Fundamentals of Metal cutting and Machining Processes
MACHINING OPERATIONS AND MACHINING TOOLS
Engineer Munyau
MACHINING OPERATIONS
AND MACHINE TOOLS
1. Turning and Related Operations
2. Drilling and Related Operations
3. Milling
4. Broaching
5. Sawing
6. Machine Operations for Special Geometries
7. Machining Centers and Turning Centers
8. Other Machining Operations
9. High Speed Machining
10. Grinding
Machining
A material removal process in which a sharp
cutting tool is used to mechanically cut away
material so that the desired part geometry
remains
Most common application: to shape metal parts
Most versatile of all manufacturing processes in
its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
Classification of Machined Parts
Rotational - cylindrical or disk-like shape
Nonrotational (also called prismatic) - block-like or
plate-like
Machined parts are classified as: (a) rotational, or (b) nonrotational,
shown here by block and flat parts.
Machining Operations and
Part Geometry
Each machining operation produces a characteristic part
geometry due to two factors:
1. Relative motions between tool and work part
• Generating – part geometry determined by
feed trajectory of cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by the
shape of the cutting tool
Generating Shape
Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling.
Forming to Create Shape
Forming to create shape: (a) form turning, (b) drilling, and (c) broaching.
Forming and Generating
Combination of forming and generating to create shape: (a) thread cutting
on a lathe, and (b) slot milling.
Turning
Single point cutting tool removes material from a rotating
work piece to generate a cylinder
Performed on a machine tool called a lathe
Variations of turning performed on a lathe:
Facing
Contour turning
Chamfering
Threading
Turning
Turning operation.
Turning Conditions
Turning Operation
Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert
Facing
Tool is fed
radially inward
Contour Turning
Instead of feeding tool parallel
to axis of rotation, tool follows
a contour that is other than
straight, thus creating a
contoured shape
Chamfering
Cutting edge cuts an angle on the corner of the cylinder,
forming a "chamfer"
Cutoff
Tool is fed radially into rotating work at some location to
cut off end of part
Threading
Pointed form tool is fed linearly across surface of rotating work
part parallel to axis of rotation at a large feed rate, thus
creating threads
Engine Lathe
Diagram of an
engine lathe,
showing its
principal
components
Methods of Holding the Work
in a Lathe
Holding the work between centers
Chuck
Collet
Face plate
Holding the Work Between
Centers
(a) mounting the work between centers using a "dog”
Chuck
(b) three-jaw chuck
Collet
Face Plate
(d) face plate for non-cylindrical workparts
Other Lathes and Turning
Machines
Turret Lathe
Tailstock replaced by “turret” that
holds up to six tools
Tools rapidly brought into action by
indexing the turret
Tool post replaced by four-sided turret
to index four tools
Applications: high production work
that requires a sequence of cuts on the
part
Boring
Difference between boring and turning:
Boring is performed on the inside diameter of
an existing hole
Turning is performed on the outside diameter
of an existing cylinder
In effect, boring is internal turning operation
Boring machines
–Horizontal or vertical - refers to the orientation
of the axis of rotation of machine spindle
Boring
Vertical Boring Mill
A vertical boring mill – for large, heavy workparts.
Drilling
Creates a round hole in a work
part
Compare to boring which can
only enlarge an existing hole
Cutting tool called a drill or drill
bit
Machine tool: drill press
Drilling
Through Holes vs. Blind Holes
Through-holes - drill exits opposite side of work
Blind-holes – does not exit work opposite side
Two hole types: (a) through-hole, and (b) blind hole.
Reaming
Used to slightly enlarge
a hole, provide better
tolerance on diameter,
and improve surface
finish
Tapping
Used to provide internal
screw threads on an
existing hole
Tool called a tap
Counterboring
Provides a stepped hole, in
which a larger diameter
follows smaller diameter
partially into the hole
Twist Drill
Drill Press
Upright drill press stands
on the floor
Bench drill similar but
smaller and mounted on
a table or bench
Radial Drill
Large drill press
designed for large
parts
Take home
Numbers 23 v 19
God is not a man; neither the son of man , that he should repent: hath
he said , and shall he not do it ? Or hath he spoken and shall he not do
it? Or hath He spoken , and shall he not make it good?
