Department of Mechanical Engineering

Faculty of Engineering

ADVANCED MANUFACTURING
TECHNOLOGY
(MEN 808)

Module Developer:

Engr. Dr Julius Thaddaeus

 Course Content

Basic metal removal processes

Introduction to the mechanics of the processes
Economics of simple processes
Introduction to machine selection, flexibility, and automation.
Organization of manufacturing, process planning, group
technology, facilities layout, and production scheduling
 CHAPTER ONE
Basic metal removal
processes

1.1 Introduction
 Machining, also known as the metal removal process, involves the controlled removal of unwanted
material from a workpiece to achieve the desired shape, size, and surface finish.
 It is widely used in manufacturing for both creating finished products and processing raw materials.
 Complex parts often require multiple machining processes in combination.
 While machining is commonly associated with metals, it is also applied to materials such as wood,
glass, plastics, and ceramics
 Chapter One cont.
 Single Point Cutter vs Multi-Point Cutter
 Chapter One cont.

1.2 Classifications
 Machining processes can be classified into conventional machining (macro and micro), abrasive finishing, and non-
traditional machining (NTM) as shown in Figure 1 .

Figure 1: Classification of Machining Processes

 Chapter One cont.

1.2.1 Conventional Machining

 Also known as traditional machining in manufacturing, this process involves the use of cutting tools to remove excess
materials from a workpiece on direct contact.
 Chapter One cont.

1.2.2 Abrasive Processes

 Abrasive machining is a material removal process that uses abrasives—small, hard particles
such as aluminum oxide or silicon carbide—to grind away material from a workpiece’s surface.
It is highly versatile and can be applied to various materials, including metals, ceramics, and
composites.
 Chapter One cont.

1.2.3 Nontraditional Machining

 These machining techniques utilize heat or force for material removal/erosion. They more
are modern with high precision.
 Chapter One cont.

1.3 Chip Formation

 A metal chip is a fragment or piece of metal produced during machining
or metal working processes, typically due to material removal from a
workpiece.
 These metal chips, produced during machining processes, are a tangible
representation of the material being removed from the workpiece, serving
as a critical indicator of the cutting process's efficiency and effectiveness
 Chapter One cont.

 The type of chip produced in a particular operation depends on the following:

o properties of material cut (i.e. ductile or brittle)
o the cutting speed
o depth of cut
o feed rate
o rake angle
o type and way of application of the cutting fluid
o surface roughness of the tool face
o coefficient of friction b/w the chip and tool interface
o Temperature of the chip on tool face
o Nature of cutting i.e. continuous or intermittent
 Chapter One cont.

 Types of Chips
 Chapter One cont.

 Types of Chips
 CHAPTER TWO
Introduction to Mechanics
of Machining

2.1 Tool Terminologies and Geometry

 The cutting tool is the key element in machining where metal
removal is required for whatsoever reason.
 For best output and optimum performance with minimum efforts and
work input, the cutting tool is designed in a specific way.
 There are various terms associated with the design of the cutting tool.
 Chapter Two cont.

 The geometry and terminology of a single point cutting tool is given:

 Chapter Two cont.
2.2 Orthogonal and Oblique Cutting
 Orthogonal and oblique cutting are two fundamental
concepts in machining and metal cutting processes.
 They describe the orientation and angle at which a
cutting tool engages with a workpiece material, such as
metal or wood.
 The main difference between orthogonal and oblique
cutting is the angle between the cutting tool and the
workpiece
Chapter Two cont.
Chapter Two cont.
 Chapter Two cont.
2.3 Turning Forces
 Chapter Two cont.
 The figure above represents an oblique turning force since the principal cutting
edge ab makes an angle with the direction of feed.
 The cutting force is R which can be resolved into three mutually perpendicular
directions:
In the direction of feed of the tool, represented by Fd, also called feed force, It
remains tangential to the generated surface.
In the direction perpendicular to feed direction, represented by Fr, also called
the thrust force. It is in radial direction and considered due to reaction
between the tool and the workpiece
In the vertical direction, represented by Fc, also called the main cutting force.
It is in the direction of movement of the tool.
 Chapter Two cont.
 Force Circle Diagram on cutting interface
 Chapter Two cont.
 In
this orthogonal machining process, the cutting forces have two
components. Only one in the feed direction, Fd and the other in the
direction of cutting Fc. So, all discussion in this course will focus on
only two components of forces.
 F is the frictional resistance of the chip acting on the tool.
 Force N is the reaction provided by the tool, acting in a direction normal to
the rake face of the tool
 Force Fs is the shear force of the metal, also called the resistance of the metal
to shear in forming the chip
 Force Fa is normal to the shear plane, also called the backing up force
provided by the workpiece on the chip
 Chapter Two cont.

Forces from Merchant Theory

 Friction force,
 Normal force,
 Shear force,
 Force normal to shear plane,
 Resultant force, =
 Coefficient of friction,
 Chapter Two cont.
 Stresses
 Shear stress is the shear strength of work material during cutting. During metal
cutting, the chips are produced due to the plastic deformation of the metal along the
shear plane.

 On the shear plane

Normal stress,
Shear stress,
 On the tool rake face
 Chapter Two cont.
2.4 Cutting Parameters
 Chapter Two cont.
 Chip thickness ratio,
Where, t = dept of cut in shaping and planning (feed, s,
turning)

Shear Angle, tan

 Velocity ratio,
Chapter Two cont.

But,
where, r = velocity ratio
= cutting velocity
= velocity of chip flow
Thus,
 Chapter Two cont.
Energy of Cutting Process
 Work done,
where, Cutting force
= Cutting velocity
 Horse power required for cutting in kW,

Where, = Gross horse power of the motor in kW

= Tare horse power (horse power consumed while running idle)
 Chapter Two cont.
 Overall efficiency of machine tool,

Where,

 Stress and Strain in the Chip

 Shear Stress
Shear stress is the shear strength of work material during cutting.
During metal cutting, the chips are produced due to the plastic
deformation of the metal along the shear plane.
 Chapter Two cont.

 Shear stress acting along the shear plane is given as:

Where, = area of the shear plane

original chip thickness (cut depth); :

width (feed)
 Chapter Two cont.
 Shear Strain ():
 Chapter Two cont.
1. The dynamometer recorded the following: feed force 200kg, cutting
force 300kg. The rake angle of the tool used was 10. The chip
thickness ratio 0.35. Find.
 Shear angle
 Shear force
 Co-efficient of friction at the chip tool interface and the
friction angle
 Compressive force at the shear
 Chapter Two cont.

Solution
 Shear angle
tan 0.367
Thus, 0.367 = 20.15o
 Shear force
= 84kg
 Normal force
= 288kg
 Chapter Two cont.

 Coefficient of friction
0.952
Thus, 0.952 = 43.59o
2. A seamless tube 3cm outside diameter is reduced in length on a lathe with the help of a
single point cutting tool. The cutting speed is 40m/min and the depth of cut is 0.125mm.
The length of the continuous chip, for the revolution of the tube on measurement comes to
be 17.77cm. The cutting force is 200kg and the feed force is 75kg. The rake angle of the
tool is 35o
Chapter Two cont.
 Chapter Two cont.

3. During the machining of AISI-1025 steel, with 0-10-6-6-8-90-1 mm. ORS shaped tool the following
observations were taken:
 Feed: 0.5mm
 Depth of cut: 2mm
 Cutting speed: 40m/min
 Shear angle: 20o
 The power consumed while machining: 3kW
 The power consumed while running idle: 0.5kW
Calculate:
 The cutting force
 Chip thickness ratio
 Normal pressure on the chip
 Chip thickness
 CHAPTER THREE
Economic of Simple
Processes
1.1 Introduction
 Design and operation of a manufacturing system must be based on economic considerations. It is always
desirable to perform a machining operation at minimum possible cost but satisfying all requirements of the
machined components.
 In real life, a component undergoes many kinds of operations like drilling, milling, etc. However, to understand
the procedure, a simple case of single pass turning has been described here. Although more practical case is of
multipass turning.
 The procedure is to develop a model (or equation) for the given kind of problem, differentiate it with respect to
feed rate or cutting speed, and then solve it to evaluate optimum cutting parameters (feed or speed)
 Chapter Three cont.

 It is not enough to suggest a feasible procedure to manufacture

the desired component, but the procedure should also be
economically justified and there are several variables that affect
the economics of a machining operation. These variables are:
 tool material and tool geometry,
 machine tool capacity (power, force, size, etc.), and
 cutting conditions (speed, feed and depth of cut).
 Chapter Three cont.
 In general, the lowest cost per component consideration leads to lower production rate.
Sometimes, optimization process may give the machining conditions which may be
beyond the capabilities of the available machine tool. Hence, in selecting the economic
operating conditions, machine tool capacities must be taken into account.
 If the selected conditions are not available on the machine tool proposed for a particular
operation, it is necessary to either change the operating conditions or review the machine
tool selection by cost comparison.
 One should not select the machine tool of the capacity higher than the desired one. The
capacity limits of a machine tool include feed, speed, power and maximum allowable
cutting force (or thrust force). Further, there may be feed and speed constraints to achieve
the desired surface finish on the component
 Chapter Three cont.
 A component usually requires more than one pass of cutting for completion. For
simplicity of analysis, we will analyze only a simple case of single pass turning
operation.
Cost per Component, Production Rate, and Profit Rate Criteria
 The machining cost per component is made up of a number of different
costs. The total cost (C) of making one component (excluding material
cost) is given by
 Chapter Three cont.
(Fixed charges are not taken into account because they will not affect
optimization.)
Where, C1 = non-productive cost per component (cost of loading and
unloading the component, idle time costs and other non-cutting time
costs),
C2 = cost of machining time,
C3 = tool changing time cost,
C4 = tool cost per component,
T = tool life,
Tac = actual cutting time;
 Chapter Three cont.
= number of tool (or cutting edge) changes per component,

Tc = machining time,

Td = time required to change a cutting edge,

Tl = sum of all non-productive times,

x = cost rate including labor and overhead cost rates, and

y = tool cost per cutting edge.
For a brazed tool tip, the cost / cutting edge

-------------------- (3)
 Chapter Three cont.

For the throw away tips,

-(4)
 From Eq 1, it is evident that cost per component can be
reduced by decreasing the loading time, unloading time,
idle time and tool changing time (by employing improved
fixtures, jigs, inspection gauges, tool holder, etc.).
 Chapter Three cont.
Improved tool materials and tool geometry which give longer tool life values
and hence would reduce the number of tool replacements and grinding costs.
Increasing the cutting speed has opposing effects on the cost per component
because C2 decreases while the total tool costs (C3+ C4) increase (Eq 1). The
production rate is inversely proportional to the production time per
component.
The total production time per component (Tt) is given by:

-------- (5)
 Chapter Three cont.
 As for minimum cost, decrease in Tl and Td will increase the production
rate. Increase in cutting speed will reduce Tc but it will increase the tool
changing time per component (tool life decreases at higher cutting speed); a
minimum time per component (TT) (or maximum production rate) will
therefore result.
 The profit rate (Pr) is expressed by:

------- (6)
 Chapter Three cont.
 where, I is income per component excluding material cost and C
is cost per component excluding material cost.
 Using Eqs. (10.1), (10.5) and (10.6), profit rate can be written as:
 Chapter Three cont.
 The variables which reduce the cost per component and increase the
production rate will increase the profit rate. In general, the speed for
maximum profit rate will differ from those for minimum cost per
component and maximum production rate.
 The generalized tool life equation for a turning operation is given by:

------ (8)
 Chapter Three cont.
where,
T = tool life in minutes,
V = cutting speed in m/min,
f = feed in m/rev,
d = depth of cut in m, and
K, A, B = constants.
1/n, 1/n1, 1/n2 are exponents of speed, feed and depth of cut,
respectively.
 In the following analysis, it is assumed that machine tool, tool and work material
have been selected. The three criteria discussed above will be applied only to a
single pass turning operations.
 Chapter Three cont.
 Example 1. In a certain manufacturing company, a turning operation is
performed under the following conditions : Depth of cut = 0.00127 m, feed
rate = 3.81 × 10–4 m / rev, work dia. = 76.2 × 10−3 m, axial length of cut =
0.1524 m, time required to load and unload components = 15 s/component,
time required to change a tool = 4 min / tool. Average cost of reconditioning
a worn tool is Rs. 2/- per cutting edge, machine operating cost is Rs. 10/hr,
number of components required per year is 30,000. The average number of
components produced are 620 at 330 RPM and 15 at 535 RPM during the
life of tools for each speed.
Find annual minimum savings (if any) by modifying the drive to give
some intermediate speed.
 CHAPTER FOUR
Introduction to Machine
Selection

1.1 Introduction
 Chapter Four cont.

1.1 Introduction
 CHAPTER FIVE
Organization of
Manufacturing

1.1 Introduction
 Chapter Five cont.

1.1 Introduction
Thank you
for
listening