Subject: BME Unit -II Prof. V.P.

TITARMARE Dated 20/04/2025

Machining Processes Unit-II

Machining is a manufacturing process in which a sharp cutting tool is used to cut away material
to leave the desired part shape. Machining is most frequently applied to shape metals.

Conventional machining, 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. The three principal machining process turning, drilling and milling. the other
machining process includes Shaping, planning, broaching and sawing.
Another group of material removal processes is the abrasive processes, which mechanically
remove material by the action of hard, abrasive particles. this process includes Grinding,
honing, lapping and superfinishing. Finally, the nontraditional processes which use various
energy forms other than a sharp cutting tool or abrasive particles to remove materials. the
energy form include mechanical, electrochemical, thermal and chemical.

Machining is used to convert casting, forgings or performed blocks of metal in to desired

shape, with size and finish specified to fulfill design requirements. Almost every manufacturing
product has component that require machining. Most of the engineering components such as
gears, bearings, clutches, tools, screws and nuts etc. need dimensional and form accuracy and
good surface finish for serving their purposes.

Machining processes are performed on a wide variety of machine tools. Each of the basic
machine tool types has many different configuration. Each process is performed on one or more
basic machine tools. For example, drilling can be performed on drill presses, milling machine,
Lathes and boring machines.

Turning (boring, facing, cutoff, taper turning, form cutting, chamfering, recessing, thread
cutting)
Milling (hobbing, generating, thread milling)
Drilling (reaming, tapping, spot facing, counterboring, countersinking)
Abrasive machining (grinding, honing, lapping)

Lathe is one of the most versatile and widely used machine tools all over the world. It is
commonly known as the mother of all other machine tool.
The main function of a lathe is to remove metal from a job to give it the required shape
and size.
The job is securely and rigidly held in the chuck or in between centers on the lathe machine
and then turn it against a single point cutting tool which will remove metal from the job
in the form of chips.
Figure shows the working principle of lathe. An engine lathe is the most basic and simplest
form of the lathe Besides the simple turning operation as described above, lathe can be
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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

used to carry out other operations also, such as drilling, reaming, boring, taper turning,
knurling, screwthread cutting, grinding etc.

DRILLING
Drilling is an operation of making a circular hole by removing a volume of metal from
the job by cutting tool called drill. A drill is a rotary end-cutting tool with one or more cutting
lips and usually one or more flutes for the passage of chips and the admission of
cutting fluid.
A drilling machine is a machine tool designed for drilling holes in metals. It is one of the
most important and versatile machine tools in a workshop. Besides drilling round holes,
many other operations can also be performed on the drilling machine such as counter-
boring, countersinking, honing, reaming, lapping, sanding etc
This is the operation of making a circular hole by removing a volume of metal from the job by
a rotating cutting tool called drill as shown in Figure. Drilling removes solid metal from the job
to produce a circular hole. Before drilling, the hole is located by drawing two lines at right angle
and a center punch is used to make an indentation for the drill point at the center to help the
drill in getting started.

A suitable drill is held in the drill machine and the drill machine is adjusted to operate at the
correct cutting speed. The drill machine is started and the drill starts rotating. Cutting fluid is
made to flow liberally and the cut is started. The rotating drill is made to feed into the job. The
hole, depending upon its length, may be drilled in one or more steps. After the drilling operation
is complete, the drill is removed from the hole and the power is turned off.

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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

MILLING

A milling machine is a machine tool that removes metal as the work is fed against a rotating
multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast
rate with the help of multiple cutting edges. One or more number of cutters can be mounted
simultaneously on the arbor of milling machine. This is the reason that a milling machine finds
wide application in production work.

Milling machine is used for machining flat surfaces, contoured surfaces, surfaces of
revolution, external and internal threads, and helical surfaces of various cross-
sections. Typical components produced by a milling are given in Figure. In many applications,
due to its higher production rate and accuracy, milling machine has even replaced shapers
and slotters.

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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

Principle of Milling

In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges.
For cutting operation, the workpiece is fed against the rotary cutter. As the workpiece moves
against the cutting edges of milling cutter, metal is removed in form chips of trochoid
shape. Machined surface is formed in one or more passes of the work.

The work to be machined is held in a vice, a rotary table, a three-jaw chuck, an index head,
between centers, in a special fixture or bolted to machine table. The rotatory speed of the
cutting tool and the feed rate of the workpiece depend upon the type of material being
machined.

There are two distinct methods of milling classified as follows:

1. Up-milling or conventional milling, and

2. Down milling or climb milling.

UP-Milling or Conventional Milling Procedure

In the up-milling or conventional milling, as shown in Figure, the metal is removed in form of
small chips by a cutter rotating against the direction of travel of the workpiece. In this
type of milling, the chip thickness is minimum at the start of the cut and maximum at the
end of cut. As a result, the cutting force also varies from zero to the maximum value per tooth
movement of the milling cutter. The major disadvantages of up-milling process are the
tendency of cutting force to lift the work from the fixtures and poor surface finish obtained.
But being a safer process, it is commonly used method of milling.

Down-Milling or Climb Milling

Down milling is shown in Figure. It is also known as climb milling. In this method, the metal is
removed by a cutter rotating in the same direction of feed of the workpiece. The effect of this

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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

is that the teeth cut downward instead of upwards. Chip thickness is maximum at the start
of the cut and minimum in the end. In this method, it is claimed that there is less friction
involved and consequently less heat is generated on the contact surface of the cutter and
workpiece. Climb milling can be used advantageously on many kinds of work to increase the
number of pieces per sharpening and to produce a better finish.

With climb milling, saws cut long thin slots more satisfactorily than with standard milling.
Another advantage is that slightly lower power consumption is obtainable by climb
milling, since there is no need to drive the table against the cutter.

GRINDING

Grinding
Grinding is a material removal process in which abrasive particles arc contained in a
bonded grinding wheel that operates at very high surface speeds. The grinding wheel is
usually disk shaped and is precisely balanced for high rotational speeds.
Grinding wheel
A grinding wheel consists of abrasive particles and bonding material. The bonding material
holds the particles in place and establishes the shape and structure of the wheel.
The way the abrasive grains, bonding material, and the air gaps are structured, determines
the parameters of the grinding wheel, which are
abrasive material,
grain size,
bonding material,
wheel grade, and
wheel structure.
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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

To achieve the desired performance in a given application, each parameter must be

carefully selected.

Bonded abrasive Grinding wheels: Abrasive grains are closely packed into different
shapes, the most common is the abrasive wheel. Grains are held together by bonding
material. Abrasive machining process that uses bonded abrasives includes
grinding, honing, superfinishing.
Abrasive materials
The abrasive materials of greatest commercial importance today are listed in the table:

Grain size
The grain size of the abrasive particle is an important parameter in determining surface
finish and material removal rate. Small grit sizes produce better finishes while larger
grain sizes permit larger material removal rates.
Grain sizes used in grinding wheels typically range between 6 and 600. Grit size 6 is
very coarse and size 600 is very fine. Finer grit sizes up to 1000 are used in some finishing
operations.
Bonding materials commonly used in grinding wheels include the following:

vitrified bond: vitrified bonding material consists chiefly of ceramic materials. Most
grinding wheels in common use are vitrified bonded wheels. They are strong and rigid,
resistant to elevated temperatures, and relatively unaffected by cutting fluids;
rubber bond: rubber is the most flexible of the bonding materials. It is used as a
bonding material in cutoff wheels;
resinoid bond: this bond is made of various thermosetting resin materials. They
have very high strength and are used for rough grinding and cutoff operations;

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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

shellac bond: shellac-bonded grinding wheels are relatively strong but not rigid. They
are often used in applications requiring a good finish;
metallic bond: metal bonds, usually bronze, are the common bond material for
diamond and CBN grinding wheels. Diamond and CBN abrasive grains are bond
material to only the outside periphery of the wheel, thus conserving the costly abrasive
materials.
Grinding wheel specification
Grinding wheels are marked with a standardized system of letters and numbers, which
specifies the parameters of the grinding wheel. Grinding wheels are available in a variety
of shapes and sizes the most popular shown in the figure:

Surface grinding
Surface grinding is an abrasive machining process in which the grinding wheel removes
material from the plain flat surfaces of the workpiece.
In surface grinding, the spindle position is either horizontal or vertical, and the relative
motion of the workpiece is achieved either by reciprocating the workpiece past the
wheel or by rotating it. The possible combinations of spindle orientations and workpiece
motions yield four types of surface grinding processes illustrated in the figure:

Work piece is reciprocating Work piece is Rotating

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Subject: BME Unit -II Prof. V.P. TITARMARE Dated 20/04/2025

Cylindrical grinding

In this operation, the external or internal cylindrical surface of a workpiece are ground. In

external cylindrical grinding (also center-type grinding) the workpiece rotates and reciprocates

along its axis, although for large and long workparts the grinding wheel reciprocates.

In internal cylindrical grinding, a small wheel grinds the inside diameter of the part. The

workpiece is held in a rotating chuck in the headstock and the wheel rotates at very high rotational
speed. In this operation, the workpiece rotates and the grinding wheel reciprocates.

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