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Machining

Machining is a material removal process that uses a sharp cutting tool to shape metal parts with high precision and versatility. It includes various operations such as turning, drilling, milling, and boring, each producing distinct part geometries based on the tool's motion and shape. Machined parts are classified as either rotational or nonrotational, with specific techniques like threading and reaming enhancing functionality.

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32 views22 pages

Machining

Machining is a material removal process that uses a sharp cutting tool to shape metal parts with high precision and versatility. It includes various operations such as turning, drilling, milling, and boring, each producing distinct part geometries based on the tool's motion and shape. Machined parts are classified as either rotational or nonrotational, with specific techniques like threading and reaming enhancing functionality.

Uploaded by

tihoco1586
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Machining

A material removal process in which a sharp cutting tool


is used to mechanically cut away material so that the
desired part geometry remains

• Most common application: to shape metal parts

• Machining is the most versatile and accurate of all


manufacturing processes in its capability to produce
a diversity of part geometries and geometric features
− Casting can also produce a variety of shapes, but
it lacks the precision and accuracy of machining
MACHINING OPERATIONS AND
MACHINE TOOLS
• Turning and Related Operations
• Drilling and Related Operations
• Milling
• Machining Centers and Turning Centers
• Other Machining Operations
• High Speed Machining
Classification of Machined Parts
1. Rotational - cylindrical or disk-like shape
2. Nonrotational (also called prismatic) - block-like or
plate-like

Figure - Machined parts are classified as: (a) rotational, or (b)


nonrotational, shown here by block and flat parts
Machining Operations and Part Geometry

Each machining operation produces a characteristic part


geometry due to two factors:
1. Relative motions between the tool and the
workpart
• Generating – part geometry is determined by
the feed trajectory of the cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by the
shape of the cutting tool
Figure: Generating shape: (a) straight turning, (b) taper
turning, (c) contour turning, (d) plain milling, (e) profile milling
Figure :Forming to create shape: (a) form turning, (b) drilling,
and (c) broaching
Figure - Combination of forming and generating to create
shape: (a) thread cutting on a lathe, and (b) slot milling
Turning

A single point cutting tool removes material from a


rotating workpiece to generate a cylindrical shape
• Performed on a machine tool called a lathe
• Variations of turning that are performed on a lathe:
− Facing
− Contour turning
− Chamfering
− Cutoff
− Threading
Figure - Turning operation
Facing
Tool is fed
radially inward

Figure : facing
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

Figure : contour turning


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

Figure : chamfering
Cutoff
Tool is fed radially into rotating work at some location to
cut off end of part

Figure : cutoff
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

Figure : threading
Boring
• Difference between boring and turning:
− Boring is performed on the inside diameter of an
existing hole
− Turning is performed on the outside diameter of
an existing cylinder
• In effect, boring is an internal turning operation
• Boring machines
− Horizontal or vertical - refers to the orientation of
the axis of rotation of machine spindle
Figure - A vertical boring mill –for large, heavy workparts
Drilling
• Creates a round hole in
a workpart
• Contrasts with boring
which can only enlarge
an existing hole
• Cutting tool called a drill
or drill bit
• Customarily performed Figure (b) drilling
on a drill press
Reaming
Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish

Figure - Machining
operations related to
drilling:
(a) reaming
Tapping
Used to provide
internal screw
threads on an
existing hole
Tool called a tap

Figure (b) tapping


Counterboring
Provides a stepped
hole, in which a
larger diameter
follows a smaller
diameter partially
into the hole

Figure (c) counterboring


Milling
Machining operation in which work is fed past a rotating
tool with multiple cutting edges
• Axis of tool rotation is perpendicular to feed direction
• Creates a planar surface; other geometries possible
either by cutter path or shape
• Other factors and terms:
− Milling is an interrupted cutting operation
− Cutting tool called a milling cutter, cutting edges
called "teeth"
− Machine tool called a milling machine
Figure - Two forms of milling:
(a) peripheral milling, and (b) face milling

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