MachiningOperations

Turning Milling Drilling

Sawing Broaching Planing

 Shear Strain

Shear Strain:

= a h = tan
 Shear Strain

AE AO + OE AO OE
= = = +
OB OB OB OB

= tan( ) + cot
Tool Inserts
 Traditional Machining
CUTTING

Turning

Drilling

Milling

Other machining operations

Shaping/Planning
Broaching
Sawing
 Cutting

Turning Milling Drilling

 Traditional
Machining
Machining
ABRASIVE MACHINING

Grinding

Others
Honing
Lapping
Surface Finishing
Polishing & Buffing

Grain Action during Grinding Wheel wear mode

9 Cutting 9 Grain fracture
9 Ploughing 9 Attritious wear
9 Rubbing 9 Bond fracture
Non-Traditional Machining

Mechanical Energy Processes

Chemical Energy Processes

Thermal Energy Processes

Chemical Energy Processes

Lathe
 ClassificationofMachinedParts
1. Rotational cylindricalordisklikeshape
2. Nonrotational (alsocalledprismatic) blocklikeorplate
like

Machined parts are classified as: (a) rotational, or (b) non -

rotational, shown here by block and flat parts
 Turning
Singlepointcuttingtoolremovesmaterialfromarotatingworkpiece
toformacylindricalshape
 d

RotationalSpeed: N = V
D 0

Depthofcut:d=(D0Df)/2

Feed:fr =Nf

Timetomachinetheworkpiece: T=L ;MRR=Vdf

fr
LatheOperations
LatheOperations
Turning
Producestraight,conical,curved,orgroovedworkpieces
Facing
Produceaflatsurfaceattheendoftheworkpiece
Drilling
Produceahole
Boring
Enlarginganexistingholeorcylindricalcavity
Parting
Cutapiecefromtheendofapart
Knurling
Producearegularlyshapedroughnessoncylindricalsurfaces
Milling
Single vs Multi-Point Tool
Milling Operations
Up Milling
Commonmethodofmilling
Chipthininthebeginningand
increasesinthickness
Workpiecehasatendencytobe
pulledup.Needsclamping
Toolengagementisnotaffected
bysurfacecharacteristics,surface
scales
Chipscanbecarriedintothe
newlymachinedsurfaceleading
topoorsurfacefinish
Down Milling
Cutting starts at the surface
where the chip is at its thickest.
High impact forces require rigid
setup
Cutting force tends to push the
work piece down reducing
clamping requirements
Less chatter
Not suitable for work piece with
hard, abrasive scales, as in hot
worked metals, forgings and
castings. Excessive tool wear
Cutting Force
 Cuttingforce
BuildsrapidlyasthetoolenterstheworkatAandprogressestoB
ForcepeaksatC
DecreasestoD
Dropstozeroabruptlyuponexit
Cyclerepeated

Cuttingforcevariationnecessitatestheuseofsmallpositive
ornegativerakeangles,particularlywithceramicorcarbide
tools
Cuttingedgeisincompressionratherthantension.(Brittlematerials
areverystrongincompression)
Positiveraketendstolifttheworkpiece
Negativerakecompressestheworkpieceandallowdeepercuts
Cutterswithpositiverakes(HSS)operatedatlowerspeeds
 Straight vs Helical Milling Cutters

Helicalcuttersengagetheworkgradually
Usuallymorethanonetoothcutstheworkpiece
Reducesshock,chatteringandproducesasmoothersurface
Drilling
ChiselEdge
Drillshavethreebasicparts:
Shank
Body
Point
Bodycontains:
Twoormorespiral/helicalgroovescalledflutes
Flutesserveaschannelsforchipsandcoolants
Flutesareseparatedbylands
Landprojectsout
Toreducefrictionbetweenthedrillandthehole,each
landisreducedindiameterexceptattheleadingedge,
leavinganarrowmargin offulldiametertosupportand
guidethedrill
Therelativelythinwebbetweentheflutesformthe
backbone
 Somedrillshaveinternallongitudinalholesthroughwhich
cuttingfluidsareforced.Improveslubrication,coolingand
washingawayofchips

Point
Coneshapedpointcontainsthecuttingedgeandthevarious
clearanceangles
Cone(point)angleaffectsthedirectionoftheflowofchips
acrossthetoolfaceandintotheflute.
118o coneangleisnormallyused.
90 118degreeusedfordrillingbrittlematerial
118 135degreesusedformoreductilematerial
Drilling Operations
Shaping
Planning
Broaching
Sawing

HackSawing
 Sawing

Bandsaw Circularsaw
MACHINETOOL
 MACHINETOOLSYSTEM

Drawings,CADmodel,Tolerances,Surfacefinish,Machinecode

Cuttingfluid

Workpiece Tool
Raw Finished
Material part

MachineTool

MachineTool Cuttingtool Cuttingfluid Operator

 REQUIREMENTS

Accuracy
Dimensional accuracy and surface finish
Depends on the rigidity of machine elements
Capacity
Produce the required number of components per unit time
Reliability and Maintainability
Probability of failure should be low
Should be easy to service
Ease of operation
Loading/unloading, tool setting, inprocess measurements should be
easily carried out through the use of appropriate devices and controls
(without being too expensive)
 BASICELEMENTS

Primarydrive
Providescuttingmotionorthecuttingspeed
Secondarydrive
Providesfeedmotion
Guideways
Guidesmotionoftool/workpiece
Structure
Bases,beds,columns,carriages,tables,housingsetc.
Constitute70 90%ofmachinetoolweight
Controlsystem
Feedbackdevicethatpermits(i)theoperationstobeperformedin
thedesiredsequenceand(ii)errorcompensation
PRIMARYDRIVE
STEPPEDPULLEYDRIVE

N1 =N(D4/D1)

N2 =N(D3/D2)

Where,
N=InputRPM
 GEARDRIVE

Threespeedgearbox Ninespeedgearbox

Moreefficientthansteppedpulleydrive
Noslipping
SECONDARYDRIVE
 RACKANDPINION

Pinion

Rack

Convertsrotarymotionofmotorintotranslatorymotion
 GUIDEWAYS

Ensurethatelementscarryingthetoolandtheworkpiece
movealongpredeterminedpaths.
Analogywithtrainmovingontracksvisviscaronroads
Requirementsformaintainingalignmentofguidesunder
operatingconditions:
Dimensionalaccuracyandsurfacefinish
Durability
Lowfriction
Reduceswear
Highstiffnessandrigidity
Providesprotectionagainststatic,pulsatingandinertial
forces
Hatchedportionisguideway
 STRUCTURE

Designedtoensure:
Highdegreeofaccuracysothattherelativepositionsof
variouspartsmountedonitareaccuratelymaintained
Safeoperationandeasymaintenanceofmachinetools

Fundamentalfeaturestofulfillabovementionedobjectives:
Materialformachinetoolstructures
Staticanddynamicstiffnessofstructure
 STRUCTUREMATERIAL

Greycastiron
Universallyusedforgeneralpuprosemachinetoolssuchas
lathes,milling,drillingmachines,shapersetc.
Lowcost
Highcompressivestrength
Gooddampingcapacity
Goodlubricatingcapacitybecauseofthepresenceoffree
graphite
Excellentcastabilityandeasytomachine
Heavy(increasestransportationandhandlingcosts)
 STIFFNESS/RIGIDITY
Staticstiffness
Duringmachining,machinetoolsaresubjectedtotension,
compression,bendingandtorsion
Elasticdeformationof:
Machinetoolelementscauseinaccuracyduringmachining
Jointscauseexcessivevibration

Dynamicstiffness
Machinetoolsaresubjectedtodynamicloads:
Toolworkinteraction
Movementsofmachineelements
Dynamicstiffnessrequiredtominimizevibrations
Especiallyimportantwithdemandforhighcuttingspeeds
 HIGHSPEEDMACHINING

Classification
Highspeed:600 1800m/min
Veryhighspeed:1800 18000m/min
Ultrahighspeed:>18000m/min

Higherproductivityandlowerproductioncosts
Improvedtolerancesincuttingoperations
Mostoftheheatgeneratedincuttingisremovedbythechip
Toolandworkpieceremainatambienttemperatures
Nothermalexpansionorwarpingintheworkpiece

Implementedforthemachiningofaircraftturbine
componentsandautomotiveengines

Fivetotentimestheproductivityoftraditionalmachining
DIMENSIONALACCURACY
 Worntoolincreasesthefinalworkpiecedimensioncompared
toasharptool
Cuttingforceincreasesasthetoolwears,resultingin
increaseddeflectionbetweenthetoolandworkpiece
BUEhasthetendencytoincreasefinalworkpiecediameter
FlankwearandBUEcancombinetoaffectbothsurfacefinish
andaccuracy