MCE 332L

Material and Manufacturing Process

Laboratory

Lab.8
Turning Process
Turning
 It is a machining process uses a single point cutting tool to
removes material from a rotating workpiece to generate a
cylindrical shape

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 Turning performed on a machine tool called a lathe

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Variations of turning that are performed on a lathe:

A- External Operations
1. Turning
2. Facing
3. Contour turning
4. Chamfering
5. Grooving
6. Cutoff
B-Internal Operations
7- Boring
8- Drilling
9- Reaming
10-Threading or Tapping

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1- Turning : The turning tool moves axially, along the side of the
workpiece, removing material to form different features, including
steps, tapers, chamfers, and contours.

These features are typically machined at a small radial depth of

cut and multiple passes are made until the end diameter is
reached.

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2- Facing
A single-point turning tool moves radially, along the end of the workpiece,
removing a thin layer of material to provide a smooth flat surface.

The depth of the face, typically very small, may be machined in a single pass or
may be reached by machining at a smaller axial depth of cut and making multiple
passes.

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3- Contour Turning
Instead of feeding the tool parallel to the axis of rotation, tool follows
a contour that is other than straight, thus creating a contoured form

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4-Chamfering
Cutting edge cuts an angle on the corner of the cylinder, forming a
"chamfer"

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5- Grooving
A single-point turning tool moves radially, into the side of the workpiece,
cutting a groove equal in width to the cutting tool.

Multiple cuts can be made to form grooves larger than the tool width
and special form tools can be used to create grooves of varying
geometries.

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6-Cutoff
Tool is fed radially into rotating work at some location to cut off end of part

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7- Boring
A boring tool enters the workpiece axially and cuts along an
internal surface to form different features.
Boring is commonly performed after drilling a hole in order to
enlarge the diameter or obtain more precise dimensions.

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8- Drilling
A drill enters the workpiece axially through the end and cuts a
hole with a diameter equal to that of the tool.

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9- Reaming
A reamer enters the workpiece axially through the end and enlarges an existing
hole to the diameter of the tool.

Reaming removes a minimal amount of material and is often performed after

drilling to obtain both a more accurate diameter and a smoother internal finish.

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10-Threading
Pointed form tool is fed linearly across surface of rotating workpart
parallel to axis of rotation at a large feed rate, thus creating threads

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Example

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Cutting parameters

• Spindle speed
• Cutting speed
• Cutting feed.
• Feed rate
• Depth of cut

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Cutting parameters
• Cutting speed , V :

The speed of the workpiece surface relative to the edge

of the cutting tool during a cut, measured in surface feet per
minute (SFM).

V = r.w

The desired cutting speed , V :a Handbook Value 19

 Cutting parameters
• Spindle speed N:
The rotational speed of the spindle and the workpiece in
revolutions per minute (RPM).

Di is largest part diameter (initial size)

N is machine speed in revolutions/minute(RPM)

k is a constant to “correct” speed (V) and part diameter (Di ) units:

V given in surface feet per minute (SFPM), D in inches: k = 12

V given in meters per second (MPS), D in mm: k = 60000
V given in meters per minute (MPM), D in mm: k = 1000
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Cutting parameters

• Cutting feed , f :
The distance that the cutting tool or workpiece advances
during one revolution of the spindle, measured in inches per revolution
(IPR).

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Cutting parameters
• Feed rate , fr :
The speed of the cutting tool's movement relative to the
workpiece as the tool makes a cut.

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Cutting parameters
• Depth of cut Doc :

 It is the depth of the tool along the axis as it makes a cut.

 In the facing operation, its an axial

 A large depth of cut will require a low feed rate, or else it will
result in a high load on the tool and reduce the tool life.

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Methods of Holding the Work in a Lathe

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• Chuck

three-jaw chuck
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• Face Plate : used for non-cylindrical workparts

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Possible Defects

Most defects in turning are inaccuracies in a feature's dimensions or

surface roughness.

There are several possible causes for these defects, including the
following:
Incorrect cutting parameters
- If the cutting parameters such as the feed rate, spindle speed, or depth
of cut are too high, the surface of the workpiece will be rougher than
desired and may contain scratch marks or even burn marks.
- Also, a large depth of cut may result in vibration of the tool and cause
inaccuracies in the cut.

Dull cutting tool

- As a tool is used, the sharp edge will wear down and become dull. A
dull tool is less capable of making precision cuts.

Unsecured workpiece
- If the workpiece is not securely clamped in the fixture, the friction of
turning may cause it to shift and alter the desired cuts. 27
Refer to Lab. Manual for work project and procedures

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This lecture collected from the following :

- Manufacturing Processes, MET 1311, Dr Simin Nasseri

Southern Polytechnic State University

- Manufacturing Processes Engineering, ISE 316 , Professor Richard A.

Wysk.

- http://www.custompartnet.com/wu/turning

(© Fundamentals of Modern Manufacturing; Materials, Processes and

Systems, by M. P. Groover)

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