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UNIT – I
FUNDAMENTALS OF MACHINING
All the processes used in manufacturing concern for changing the ingots into usable
products may be classified into primary shaping processes, secondary machining processes.
Primary Shaping or non-cutting Processes: These are manufacturing a product from an
amorphous material, in which no chip formation takes place, and the metal is shaped under the
action of heat, pressure or both. Some processes produce finish products or articles into its usable
form where as others do not, and require further working to finish a component to the desired
shape and size. Some of the important primary shaping processes are, Casting, Powder
metallurgy, Plastic technology, Gas cutting, bending and Forging.
Secondary or Machining Processes: As large number of components requires further
processing after the primary processes. These components are subjected to one or more number
of machining operations in machine shops, to obtain the desired shape and dimensional accuracy
on flat and cylindrical jobs. These are other processes in which the components are brought to
the desired shape and size by removing the unwanted material from the parent metal in the form
of chips through machining.
Machining is the process of removing the material from the work piece by means of a
cutting tool in order to obtain a desired shape and size.
Basic objectives of principles of metal cutting operations,
1. Quick metal removal.
2. High class surface finish.
3. Economy in tool cost.
4. Less power consumption.
5. Economy in the cost of replacement and sharpening of tools.
6. Minimum idle time of machine tools.
Elements of metal cutting processes:
The process of metal cutting in which chip is formed is affected by a relative motion between the
work piece and the hard edge of a cutting tool held against the work piece. Depending on the
nature of this relative motion, metal cutting processes are called by names given below table.
Operation Motion of work piece Motion of cutting tool
Turing Rotary Forward translation
Boring Forward translation Rotation
Rotation as well as translator
Drilling Fixed
feed.
Planning Translatory Intermediate translation
Milling Translatory Rotation
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