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Books:: Machining Technology & Metrology

This document discusses machining technology and metrology. It defines machining as a process that uses cutting tools to remove excess material from preformed blanks to produce parts with desired dimensions and surface finishes. The document outlines the basic principles of machining, including the functions of machine tools in firmly holding workpieces and tools and providing motion and power. It also discusses key tool geometry concepts such as generatrix, directrix, rake angle, and clearance angle.

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236 views8 pages

Books:: Machining Technology & Metrology

This document discusses machining technology and metrology. It defines machining as a process that uses cutting tools to remove excess material from preformed blanks to produce parts with desired dimensions and surface finishes. The document outlines the basic principles of machining, including the functions of machine tools in firmly holding workpieces and tools and providing motion and power. It also discusses key tool geometry concepts such as generatrix, directrix, rake angle, and clearance angle.

Uploaded by

aritra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 8

Machining Technology & Metrology

Books:
 P N Rao
 Ghosh & Mallick
 Hazra & Choudhury
 Machine Tool Design by Sen & Bhattacharya
 Principle of Metal Cutting by Amitava Bhattacharya

Purpose of Machining
Most of the engineering components such as gears, bearings, clutches, tools, screws
and nuts etc. need dimensional and form accuracy and good surface finish for
serving their purposes.
Preforming like casting, forging etc. generally cannot provide the desired accuracy
and finish.
For that such preformed parts, called blanks, need semi-finishing and finishing and
it is done by machining and grinding.
Grinding is also basically a machining process.

Machining to high accuracy and finish essentially enables a product


• fulfill its functional requirements
• improve its performance
• prolong its service

Raw material Finish product


Machining

Waste

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Machining Technology & Metrology

Principle of Machining
A metal rod of irregular shape, size and surface is converted into a finished rod of
desired dimension and surface by machining by proper relative motions of the tool-
work pair.

Machining: Machining is an essential process of finishing by which jobs are


produced to the desired dimensions and surface finish by gradually removing the
excess material from the preformed blank in the form of chips with the help of
cutting tool(s) moved past the work surface(s).

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Machining Technology & Metrology

The blank and the cutting tool are properly mounted (in fixtures) and moved in a
powerful device called machine tool enabling gradual removal of layer of material
from the work surface resulting in its desired dimensions and surface finish.
Additionally some environment called cutting fluid is generally used to ease
machining by cooling and lubrication.
MFTW (Machine, Fixture, Tool, Work piece)
Quality: Shape, Size, Accuracy, Surface Finish, Subsurface metallurgy

Basic functions of Machine Tools


Machine Tools basically produce geometrical surfaces like flat, cylindrical or any
contour on the preformed blanks by machining work with the help of cutting tools.
The physical functions of a Machine Tool in machining are:
• firmly holding the blank and the tool
• transmit motions to the tool and the blank
• provide power to the tool-work pair for the machining action.
• control of the machining parameters, i.e., speed, feed and depth of cut.

Machine Tool: A machine tool is a non-portable power operated and reasonably


valued device or system of devices in which energy is expended to produce jobs of
desired size, shape and surface finish by removing excess material from the
preformed blanks in the form of chips with the help of cutting tools moved past the
work surface(s).
Mechanism: It is a combination of rigid bodies through which motion can be
transmitted and transferred.

Machine: It is a combination of rigid bodies through which both motion and energy
can be transmitted and transferred.

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Machining Technology & Metrology

Generating line: the first line which is obtained is called generating line.
First motion (Primary guiding motion/main motion): The first motion by which
generating line can be obtained (Genratrix)
Second motion (Feed motion): The motion required to obtain the required surfaces
(Directrix)

The connections in case of straight longitudinal turning shown in above Fig.


Generatrix (G) – Cutting motion (CM) – Work (W)
Directrix (D) – Feed motion (FM) – Tool (T)

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Machining Technology & Metrology

In case of making flat surface in a shaping machine as shown in Fig. the connections
are:
G – CM – T
D – FM – W
which indicates that in shaping flat surfaces the Generatrix is provided by the cutting
motion imparted to the cutting tool and the Directrix is provided by the feed motion
of the work.

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Machining Technology & Metrology

Concept of generatrix and directrix.


(a) Rectilinear generatrix and directrix.
(b) Directrix perpendicular to the plane of generatrix.
(c) Directrix in the plane of generatrix.

Cutting tools
Cutting tools may be classified according to the number of major cutting edges
(points) involved as follows:
• Single point: e.g., turning tools, shaping, planning and slotting tools and boring
tools
• Double (two) point: e.g., drills
• Multipoint (more than two): e.g., milling cutters, broaching tools, hobs, gear
shaping cutters etc.

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Machining Technology & Metrology

Concept of rake and clearance angles of cutting tools.


The word tool geometry is basically referred to some specific angles or slope of the
salient faces and edges of the tools at their cutting point. Rake angle and clearance
angle are the most significant for all the cutting tools.

• Rake angle (γ): Angle of inclination of rake surface from reference plane
• Clearance angle (α): Angle of inclination of clearance or flank surface from the
finished surface

Relative advantages of such rake angles are:


• Positive rake – helps reduce cutting force and thus cutting power requirement.
• Negative rake – to increase edge-strength and life of the tool
• Zero rake – to simplify design and manufacture of the form tools.

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Machining Technology & Metrology

Clearance angle is essentially provided to avoid rubbing of the tool (flank) with the
machined surface which causes loss of energy and damages of both the tool and the
job surface. Hence, clearance angle is a must and must be positive (3o ~ 15o
depending upon tool-work materials and type of the machining operations like
turning, drilling, boring etc.)

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