Mechanical Engineering B.

E V SEM

DIGITAL NOTES

Manufacturing Techniques
5ME05 - Open Elective-I

Unit - II

B.E –III Year – V Semester

DEPARTMENT OF MECHANICAL ENGINEERING

Dr. Sau. Kamaltai Gawai Institute of Engineering

and Technology,
Darapur, Tq- Darapur Dist:- Amravati (M.S)
Pin-444814
(Affiliated to SGBAU, Amravati, Approved by AICTE –Accredited NAAC-“B” )

Department Of Mechanical Engineering, KGIET. 1

Mechanical Engineering B. E V SEM

Dr. Sau. Kamaltai Gawai Institute of Engineering and Technology, Darapur,

Tq- Darapur Dist:- Amravati (M.S) Pin-444814 (MS)

COURSE LEARNING OBJECTIVES

1. To study the fundamentals of different manufacturing processes and various activities in manufacturing.
2. To study the fundamentals of metals & alloys, properties of engineering materials like ferrous, non-
ferrous metals and their alloys
3. To study different machine tools. cutting tools used in machine shop , various operations performed with
working principles of these machine tools
4. To study the activities related to mechanical working of metals, various hot working & cold working
operations fundamentals of metal forming ; sheet metal working processes with different tools and equipment
5. To study the necessary details regarding pattern making, molding, core making and casting with foundry
tools & equipment, also melting practice by cupola furnace.
6. To study different Joining processes, basic terms of welding processes tike arc welding, gas welding,
Resistance welding. friction welding , soldering ; brazing processes with tools & processes.
7. To study the methods of producing metal powders 8. To study plastic part manufacturing by different
processes like extrusion. Injection, blow, compression, and transfer moulding processes.
COURSE OUTCOMES:
1. Apply the knowledge of various manufacturing techniques and its applications in engineering.
2. Understand the knowledge of machining operations, sheet metal working and processes.
3. Students will show the ability to apply various joining methods in practice.
4. Students will exhibit the knowledge of powder metallurgy.

Unit II : Introduction to cutting type shaping processes, Basic concept of metal

cutting, Types of cutting tools, Orthogonal & oblique cutting, General purpose
machines Vs Special purpose machines. (8Hrs)

Unit II : Introduction to cutting type shaping processes, Basic concept of metal cutting,
Types of cutting tools, Orthogonal & oblique cutting, General purpose machines Vs
Special purpose machines. (8Hrs)

Department Of Mechanical Engineering, KGIET. 2

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UNIT -2
Introduction to cutting type shaping processes.

Machining is not just one process; it is a group of processes. The common feature is the use of a cutting
tool to form a chip that is removed from the workpart. To perform the operation, relative motion is required
between the tool and work. This relative motion is achieved in most machining operations by means of a
primary motion, called the cutting speed, and a secondary motion, called the feed. The shape of the tool and
its penetration into the work surface, combined with these motions, produces the desired geometry of the
resulting work surface.
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 ‘‘family tree’’ is
shown in Figure 21.1. 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’’ include shaping,
planing, broaching, and sawing.
Another group of material removal processes is
the abrasive processes, which mechanically remove
material by the action of hard, abrasive particles. The
‘‘other abrasive processes’’ include honing, lapping,
and super finishing. Finally, there are the nontraditional
processes, which use various energy forms other
than a sharp cutting tool or abrasive particles to remove
material. The energy forms include mechanical,
electrochemical, thermal, and chemical.

Machining is a manufacturing process in which

a sharp cutting tool is used to cut away material to
leave the desired part shape. The predominant cutting
action in machining involves shear deformation of the
work material to form a chip; as the chip is removed, a
new surface is exposed. Machining is most frequently applied to shape metals. The process is illustrated in
the diagram of Figure 21.2. Machining is one of the most important manufacturing processes. The
Industrial Revolution and the growth of the manufacturing-based economies of the world can be traced
largely to the development of the various machining operations.

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Machining is important commercially and technologically for several reasons:

 Variety of work materials. Machining can be applied to a wide variety of work materials. Virtually
all solid metals can be machined. Plastics and plastic composites can also be cut by machining.
Ceramics pose difficulties because of their high hardness and brittleness; however, most ceramics
can be successfully cut by the abrasive machining processes.
 Variety of part shapes and geometric features. Machining can be used to create any regular
geometry, such as flat planes, round holes, and cylinders. By introducing variations in tool shapes
and tool paths, irregular geometries can be created, such as screw threads and T-slots. By
combining several machining operations in sequence, shapes of almost unlimited complexity and
variety can be produced.
 Dimensional accuracy. Machining can produce dimensions to very close tolerances. Some
machining processes can achieve tolerances of _0.025 mm (_0.001 in), much more accurate than
most other processes.
 Good surface finishes. Machining is capable of creating very smooth surface finishes. Roughness
values less than 0.4 microns (16 m-in.) can be achieved in conventional machining operations.
Some abrasive processes can achieve even better finishes. On the other hand, certain disadvantages
are associated with machining and other material removal processes:
 Wasteful of material. Machining is inherently wasteful of material. The chips generated in a
machining operation are wasted material. Although these chips can usually be recycled, they
represent waste in terms of the unit operation.
 Time consuming. A machining operation generally takes more time to shape a given part than
alternative shaping processes such as casting or forging.

Machining is generally performed after other manufacturing processes such as casting or bulk
deformation (e.g., forging, bar drawing). The other processes create the general shape of the starting
workpart, and machining provides the final geometry, dimensions, and finish.

Basic concept of metal cutting.

There are many kinds of machining operations, each of which is capable of generating a certain part
geometry and surface texture. Now it is appropriate to identify and define the three most common types:
turning, drilling, and milling, illustrated in Figure 21.3. In turning, a cutting tool with a single cutting edge
is used to remove material from a rotating work piece to generate a cylindrical shape, as in Figure
21.3(a).The speed motion in turning is provided by the rotating workpart, and the feed motion is achieved
by the cutting Tool moving slowly in a direction parallel to the axis of rotation of the work piece. Drilling
is used to create a round hole. It is accomplished by a rotating tool that typically has two cutting edges. The
tool is fed in a direction parallel to its axis of rotation into the workpart to form the round hole, as in Figure
21.3(b). In milling, a rotating tool with multiple cutting edges is fed slowly across the work material to
generate a plane or straight surface. The direction of the feed motion is perpendicular to the tool’s axis of
rotation. The speed motion is provided by the rotating milling cutter. The two basic forms of milling are
peripheral milling and face milling, as in Figure 21.3(c) and (d). Other conventional machining operations
include shaping, planing, broaching, and sawing (Section 22.6). Also, grinding and similar abrasive
operations are often included within the category of machining. These processes commonly follow the
conventional machining operations and are used to achieve a superior surface finish on the workpart.

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Types of cutting tools –

A cutting tool has one or more sharp cutting edges and is made of a material that is harder than the
work material. The cutting edge serves to separate a chip from the parent work material, as in Figure 21.2.
Connected to the cutting edge are two surfaces of the tool: the rake face and the flank. The rake face, which
directs the flow of the newly formed chip, is oriented at a certain angle called the rake angle a. It is
measured relative to a plane perpendicular to the work surface. The rake angle can be positive, as in Figure
21.2(a), or negative as in (b). The flank of the tool provides a clearance between the tool and the newly
generated work surface, thus protecting the surface from abrasion, which would degrade the finish. This
flank surface is oriented at an angle called the relief angle. Most cutting tools in practice have more
complex geometries than those in Figure 21.2. There are two basic types, examples of which are illustrated
in Figure 21.4: (a) single-point tools and (b) multiple-cutting-edge tools. A single-point tool has one cutting
edge and is used for operations such as turning. In addition to the tool features shown in Figure 21.2, there
is one tool point from which the name of this cutting tool is derived. During machining, the point of the
tool penetrates below the original work surface of the part. The point is usually rounded to a certain radius,
called the nose radius. Multiple-cutting-edge tools have more than one cutting edge and usually achieve
their motion relative to the workpart by rotating. Drilling and milling use rotating multiple-cutting-edge
tools. Figure 21.4(b) shows a helical milling cutter used in peripheral milling. Although the shape is quite
different from a single point tool, many elements of tool geometry are similar.

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Cutting Conditions - Relative motion is required between the tool and work to perform a machining
operation. The primary motion is accomplished at a certain cutting speed v. In addition, the tool must be
moved laterally across the work. This is a much slower motion, called the feed f. The remaining dimension
of the cut is the penetration of the cutting tool below the original work surface, called the depth of cut d.
collectively; speed, feed, and depth of cut are called the cutting conditions. They form the three dimensions
Of the machining process and for certain operations (e.g., most single-point tool operations) they can be
used to calculate the material removal rate for the process:
RMR = v.f.d
3 3
Where RMR= material removal rate,mm /s (in /min); v= cutting speed, m/s (ft/min), which must be
converted to mm/s (in/min); f = feed, mm (in); and d = depth of cut, mm (in).

The cutting conditions for a turning operation are depicted in Figure 21.5. Typical units used for cutting
speed are m/s (ft/min). Feed in turning is expressed in mm/rev (in/rev), and depth of cut is expressed in mm
(in). In other machining operations, interpretations of the cutting conditions may differ. For example, in a
drilling operation, depth is interpreted as the depth of the drilled hole. Machining operations usually divide
into two categories, distinguished by purpose and cutting conditions: roughing cuts and finishing cuts.
Roughing cuts are used to remove large amounts of material from the starting workpart as rapidly as
possible, in order to produce a shape close to the desired form, but leaving some material on the piece for a
subsequent finishing operation. Finishing cuts are used to complete the part and achieve the final
dimensions, tolerances, and surface finish. In production machining jobs, one or more roughing cuts are
usually performed on the work, followed by one or two finishing cuts. Roughing operations are performed
at high feeds and depths—feeds of 0.4 to 1.25 mm/rev (0.015–0.050 in/rev) and depths of 2.5 to 20 mm
(0.100–0.750 in) are typical. Finishing operations are carried out at low feeds and depths—feeds of 0.125
to 0.4 mm(0.005–0.015 in/rev) and depths of 0.75 to 2.0mm(0.030–0.075 in) are typical. Cutting speeds are
lower in roughing than in finishing.
A cutting fluid is often applied to the machining operation to cool and lubricate the cutting tool
(cutting fluids are discussed in Section 23.4). Determining whether a cutting fluid should be used, and, if
so, choosing the proper cutting fluid, is usually included within the scope of cutting conditions. Given the
work material and tooling, the selection of these conditions is very influential in determining the success of
a machining operation.
Theory of Chip Formation In Metal Machining
In a cutting process, the position of cutting edge of the tool with respect to the work piece is important,
based on which metal cutting process are classified into two categories.
 Orthogonal cutting
 Oblique cutting
Orthogonal cutting also called two-dimensional cutting process. While the oblique cutting known as a
three-dimensional cutting process.
Orthogonal cutting
In orthogonal cutting, the cutting edge inclination is zero and chip is expected to flow along the orthogonal
plane. The cutting tool is presented to the workpiece in such a way that the cutting edge is normal to the
tool feed direction. In orthogonal cutting, the radial force is zero, and it involves only two component of
force; this simplifies the analysis of cutting motion.
Oblique cutting
In oblique cutting, chip flow deviates from the orthogonal plane. Tool is presented to workpiece at an acute
angle (θ < 90°) to the tool feed motion. The analysis of cutting includes three mutually perpendicular
component of force and it is being very difficult to analyses.

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Formation of the chip depends on the type of material being machined and the cutting conditions of the
operation. Four basic types of chip can be distinguished, illustrated in Figure 21.9:
 Discontinuous chip. When relatively brittle materials (e.g., cast irons) are machined at low cutting
speeds, the chips often form into separate segments (sometimes the segments are loosely attached).
This tends to impart an irregular texture to the machined surface. High tool–chip friction and large
feed and depth of cut promote the formation of this chip type.
 Continuous chip. When ductile work materials are cut at high speeds and relatively small feeds and
depths, long continuous chips are formed. A good surface finish typically results when this chip
type is formed. A sharp cutting edge on the tool and low tool–chip friction encourage the formation
of continuous chips. Long, continuous chips (as in turning) can cause problems with regard to chip
disposal and/or tangling about the tool. To solve these problems, turning tools are often equipped
with chip breakers.
 Continuous chip with built-up edge. When machining ductile materials at low-to-medium cutting
speeds, friction between tool and chip tends to cause portions of the work material to adhere to the
rake face of the tool near the cutting edge. This formation is called a built-up edge (BUE). The

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formation of a BUE is cyclical; it forms and grows, then becomes unstable and breaks off. Much of
the detached BUE is carried away with the chip, sometimes taking portions of the tool rake face
with it, which reduces the life of the cutting tool. Portions of the detached BUE that are not carried
off with the chip become imbedded in the newly created work surface, causing the surface to
become rough.
 Serrated chips (the term shear-localized is also used for this fourth chip type). These chips are
semi-continuous in the sense that they possess a saw-tooth appearance that is produced by a cyclical
chip formation of alternating high shear strain followed by low shear strain. This fourth type of chip
is most closely associated with certain difficult-to-machine metals such as titanium alloys, nickel-
base super alloys, and austenitic stainless steels when they are machined at higher cutting speeds.
However, the phenomenon is also found with more common work metals (e.g., steels) when they
are cut at high speeds.

General purpose machines Vs Special purpose machines.

End of Unit - 2