Lecture 1

Introduction to Manufacturing and

Machining
 What is manufacturing process?
The process of converting raw materials into finished products.

There are various manufacturing methods

Casting, welding, Forming, conventional machining, non-conventional machining and rapid

prototyping.

Raw materials Shape and size

Manufacturing
Product
Process
Manufacturing Processes

Manufacturing
Processes: Casting
 Manufacturing
Processes: Casting
Manufacturing Processes

Manufacturing
Processes: Welding

https://youtu.be/ywzib5Ocyn0
Manufacturing Processes:
Welding
 Extrusion

Manufacturing Processes:
Forming
Manufacturing Processes
Machining is the process of producing a work piece by removing unwanted material from a block of metal, in the
form of chips.

Manufacturing
Processes: Machining

(e) Grinding
What is Machining?
• It is a process of producing a product or a component by removal of
material in the form of chips using a tool
 Importance of Machining Process

1. Improve the dimensional accuracy & tolerance of

the components produced

2. Internal & external surface features can easily

produced
Machined Parts
3. Specified surface characteristics or texture can be
achieved on a part

4. May be economical to produce a component

Micro Machined Parts

Machining as a system
• It consists of
Workpiece

Cutting tool

Tool holder

Work holding devices and

Machine tools
Machining Requirements

Fig : Represents the essential requirements for machining work

 Classification of Machining Process

Machining or Cutting Processes – material removal by a sharp cutting tool,

e.g., turning, milling, drilling, boring, reaming etc.,

Abrasive processes – material removal by hard, abrasive particles, e.g.,

grinding, lapping, honing etc.,

Non-traditional Processes or Special Processes - various energy forms other

than sharp cutting tool to remove material.
Classification of Machining Process
Examples of Machining Processes
 Basic Elements of Machining
The Basic Elements of Machining Operations are

 Work piece

 Cutting Tool

 Chip
 Brief not on machining parameters
Feed, Speed, and Depth of Cut

• Cutting speed is defined as the speed at which the work moves with respect to
the tool. It is usually expressed in m/min.

• Feed rate is defined as the distance the tool travels during one revolution of
the part. It is usually expressed in mm/rev.

• Depth of cut is the amount of material to be removed. It is usually expressed

in mm.
Next Lecture – Chip Formation

• Mechanism of chip formation

• Types of chip formation – Conditions, Advantages & disadvantages
1. Continuous chip
2. Discontinuous chip
3. Serrated Chips
4. Continuous chip with Built-up Edge (BUE)
• Chip breakers