flat surfaces either horizontal, vertical or

angular planes.

— It also makes gear teeth.

— Make keyways in pulleys or gears.

— It also produce contour of concave/convex or a combination of these.

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