Course Title: Lecture Contact Hours:

MANUFACTURING TECHNOLOGY 3.00

Course Code: Credit Hours:

ME-233 3.00

Cdr Shaheen Ahmed (E), BN

ME Department

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 CO-PO MAPPING

CO Course Learning Outcome PO

CO-1 Demonstrate knowledge of manufacturing processes with set of fictional PO-1, PO-7
requirements and product development

CO-2 Analyze various machines and machining operations of manufacturing PO-1, PO-2
products

CO-3 Clear understanding of economic performance and quality manufacturing PO-1, PO-2
products

CO-4 Design theoretical impacts of materials in product and their failure analysis PO-3, PO-12

ME-233 2
 CO-PO MAPPING

Justification for CO-PO Mapping

Mapping Justification
CO1-PO1 Understanding the knowledge associated with manufacturing and product development
CO1-PO7 Students will be able to understand about product manufacturing and associated feature and
apply their knowledge by ensuring environment and sustainability
CO2-PO1 Students will be able to conduct different machining operation by gaining knowledge about
machining processes
CO2-PO2 Students will apply appropriate techniques, resources, and modern engineering of machining to
improve productivity of industry
CO3-PO1 Students will be able to evaluate the quality of manufacturing keeping mind its economic points
of view
CO3-PO2 Students will be able to analyze efficiency by selecting method of production
CO4-PO3 Students will be able to analyze materials at design point of view
CO4-PO12 Students will be able to conduct investigation, design the product which will prepare them to
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take challenges in upcoming future
 MANUFACTURING TECHNOLOGY
ME-233

Reference Books:
➢ Manufacturing Engineering and Technology
By: Serope Kalpakjian, Steven R. Schmid
➢ Manufacturing processes and materials for
engineering
By: Doyle Morris
➢ Introduction to Manufacturing process
By: Jhon A Schey

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 MANUFACTURING TECHNOLOGY
ME-233
Course Content
➢ Basic manufacturing process overview ➢ Metal cutting and operation
➢ Methods of manufacture and process ➢ Machine Tools and operations
➢ Introduction to Plastic, ceramic and ➢ Quality Control
glass product manufacturing processes

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 Metal cutting and operation

➢ Cutting Tools Materials ➢ Types of Motions in Machining

➢ Geometry and Surface Finish ➢ Turning and Boring
➢ Effect of Machining Parameters on ➢ Shaping, Planning and Slotting
Surface Finish ➢ Thread Cutting
➢ Machining Equations for Cutting ➢ Drilling and Milling
Operations ➢ Gear Tooth Cutting
➢ Mechanics of Machining Processes ➢ Machining Parameter and Related
➢ Tool Wear and Tool Life Quantities

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 Mechanics of Machining Processes

Book:
Manufacturing Engineering and Technology
By: Serope Kalpakjian, Steven R. Schmid

Chapter 21
Fundamentals of Machining

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Introduction

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In the turning process, illustrated in greater detail in Fig. 21.2, the cutting tool is
set at a certain depth of cut (mm), and travels to the left with a certain cutting
speed as the workpiece rotates. The feed, or feed rate, is the distance the tool
travels per revolution of the workpiece (mm/rev); this movement of the cutting
tool produces a chip, which moves up the face of the tool.
In order to analyze this basic machining process in greater detail, a two-
dimensional model of it is presented in Fig. 21.3a. In this idealized model, a
cutting tool moves to the left along the workpiece at a constant velocity, V , and a
depth of cut, to. Ahead of the tool, a chip is produced by plastic deformation,
shearing the material continuously along the shear plane. This phenomenon can
easily be demonstrated by slowly scraping the surface of a stick of butter
lengthwise with a sharp knife, and observing how a chip is being produced.
Chocolate shavings, used as decorations on cakes and pastries, are produced in a
similar manner.
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Mechanics of Cutting
The factors that influence the cutting operation are outlined in Table 21.1. In
order to appreciate the contents of this table, consider the major independent
variables in the basic cutting process:
(a) tool material and coatings, if any;
(b) tool shape, its surface finish and sharpness;
(c) workpiece material and its processing history;
(d) cutting speed, feed, and depth of cut;
(e) cutting fluids, if any;
(f) characteristics of the machine tool; and
(g) the type of workholding device and fixturing.
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Dependent variables in machining are those that are influenced by changes made
in the independent variables listed above. They include:
(a) type of chip produced,
(b) force and energy dissipated during cutting,
(c) temperature rise in the workpiece, the tool, and the chip,
(d) tool wear and failure, and
(e) surface finish and surface integrity of the workpiece.

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Type of Machining: According to the relative motion between the workpiece and the tool
Machining is of two types: (a) Orthogonal Cutting and (b) Oblique Cutting
Orthogonal Cutting Oblique Cutting
The cutting edge is perpendicular to the The angle between the cutting edge and the
direction of the tool travel direction of tool travel is less than 90 degree.
The chip flow angle is Zero The chip flow angle is more than Zero
Tool life is less Tool life is more
Two components of forces: 1. Axial. 2. Three components of forces: 1. Axial. 2.
Tangential Tangential and 3. Radial
Poor surface finish Good surface finish
Use in slotting, Parting, Grooving and Pipe Use in Turning, milling, drilling and grinding
cutting
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Machining Equations for Cutting Operations

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Types of Chips Produced in Metal Cutting

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Figure 21.5: Basic types of chips produced in orthogonal metal cutting, their schematic representation,
and photomicrographs of the cutting zone: (a) continuous chip, with narrow, straight, and primary
shear zone; (b) continuous chip, with secondary shear zone at the chip–tool interface 30
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Figure 21.5: Basic types of chips

produced in orthogonal metal cutting,
their schematic representation, and
photomicrographs of the cutting zone:
(c) built-up edge;

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Figure 21.6: (a) Hardness
distribution in a built-up edge in
3115 steel. Note that some regions
within the built-up edge are as
much as three times harder than the
bulk metal being machined. (b)
Surface finish produced in turning
5130 steel with a built-up edge. (c)
Surface finish on 1018 steel in face
milling. Magnifications: 15×.

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Figure 21.7: (a) Machining aluminum using an insert without a chip breaker;
note the long chips that can interfere with the tool and present a safety hazard.
(b) Machining aluminum with a chip breaker.
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Figure 21.7: (c) Schematic illustration of the action of a chip breaker; note that the chip breaker
decreases the radius of curvature of the chip and eventually breaks it. (d) Chip breaker clamped on
the rake face of a cutting tool.
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Figure 21.7: (e) Grooves in cutting tools acting as chip breakers; the majority of
cutting tools are now inserts with built-in chip-breaker features.

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Oblique Cutting

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Cutting Forces and Power

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Figure 21.11: (a) Forces
acting in the cutting zone
during two-dimensional
cutting. Note that the
resultant force, R, must be
colinear to balance the
forces.

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Figure 21.11:. (b) Force
circle to determine
various forces acting in
the cutting zone.

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Table 21.2: Approximate Range

of Energy Requirements in
Cutting Operations at the Drive
Motor of the Machine Tool,
Corrected for 80% Efficiency
(for dull tools, multiply by 1.25).

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It can be seen from Eq. (21.23) that the mean cutting temperature increases with workpiece strength,
cutting speed, and depth of cut, and decreases with increasing specific heat and thermal conductivity
of the workpiece material.

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Figure 21.12: Typical temperature

distribution in the cutting zone.
Note the severe temperature
gradients within the tool and the
chip, and that the workpiece is
relatively cool.

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The chip carries away most of the heat generated. In a

typical machining operation, it has been estimated
that 90% of the energy is removed by the chip, with
the remainder taken by the tool and the workpiece.
Note also that, as the cutting speed increases, a larger
proportion of the total heat generated is carried away
by the chip, and less heat is transferred elsewhere.
This is one reason for the continued trend of
Figure 21.14: Proportion of increasing machining speeds (see high-speed
the heat generated in machining, Section 25.5). The other main benefit of
cutting transferred to the
tool, workpiece, and chip as
higher cutting speeds is associated with the favorable
a function of the cutting economics in reducing machining time .
speed. Note that the chip
removes most of the heat.
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Figure 21.15: (a) Features of tool wear in a turning operation. The VB indicates
average flank wear. 69
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Figure 21.15: (b)–(e) Examples of wear in cutting tools: (b) flank wear, (c) crater
wear, 70
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Figure 21.15: (d) thermal cracking, and (e) flank wear and built-up edge.
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Table 21.3: Ranges of n

Values for the Taylor
Equation [Eq. (21.25)] for
Various Tool Materials.

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Taking n = 0.15, x = 0.15, and y = 0.6 as typical values encountered in machining

practice

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Figure 21.16: Effect of

workpiece hardness and
microstructure on tool life in
turning ductile cast iron. Note
the rapid decrease in tool life
(approaching zero) as the
cutting speed increases.

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Figure 21.17: Tool-life curves for a variety

of cutting-tool materials. The negative
reciprocal of the slope of these curves is
the exponent n in the Taylor tool-life
equation [Eq. (21.25)], and C is the cutting
speed at T = 1 min, ranging from about 60
to 3000 m/min in this figure.

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Table 21.4: Allowable Average

Wear Land (see VB in Fig. 21.15a)
for Cutting Tools in Various
Machining Operations.

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Figure 21.18: (a) Schematic illustrations of types of wear observed on various cutting tools.
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Figure 21.18: (b) Schematic illustrations of catastrophic tool failures. A wide range
of parameters influence these wear and failure patterns.
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Figure 21.21: Machined surfaces

produced on steel (highly
magnified), as observed with a
scanning electron microscope: (a)
turned surface and (b) surface
produced by shaping.
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Figure 21.22: Schematic illustration of a

dull tool with respect to the depth of
cut in orthogonal machining
(exaggerated). Note that the tool has a
positive rake angle, but as the depth of
cut decreases, the rake angle effectively
can become negative. The tool then
simply rides over the workpiece
(without cutting) and burnishes its
surface; this action raises the workpiece
temperature and causes surface
residual stresses.

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Figure 21.23: Schematic illustration

of feed marks on a surface being
turned (exaggerated).

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Machinability

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Machinability of Ferrous Metals

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Effects of Various Elements in Steels

The presence of aluminum and silicon is always harmful, because these elements
combine with oxygen, forming aluminum oxide and silicates, which are hard
and abrasive. As a result, tool wear increases and machinability is reduced.

Carbon and manganese have various effects on the machinability of steels,

depending on their composition. Plain low-carbon steels (less than 0.15% C) can
produce poor surface finish by forming a built-up edge.

Other alloying elements, such as nickel, chromium, molybdenum, and vanadium,

that otherwise improve the properties of steels also generally reduce
machinability.

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Machinability of Nonferrous Metals

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Machinability of Miscellaneous Materials

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THE END

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