MANUFACTURING PROCESSES

TURNING, SHAPING and

DRILLING

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 TURNING & RELATED OPERATIONS
• TURNING is a machining process in
which a single-point tool removes
material from the surface of a rotating
workpiece.
• The tool is fed linearly in a direction
parallel to the axis of rotation to
generate a cylindrical geometry.
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 TURNING & RELATED OPERATIONS
Turning is traditionally carried out on a machine tool
called a LATHE, which provides power to turn the part
at a given rotational speed and to feed the tool at a
specified rate and depth of cut.

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LATHE MACHINE

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TURNING

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 OPERATIONS RELATED TO TURNING
• A variety of other machining operations can be
performed on a lathe in addition to turning.
• Following slides will give a brief overview of
these operations.

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 FACING
• The tool is fed radialy into the rotating work on
one end to create a flat surface on the end.

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 TAPER TURNING
• Instead of feeding the tool parallel to the axis of
rotation of the work, the tool is fed at an angle,
thus creating a tapered cylinder or conical shape.

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TAPER TURNING

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 CONTOUR TURNING
• Instead of feeding the tool along a straight line
parallel to the axis of rotation as in turning, the tool
follows a contour that is other than straight, thus
creating a contoured form in the turned part.

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 FORM TURNING
• In this operation, sometimes called forming , the
tool has a shape that is imparted to the work by
plunging the tool radially into the work.

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 CHAMFERING
• The cutting edge of the tool is used to cut an
angle on the corner of the cylinder, forming what
is called a ‘‘ chamfer. ’’

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 CUTOFF
• The tool is fed radially into the rotating work at
some location along its length to cut off the end of
the part. This operation is sometimes referred to as
parting .

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 THREADING
• A pointed tool is fed linearly across the outside
surface of the rotating workpart in a direction
parallel to the axis of rotation at a large effective
feed rate, thus creating threads in the cylinder.

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 DRILLING
• Drilling can be performed on a lathe by feeding
the drill into the rotating work along its axis.
Reaming can be performed in a similar way.

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 BORING
• A single-point tool is fed linearly, parallel to the
axis of rotation, on the inside diameter of an
existing hole in the part.

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 KNURLING
• This is not a machining operation because it does
not involve cutting of material. Instead, it is a metal
forming operation used to produce a regular cross-
hatched pattern in the work surface.

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 TURNING PARAMETERS

Df

Do

l
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CUTTING SPEED ( v ) mm/min

v = π Do N

v cutting speed mm/min

N rotational speed rev/min
Do original dia of the part mm

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 Feed ( f ) mm/rev or mm/stroke
• Feed ( f ) mm/rev, may be defined as the small
relative movement per cycle (per revolution or
per stroke ) of the cutting tool in a direction
usually normal to the cutting speed direction.

• Feed ( f ) mm/rev is the distance cutting tool

advances along length of workpiece for every
revolution of the spindle.

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 Feed Rate ( fr ) mm/min
• Feed Rate ( fr ) : The feed can be converted to
a linear travel rate (Feed Rate) ( fr ) in mm/min
by the formula

fr = Nf

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 DEPTH OF CUT ( d ) mm
• It is defined as the depth of penetration of the
tool into the work piece during machining.
or
• In other words, it is the perpendicular distance
measured from the machined surface to the
unmachined surface of the work piece.
or
• The thickness of material removed by one pass
of the cutting tool is called Depth of Cut.
 MACHINING LENGTH ( l ) mm
l Tool pre-travel

L a

l = L + a
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 MACHINING TIME (TM) min
• The time required to machine a workpiece length
“ l ” is given by:
l l
TM = =
Feed rate fr

l π Do l
TM = =
fN fv
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 MATERIAL REMOVAL RATE ( RMR ) mm3/min

• It is the volume of material removed per unit

time.

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 NO. OF PASSES (n)

Do - Df
No. of Passes (n) =
2(d)

Total machining time = n TM

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 Power Requirement (P)

W. s
Unit Power =
mm3

Power (P) = Unit Power X MRR (W)

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 TURNING NUMERICAL 1

• A cylindrical workpart 125 mm in diameter and

900 mm long is to be turned in an engine lathe.
Cutting speed = 2.50 m/s, feed = 0.3 mm/rev,
and depth of cut = 2 mm. Determine (a) cutting
time, and (b) metal removal rate.

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 TURNING NUMERICAL 1

Do = 125 mm

l = 900 mm

v = 2.50 m/s = 2500 mm/s

f= 0.3 mm/rev

d =2 mm

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 TURNING NUMERICAL 1

N = (2500)/125π = 6.366 rev/s

fr = 6.366(.3) = 1.91 mm/s

TM = 900/1.91 = 471.2 s = 7.85 min

MRR = vfd

= (2500)(.3)(2.0)

= 1500 mm 3/s 30
 TURNING NUMERICAL 2
• In a production turning operation, the foreman
has decided that the single pass must be
completed on the cylindrical workpiece in 5.0
min. The piece is 400 mm long and 150 mm in
diameter. Using a feed = 0.30 mm/rev and a
depth of cut = 4.0 mm, what cutting speed must
be used to meet this machining time
requirement?

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 TURNING NUMERICAL 2

TM= 5.0 min

l = 400 mm

Do = 150 mm Ans:-125.7 m/min

f= 0.3 mm/rev

d =4 mm Extra Info

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 SHAPING AND PLANING
• Shaping and planing are similar operations, both
involving the use of a single-point cutting tool
moved linearly relative to the workpart.
• In conventional shaping and planing, a straight,
flat surface is created by this action.
• In SHAPING, the speed motion is accomplished
by moving the cutting tool; while in PLANING,
the speed motion is accomplished by moving the
workpart.
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SHAPING

Speed
Motion

Feed
Motion

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SHAPER

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PLANING

Feed
Motion

Speed
Motion

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PLANER

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 DRILLING
• DRILLING is a machining operation used to
create a round hole in a workpart.
• Drilling is usually performed with a rotating
cylindrical tool that has two cutting edges on its
working end.
• The tool is called a drill or drill bit.
• The tool is fed in a direction parallel to its axis of
rotation into the workpart to form the round
hole.
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DRILLING

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DRILL BIT
Cone angle 118°-135°

Cutting
edge

10°-45°

Land

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 DRILL BIT

FLUTE

CUTTING
EDGE
LAND
DRILL BIT

10°-45°

Land

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 DRILLING
• The most common types of drills are twist drills .
• These have three basic parts: the body, the
point, and the shank.
• The body contains two or more spiral or helical
grooves, called flutes, separated by lands .
• The lands terminate in the point, with the
leading edge of each land forming a cutting
edge.

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 DRILLING
• The flutes serve as channels through which the
chips are withdrawn from the hole and coolant gets
to the cutting edges.
• The cone-shaped point on a drill contains the
cutting edges and the various clearance angles.
• The rotating drill feeds into the stationary workpart
to form a hole whose diameter is equal to the drill
diameter.
• Drilling is customarily performed on a drill press ,
although other machine tools also perform this
operation.
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 DRILLING

Drill bit

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DRILLING
 DRILLING

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 OPERATIONS RELATED TO DRILLING
• Several operations are related to drilling.
• Most of the operations follow drilling; a hole
must be made first by drilling, and then the hole
is modified by one of the other operations.
• Centering and spot facing are exceptions to this
rule.
• All of the operations use rotating tools.

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 REAMING
• Reaming is used to slightly enlarge a hole, to
provide a better tolerance on its diameter, and
to improve its surface finish.
• The tool is called a reamer, and it usually has
straight flutes.

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 TAPPING
• This operation is performed by a tap and is used
to provide internal screw threads on an existing
hole.

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 COUNTERBORING
• Counterboring provides a stepped hole, in which a
larger diameter follows a smaller diameter partially into
the hole.
• A counterbored hole is used to seat bolt heads into
a hole so the heads do not protrude above the surface.

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 COUNTER SINKING
• This is similar to counterboring, except that the
step in the hole is cone-shaped for flat head
screws and bolts.

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 CENTERING
• Also called center drilling, this operation drills a
starting hole to accurately establish its location
for subsequent drilling.
• The tool is called a center drill.

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THANK YOU

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