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Importance of Material Removal Processes

➢ Importance of metal removal processes can be appreciated by observing nearly
every device having one or more machined surfaces or holes
Fundamentals of Machining ➢ There are several reasons for developing a rational approach towards material
removal processes, some of them are as below:
➢ It can be applied to wide variety of materials
➢ Can produce a variety of shapes and geometric features
➢ Dimensional accuracy
➢ Good surface finish
➢ Some limitations of machining
➢ Produces lot of waste
➢ Time consuming

➢ CLASSIFICATION OF METAL REMOVAL PROCESSES

➢ Metal cutting
➢ Grinding
➢ Advanced material removal processes
Sunny Zafar
School of Engineering
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What is machining? Purpose and principle of machining

➢ Casting imposes severe problems from materials properties and
Job Blank accuracy
Excess material ➢ Forming becomes impractical when job is too large
➢ Both methods (casting and forming) not suitable for geometrically
complex jobs.
Cutting tool
CM FM ➢ Purpose of machining: To enable the finished product to fulfil the
functional requirements, good performance and provide longer service
life.
➢ Principle of machining: Remove excess material in form of small chips
➢ Machining is conversion of raw material in to final product (with desired (layer by layer fashion)
shape, size and finish) by removal of excess material (from the blank) in
the form of small chips.
➢ A cutting tool removes the excess material from the blank through
physical contact.
Remove the top layer
➢ A machine tool provides the necessary relative motions between the strip by strip
tool and work piece.
Work piece

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Definitions Classification of machining processes

➢ Machining: It is an essential process of finishing by which job of Machining processes
desired dimensions and surface finish are produced by gradually
removing excess material from a preformed blank in the form of chips
with help of a cutting tool moved past the work piece.
Conventional machining Non-conventional machining
➢ Machine tool: A machine tool is a non-portable power operated
reasonably valued device or a system of device in which energy is
expended to produce job of desired shape and size; shape; finish by Electric discharge
Chemical
roving the excess material from preformed blanks in form of chips using Cutting Mechanical abrasion Abrasive jet
a cutting tool. Water jet
Laser beam
Electron beam
Circular Various Bonded Loose Ultrasonic
shapes shapes abrasives abrasives Plasm beam
Electro chemical
Turning Milling Grinding Polishing
Boring Planning Honing Buffing
Drilling Shaping
Broaching
Sawing
Gear forming/
generating
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Machining operations and part geometry Machining operations and part geometry
➢ Machining operations produce parts by following methods: ➢ Relative motion between tool and workpiece
➢ Relative motion between tool and workpiece ➢ Forming: Part geometry → shape of the cutting tool
➢ Generating: Part geometry → trajectory of the cutting tool

Fig: Forming to create shape in machining: (a) form turning, (b) drilling, and (c) broaching
Fig: Generating shape in machining: (a) straight turning, (b) taper turning, (c) contour turning, (d)
plain milling, and (e) profile milling 7 8

Machining operations and part geometry Lathe machine

➢ Relative motion between tool and workpiece ➢ It is a versatile machine tool, manually operated, and widely used in low
➢ Combination of generation and forming: Part geometry → shape of the cutting tool and medium production. The term engine dates from the time when
these machines were driven by steam engines.

Fig: Combination of forming and generating to create shape: (a) thread cutting on a lathe,
and (b) slot milling.
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CNC lathe machine Some operations on lathe machine

➢ On a CNC machine it is possible to make hundreds or even thousands ➢ Facing: The tool is fed radially into the rotating work on one end to create a flat
of the same item in a day. First a design is drawn using design software, surface on the end.
then it is processed by the computer and manufactured using the CNC
machine.

➢ Taper turning: Tool is fed at an angle, thus creating a tapered cylinder or conical
shape.

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Some operations on lathe machine Some operations on lathe machine

➢ Contour turning: Tool follows a contour that is other than straight, thus creating a ➢ Chamfering: The cutting edge of the tool is used to cut an angle on the corner of
contoured form in the turned part. the cylinder, forming what is called a ‘‘chamfer.

➢ Form turning: In this operation, sometimes called forming, the tool has a shape ➢ Cutoff: The tool is fed radially into the rotating work at some location along its
that is imparted to the work by plunging the tool radially into the work. length to cut off the end of the part. This operation is sometimes referred to as
parting.

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Some operations on lathe machine Some operations on lathe machine

➢ Threading: A pointed tool is fed linearly across the outside surface of the ➢ Drilling: Drilling can be performed on a lathe by feeding the drill into the rotating
rotating workpiece in a direction parallel to the axis of rotation at a large work along its axis. Reaming can be performed in a similar way.
effective feed rate, thus creating threads in the cylinder.

➢ Boring: A single-point tool is fed linearly, parallel to the axis of rotation, on the
inside diameter of an existing hole in the part. ➢ Knurling: Used to produce a regular crosshatched pattern in the work surface.
Sometimes not considered as machining operation

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Lathe machine Drill machine

➢ Methods to hold the job on the lathe machine ➢ Drilling, is a machining operation used to create a round hole in a
workpiece.
➢ 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.

Fig: Work holding methods used in lathes: (a) mounting the work between centers using a Fig: Two hole types: (a) through hole and (b) blind hole.
dog, (b) three-jaw chuck, (c) collet, and (d) faceplate for noncylindrical workparts.
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Drilling Drilling
➢ Operations related to drill machine ➢ Operations related to drill machine
➢ Reaming: Reaming is used to slightly enlarge a hole, to provide a better ➢ Tapping: This operation is performed by a tap and is used to provide internal
tolerance on its diameter, and to improve its surface finish. The tool is called a screw threads on an existing hole.
reamer, and it usually has straight flutes.

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Drilling Drilling
➢ Operations related to drill machine ➢ Operations related to drill machine
➢ Counterboring: Counterboring provides a stepped hole, in which a larger ➢ Countersinking: This is similar to counterboring, except that the step in the hole
diameter follows a smaller diameter partially into the hole. A counterbored hole is cone-shaped for flat head screws and bolts.
is used to seat bolt heads into a hole so the heads do not protrude above the
surface.

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Drilling Drilling
➢ Operations related to drill machine ➢ Operations related to drill machine
➢ Centering: Also called center drilling, this operation drills a starting hole to ➢ Spot facing: Spot facing is similar to milling. It is used to provide a flat machined
accurately establish its location for subsequent drilling. The tool is called a surface on the work part in a localized area.
center drill

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Milling Milling
➢ Milling is a machining operation in which a workpiece is fed past a ➢ Milling is an interrupted cutting operation; the teeth of the milling cutter
rotating cylindrical tool with multiple cutting edges. enter and exit the work during each revolution.
➢ Orientation between the tool axis and the feed direction is one of the ➢ This interrupted cutting action subjects the teeth to a cycle of impact
features that distinguishes milling from drilling. The cutting tool in milling force and thermal shock on every rotation.
is called a milling cutter and the cutting edges are called teeth.
➢ Milling machine

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Milling Milling
➢ Operations related to milling machine ➢ Types of peripheral milling
➢ Peripheral Milling In peripheral milling, also called plain milling, the axis of the ➢ Slab milling: the basic form of peripheral milling in which the cutter width
tool is parallel to the surface being machined, and the operation is performed by extends beyond the workpiece on both sides.
cutting edges on the outside periphery of the cutter.

➢ Slotting: (also called slot milling), The width of the cutter is less than the
workpiece width, creating a slot in the work—when the cutter is very thin, this
operation can be used to mill narrow slots or cut a workpiece in two, called saw
milling

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Milling Milling
➢ Types of peripheral milling ➢ Types of peripheral milling
➢ Side Milling: in which the cutter machines the side of the workpiece ➢ Form milling: Milling teeth have a special profile that determines the shape of
the slot that is cut in the work. Form milling is therefore classified as a forming
operation

➢ Straddle milling: Same as side milling, only cutting takes place on both sides of
the work

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Milling Milling
➢ Operations related to milling machine ➢ Operations related to milling machine
➢ In face milling, the axis of the cutter is perpendicular to the surface being milled, ➢ Types of face milling.
and machining is performed by cutting edges on both the end and outside
periphery of the cutter

Fig: Face milling: (a) conventional Face milling,(b)partial face milling, (c) end milling,
(d) profile milling, (e) pocket milling, and (f) surface contouring.
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Milling Some operations on milling machine

➢ Up milling and down milling
➢ Up milling: also called conventional milling, the direction of motion of the cutter
teeth is opposite the feed direction when the teeth cut into the work. It is milling
‘‘against the feed.’’
➢ Down milling: also called climb milling, the direction of cutter motion is the same
as the feed direction when the teeth cut the work. It is milling ‘‘with the feed.”

Fig: Two forms of peripheral milling operation with a 20-teeth cutter: (a) up
milling, and (b) down milling. 33

Shaper
➢ Shaping involves the use of a single-point cutting tool moved linearly
relative to the workpiece.
➢ In shaping, a straight, flat surface is created by this action.

Thanks!

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