Machining Operations-VI

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 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

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 Machining

Cutting action involves shear deformation of

work material to form a chip.
As chip is removed, new surface is exposed.

Figure 21.2 (a) A cross‑sectional view of the

machining process, (b) tool with negative rake angle;
compare with positive rake angle in (a).

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 Diagrammatic Representation of
Material Removal Operations

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10
 Machining Operations

 Machining with single-point tools.

 Machining with multiple-point tools.

 Machining with abrasive wheels.

 Non-conventional machining.

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 Machining Using Single-Point
Cutting Tools

Lathes are designed to rotate the Work piece

and feed the cutting tool in the direction
necessary to generate the required machined
surface.

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 Lathe Operations

Turning
Contour turning
 Facing
 Boring
 External Threading
 Cut-off
Chamfering

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 Turning Operation

Motion:
– Turning work piece along an horizontal axis.
– Linear feeding motion of a tool along two other axes.
Principal surfaces & features:
– Concentric cylindrical outer surfaces & holes.
– Plane surfaces normal to work-piece axis.
– Threaded section of bolts, screws, ...

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 Contour Turning

• Instead of feeding the tool parallel to the

axis of rotation, tool follows a contour that is
not necessarily straight (thus creating a
contoured form).

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 Facing

• Facing is the process of removing metal from the end of

a work piece to produce a flat surface.

• Most often, the work piece is cylindrical but using a 4-jaw

chuck you can face rectangular or odd shaped work to
form cubes and other non cylindrical shapes.

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 Boring

To enlarge a hole or cylindrical cavity made by a previous

process or to produce circular internal grooves

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 Horizontal Boring Operations

Motion:
–Work piece secured on a stationary horizontal table
– Turn and feeding motion of a tool on a horizontal ram
Principal surfaces & features:
– Large cylindrical hole

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 Vertical Boring Operations

Motion:
Turning work-piece in a horizontal plane
Linear feeding motion of a tool along two axes in the plane

Principal surfaces & features:

Large cylindrical inner or outer surface

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 Shaping Operations

Motion:
Linear (quick return) motion of tool, horizontal or vertical.
Stable work piece.

Principal surfaces & features:

Shaper is a machine tool which produces flat surfaces in
horizontal, vertical or inclined planes depending upon the
orientation of the cutting tool.
Tool is clamped in the tool post mounted on the ram of the
machine. Tool cuts the material in the forward stroke, no
cutting during return stroke.
Job is held rigidly in a vice.

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 • Shaper is defined as a process for removing metal
surfaces in horizontal, vertical and angular planes by
the use of a single point cutting tool.

• Producing a flat or plane surface which may be in a

horizontal, vertical or an angular plane.

• Making slots, grooves and keyways.

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 Cut-Off

Tool is fed radially into rotating work at some

location to cut off end of part or provide a
groove.

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 Chamfering

Cutting edge cuts an angle on the corner of the

cylinder, forming a “chamfer”.

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 External Threading

• A screw thread on the outside of a cone or cylinder

(such as the thread on a plug gage)
• Pointed form tool is fed linearly across surface of
rotating work part parallel to axis of rotation at a large
feed rate, thus creating threads

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 Machining Using Multipoint Tools

•Milling
•Drill
•Broaching

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 Drilling

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 Horizontal Milling

Motion:
– Turning tool along a horizontal axis.
– Linear feeding motion by work-piece.

Principal surfaces & features:

– Accurate large plane surface.
– Partial circular surface.
– Special features with special tools

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 Vertical Milling

Motion:
– Turning tool moving vertically.
– Linear feeding motion by work-piece.

Principal surfaces & features:

– Accurate large plane surface.
– Partial circular surface.
– Large cylindrical hole.
– Special features with special tools.

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 Broaching Operations

Motion:
– Tool reciprocating vertically.
– Linear feeding motion by work-piece.
Principal surfaces & features:
– Long concave slot on an outer surface.
– Special slots with special tools.

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 Grinding with Abrasive Tools

Surface grinding with rotating abrasive tools

• Machine types:
– Vertical grinder
– Horizontal grinder
– Horizontal internal grinder

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Non-conventional Machining Processes

Non-conventional machining process refer to

a group of processes that removes excess of
material by various techniques involving
different forms of energies( Like mechanical,
thermal, electrical, chemical or combination of
these energies). They don’t use sharp cutting
tool like conventional machining.

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 Ultrasonic Machining

Ultrasonic machining:
– Piezoelectric transducer to generate a HF motion(20 ~ 40 kHz).
– Abrasive slurry between tool and work piece to form a cavity.

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 Water Jet Machining

• Water jet machining:

– Pressurized water thru a nozzle of .07 to .5 mm.
– To drill a hole or slit a sheet material.

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 Abrasive- Jet Machining

• Abrasive-jet machining:
– Eroding action of high-velocity stream of abrasive gas.

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 Electric Discharge Machining

Electrical-discharge machining:
– Repetitive spark discharge

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 END

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