Metal removal processes

Metal Cutting
Process where a stronger metal is used to cut a softer metal. One of the most popular and commonly used manufacturing processes. Lathe has been used since mid-seventeenth century. Metal cutting also includes methods of machining such as:

 Parts after heat treatment are usually distorted and hence need machining Accurate dimension, sharp corners Desired texture - such as shiny finish, mirrored surface etc. With modern machine it can be very economical Disadvantages
Higher cost of labor and tools Scrap metal results Longer cycle time

Mechanics of Chip Formation

Most important factors in all machining process:
Geometry of cutting tool Machining conditions:
Speed of tool Speed of workpiece Hardness of workpiece Hardness of tool

Work holding and fixtures Coolant, type of process, accuracy issues, etc. Machine condition - such as stiffness

Indirect effect
Type of chips formed Temperature rise Surface finish Tool wear etc