Manufacturing Processes-I

Machining Processes

Dr. M. Muhshin Aziz Khan

Associate Professor
Material Removal Processes
A family of shaping operations, the common
feature of which is removal of material from a
starting workpiece so that the remaining part
has the desired geometry
 Machining – material removal by a sharp
cutting tool, e.g., turning, milling, drilling
 Abrasive processes – material removal by
hard, abrasive particles, e.g., grinding
 Nontraditional processes - various forms
of energy other than sharp cutting tool are
used to remove material
 Material Removal Processes
 The family tree
 Machining
A material removal process in which a sharp cutting
tool is used to mechanically remove unwanted
material to obtain a desired part geometry.
 Cutting action involves shear deformation of work
material in the form of a chip.
 As chip is removed, new surface is exposed.

 Most common application: to provide shapes to

metal parts
 Most versatile of all manufacturing processes in its
capability to produce a diversity of part geometries
and geometric features with high precision and
accuracy-
 Casting can also produce a variety of shapes,

but it lacks the precision and accuracy of

machining
 Why Machining is Important

 Variety of work materials can be machined

 Most frequently used to cut metals
 Variety of part shapes and special geometric
features can be made:
 Screw threads
 Accurate round holes
 Very straight edges and surfaces
 Good dimensional accuracy and surface finish
Disadvantages with Machining

 Wasteful of material
 Chips generated in machining are wasted
material
 At least in the unit operation

 Time consuming
 A machining operation generally takes
longer to shape a given part than alternative
shaping processes
Machining in the Manufacturing
Sequence
 Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
 Other processes create the general shape of
the starting workpiece.
 Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot create
 Classification of Machined Parts

 Rotational: cylindrical or disk‑like shape

 Non-rotational (also called prismatic):
block‑like or plate‑like

Fig1 Machined parts are classified as: (a) rotational, or (b) non-
rotational, shown here by block and flat parts.
Machining Operations and Part Geometry
 In machining operations, either job or tool are moved against
each other to make a desired shape.
 Each machining operation produces a geometric feature of
the part due to two factors:
 Relative motions between tool and workpiece
 Generating:
 Shape of the cutting tool does not play any role in
producing the desired shape of a component.
 Motion of the tool or workpiece forms the basis of
production i.e. part geometry is determined by
feed trajectory of cutting tool or workpiece.
 Shape of the cutting tool
 Forming:
 Surface produced is the true replica of the shape
of the cutting tool.
 It is the formed shape of the tool that enables the
production of a particular shape, and not merely
the relative movements.
 Generating Shape

Fig 2 Generating shape: (a) straight turning, (b) taper turning,

(c) contour turning, (d) plain milling, (e) profile milling.
Forming to Create Shape

Fig 3 Forming to create shape: (a) form turning,

(b) drilling, and (c) broaching.
 Forming and Generating

Fig 4 Combination of forming and generating to create shape:

(a) thread cutting on a lathe, and (b) slot milling.
 Cutting Tool Classification
 Cutting tool performs the main machining operation.
 It is a body having teeth or cutting edges on it.
 Tools can be divided into two categories:
1. Single-Point Tools
 One dominant cutting edge.

 Point is usually rounded to form a nose radius.

 Turning, facing, boring, parting and sorting,

planning and shaping tools use single point

tools.
2. Multiple Point or Cutting Edge Tools
 More than one cutting edge.

 Motion relative to work achieved mostly by

rotating.
 Drilling, reaming, and milling use rotating

multiple cutting edge tools

Operating Conditions in Machining
 Set of process parameters selected for machining is reffered to as
operating condition in machining operations.
 The cutting conditions for metal removal are selected so that:
 optimal input power is required for machining
 tool life becomes reasonably high and
 cutting time is kept short.
 Three primary process parameters for machining:
 Cutting speed
 primary motion

 The distance travelled by the worksurface in a unit time with

reference to the cutting edge
 Surface speed of the workpiece at which the workpiece
passes the cutter.
 Simply referred to as speed, v and expressed in m/min.

 It is difficult to standardize the cutting speed of a material,

as it depends on many factors:
 Chararacteristics of workpiece material

 Cutting tool material

 Types of machine tool and machining operations

 Depth of cut, and

 Amount of feed.
Operating Conditions in Machining
 Feed
 Secondary motion
 It refers to the amount of tool advancement per revolution of
the job parallel to the surface of the job to be machined.
 Expressed in mm/rev for turning, mm/tooth for milling.
 Feed of a tool depends on:
 The depth of cut,
 The surface finish required,
 Characteristics of the cutting tool and workpiece material,
 Purpose of the machining (rough or finish machining),
and
 Rigidity of the machine tool used.

 Depth of cut
 Penetration of the tool below the original work surface.
 It refers to the advancement of the cutting tool in the job in a
direction perpendicular to the surface being machined.
 Depth of cut varies depending on the type of surface finish
required
Cutting Conditions in Turning

 Speed, feed, and depth of cut in a turning

operation
 Roughing vs. Finishing Cuts
 In production, several roughing cuts are usually
taken on a part, followed by one or two
finishing cuts.

 Roughing - removes large amounts of

material from starting workpiece
 Some material remains for finish cutting

 High feeds and depths, low speeds

 Finishing - completes part geometry

 Final dimensions, tolerances, and finish

 Low feeds and depths, high cutting

speeds
 Machining Equipment
 A power‑driven machine that performs various metal
cutting operations for providing different shapes and
sizes.
 Also known as machine tool.
 Functions in machining:
 Holds and supports cutting tool and workpiece

 Directs and guides cutting tool relative to work

 Provides power at speed, feed, and depth of cut

that have been set

 Machine tool and machine are two different things.
 Machine tools when taken as a group can

produce a machine tool, which is not true for

machines.
Turning and related operations
The workpiece is rotated against a single point cutting tool that
removes unwanted material to generate cylindrical or axis-
symmetric parts.
 Cutting tool is moved on a precise path with respect to
rotating workpiece (axis of rotation).
 Turning operation is performed on a machine tool called a
lathe.
 The job is securely and rigidly set in the chuck or in
between centres on the lathe machine and then
 turn it against a single point cutting tool that removes
metal from the job in the form of chips.
 Various turning operations performed on a lathe:
 Facing

 Taper turning

 Contour turning

 Chamfering

 Cutoff

 Threading
 Taper turning
 A taper is defined as a uniform increase or decrease in diameter of
a cylindrical workpiece measured along its length.
 Taper turning is a process of producing a conical surface by
gradual reduction in diameter from a cylindrical workpiece.
 A taper is generally turned by feeding the tool at an angle to
the axis of rotation of the workpiece.
 The angle formed by the path of the tool with the axis of the
workpiece should correspond to the half taper angle.
 Taper in British system is expressed in taper per feet or taper
per inch.
D d
 Taper per inch 
l
 Cone-shaped parts can be produced on a lathe:
 By a compound slide or rest
 By offsetting the tailstock
 By a taper turning attachment
 By a forming tool.
 Taper turning …Cont’d

Taper turing by compound slide

 The compound slide consists of a base graduated in degrees
which can be swivelled to any angle with the axis of the
workpiece.
 Suitable for short tapers as the length of the compound slide is
limited.
 How it works:
 The compound slide is set to a required angle and

 Feed is then provided to the cutting tool manually.

 Two methods commonly used for setting of

compound slides:
 By means of graduations
 In accordance with the master specimen.
The empirical formula used for calculating the
taper is D d  H
 tan 
2L 2 Base
 Taper turning …Cont’d

Taper turing by offsetting the tailstock

 The oldest and most commonly used method of taper turning.
 This method is generally used for turning long and slim tapers.
 How it works:
 The tailstock centre is offset (relocated) from the centre, and

 Cutting tool is then moved in longitudinal direction.

 Its advantage is that an automatic longitudinal feed can be engaged.

 The amount of relocation (offset) of the tailstock should not exceed
1/50th of the length of the workpiece.
 The lathe centres will have a poor contact.

 The formula used for finding the tailstock set over is:
 Taiilstock offsetting = taper length x sine of half the taper angle.

D d 
 L  sin
2 2
 When a part of the workpiece is to be given a taper, then
Tailstock offsetting =
D d total .length .of .the . job
( )( )
2 taper .length
Taper turning …Cont’d

Taper turning by a forming tool

 A flat tool set at a proper angle is used for cutting a taper
on the workpiece.
 Limited to short external tapers and is not commonly
used.

Rules for taper turning

 Always set the cutting edge of the tool to the exact
centre height.
 While developing tapers with a compound slide between
centres, the compound slide must be properly aligned.
 While producing tapers with offsetting tailstock, length of
the workpieces and depth of centre holes must be the
same.
 While cutting tapers with a taper turning attachment, the
sliding parts must be properly lubricated.
 Facing
 A process of making flat surface whose
plane is normal to the axis of rotation of
the part.
 How the process works:
 Workpiece is rigidly fixed on a
faceplate or chuck, and
 The cutting tool is then moved
radially toward the axis of rotation.
 Cutting tool can also be moved
from the centre, but other
direction is more common.
 Facing, in turn, reduces length of the
part.
 The operation is used to produce flat
surfaces on casting and other parts
that usually also require turning or
some other lathe operation.
 Grooving
 A process of cutting grooves into
internal or external surface.
 Internal grooves are usually
called recesses.
 How the process works:
 Cutting tool is ground to the
width and bottom shape
required, and then
 fed radially into the rotating
workpiece
 The result is a groove of
desired dimensions in the
part.
 Knurling
 A process of rendering a rough surface on a workpiece by making
a series of indentations or depressions on it.
 Knurling is not a machining operation as the knurl is formed,
not cut.
 Indentations are generally of criss-cross pattern (diamond
pattern) and can be classified into three categories: coarse,
medium, and fine.
 Another form of indentation is known as straight knurling
 How the process works:
 The hardened knurl tool is pressed and rolled against the
cylindrical surface of the rotating workpiece with high
pressure, causing surface material of the workpiece to flow
into peaks and valley according to the pattern of the
knurling tool.
 A rough surface of particular pattern is formed in the
finished part.
 Uses of knurling operation:
 To improve the grip if the part must be held or rotated by
hand when it is used.
 To increase diameter of the part slightly to facilitate a press
fit.
 Decoration purpose.
 Cutting off (Parting)
 A process of severing the final part from the
remaining bar stock.
 How the process works:
 A cutoff tool, a narrow grooving tool, is fed
radially into the rotating workpiece.
 When the cutting edge advances the
axis of rotation of the part, the part is
severed and falls to the bed of the
machine.
 Use of parting operation:
 When the final parts are made from the bar
stock, it is used as final operation to sever
the part from the remaining bar material.
 Chamfering
 A process of beveling the sharp edges of
the workpiece to avoid any injuries to the
persons using the finished product.
 How the process works:
 Similar to form turning
 A chamfer tool is used that has its
cutting edge at a desired chamfer
angle, usually 45°.

 The chamfer is provided

 For better look,
 To enable nut to start freely on
threaded workpiece,
 To remove the burrs, and
 To protect the end of the workpiece
being damaged.
 Thread Cutting
 An operation of cutting threads or helical grooves of specific shape (V or
square) on the external cylindrical surface of the job.
 How the process works:
 The job is held in between centers or in a chuck and the single
point cutting tool (thread cutting tool) is held on tool post.
 To make or cut threads:
 the cutting tool is brought to the start of job and a small depth
of cut is given to cutting tool using cross slide.
 The cutting tool must travel a distance equal to the pitch of
the thread to be cut (in mm) as the work piece completes a
revolution.
 The pitch of the thread to be cut equals to
r. p.m. of lead screw
r.p.m. of workpiece × Pitch of lead screw.

 These definite relative rotary and linear motions between

job and cutting tool are achieved by:
 locking or engaging a carriage motion with lead screw
and nut mechanism, and
 fixing a gear ratio between head stock spindle and lead
screw (change gear mechanism or gear box).
 Primary Machining Parameters
 Cutting Speed – (v)
 Primary motion
 Peripheral speed m/s ft/min
 Feed – (f)
 Secondary motion
 Turning: mm/rev in/rev
 Milling: mm/tooth in/tooth
 Depth of Cut – (d)
 Penetration of tool below original work surface
 Single parameter mm in
 Resulting in Material Removal Rate – (MRR)
MRR = v f d mm3/s in3/min
where v = cutting speed; f = feed; d = depth of cut
30
Machining Calculations: Turning
 Spindle Speed - N (rpm)
v
 v = cutting speed N 
π Do
 Do = outer diameter

 Feed Rate - fr (mm/min -or- in/min)

 f = feed per rev
fr  N f
 Depth of Cut - d (mm -or- in)
 Do = outer diameter
 Df = final diameter Do  D f
d 
2
 Machining Time - Tm (min)
 L = Actual length of cut L
T
= A (2-5mm) + Lw + O(1-3mm)m 
fr

 Material Removal Rate - MRR (mm3/min -or- in3/min)

MRR  v f d
 Example
In a production turning operation, the foreman has decided that a
single pass must be completed on a 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?
Solution:
Machining Time:
Tm = L/fr = L/(N*f) = (πDo * L)/(v*f)

v = (π Do *L)/(f*Tm)
= π(0.4)(0.15)/(0.30)(10-3)(5.0)
= 0.1257(103) m/min
= 125.7 m/min
Power and Energy Relationships
 Product of cutting force and speed provides the power (energy per
unit time) required to perform a machining operation:
Pc = Fc * v N-m/s (W) ft-lb/min
where:
Pc = cutting power requirement;
Fc = cutting force; and
v = cutting speed
 Customary U.S. units for power are Horsepower (= 33000 ft-lb/min).
 HPc = (Fc * v) / 33000.

 The Gross power required to operate the machine tool is greater

than the power delivered to machining process.
 Mechanical losses in motor and drive train in the machine tool.
 These losses are accounted for by mechanical efficiency of the
machine tool.

Pc HPc
Pg  HPg 
E E
where, E = mechanical efficiency of machine tool.
 Typical values of E for machine tools is around 90%
 Unit Power in Machining
 Useful to convert power into power per unit volume rate of metal
cut
 This is called the unit power, Pu or unit horsepower, HPu
Pc HPc
Pu  HP 
MRR u
MRR
 Unit power is also known as specific energy, U i.e. Power
required to cut unit volume of material
Pc F
U  Pu   c
MRR t ow
where MRR = material removal rate
t0 = un-deformed chip thickness;
w = width of the chip; and
Fc = cutting force

 Tool sharpness is taken into account multiply by

1.00 – 1.25
 Example
 In a turning operation on stainless steel with hardness =
200 HB, the cutting speed = 200 m/min, feed = 0.25
mm/rev, and depth of cut = 7.5 mm. How much power will
the lathe draw in performing this operation if its mechanical
efficiency = 90%.
 From Table 21.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
Pc
Pu 
MRR

 MRR = v * f * d
 Turning Operation
 Workpice Materials
 Aluminum
 Brass
 Plastics
 Cast Iron
 Mild Steel
 Effect of Turning on Work Material Properties
 Mechanical
 Creates residual stresses, micro cracks
 May cause workhardening of unhardened materials
 Physical
 Little effect
 Chemical
 Little effect
 Advantages
 Increased production with medium and high turret lathes.
 Disadvantages
 Limited to rotational parts.
 High equipment cost.
 Significant tool wear.
 Low production rate.
 Large amount of scrap.
 Drilling
 It is an operation of making a round hole in a workpiece usually by means
of a rotating tool (drill bit) that has two or more cutting edges.
 How the process works:
 The job is placed on the adjustable table or base and is clamped
firmly both foe safety and accuracy to overcome the high drilling
torque.
 A loose workpiece can get damaged or break the drill or
injure the operator.
 The cutting tool is fastened to the end of the vertical spindle and is
rotated at the desired speed.
 The rotating drill is fed against the stationary workpiece by hand
feed or power feed.
 Vertical motion of the drill is the feed in drilling operations.
 Manual feed requires some skill in judging the appropriate
feed rate.
 Problem in drilling:
 Hole produced by drilling is larger than the drill diameter.
 Amount of oversize depends on:
 The quality of drill, the equipment used and the practices
employed.
 Through Holes vs. Blind Holes
 Through‑holes
 drill exits the opposite side of work
 Blind‑holes
 drill does not exit work on opposite side

Two hole types: (a) through‑hole, and (b) blind hole

Machining Calculations: Drilling
 Spindle Speed - N (rpm)
v = cutting speed v
N 


 D = tool diameter π D
 Feed Rate - fr (mm/min -or- in/min)
 f = feed per rev fr  N f
 Machining Time - Tm (min)
 Through Hole :
 t = thickness t  ( A  O )  12 D tan  90  2 
Tm 
  = tip angle fr
 Blind Hole : d  (A)
 d = depth Tm 
fr
 Material Removal Rate - MRR (mm3/min -or- in3/min)

π D 2 fr
MRR 
4
 Drilling Operation
 Workpice Materials
 Aluminum alloys
 Magnesium alloys
 Copper alloys
 Stainless steels
 Cast iron
 Plastics

 Effect of Drilling on Work Material Properties

 Mechanical
 Very thin layer of highly stressed and disturbed material on
new surface.
 Physical
 Little effect
 Chemical
 Increased probability of corrosion at stressed surface.
 Advantages
 High production rate.
 Disadvantages
 Skilled labor is required according to the hole location and
accuracy
 Boring
 It is an operation of enlarging of a hole already made in a work
piece.
 A long bar used to position a single-point tool for boring
operations.
 The diameter of the boring tool fitted with a tool bit has to be
smaller than the hole in the work piece.
 How the process works:
 A boring tool or a bit (single point cutting tool) mounted on a
rigid bar is
 held in the tool post and

 fed into the work by hand or power in the similar way as for
turning.
 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 internal turning operation.

 Boring machines
 Horizontal or vertical - refers to the orientation of the axis of
rotation of machine spindle
 Boring Operation
 Workpice Materials
 Aluminum
 Brass
 Plastics
 Cast Iron
 Mild Steel

 Effect of Boring on Work Material Properties

 Mechanical
 Creates residual stresses, micro cracks
 May cause work hardening of unhardened materials.
 Physical
 Little effect
 Chemical
 Little effect.

 Advantages
 Finish machining of cylindrical surfaces on very large
workpiece.
 Reaming
 This is the operation of sizing and finishing a hole already made by
a drill.
 A multi-point cutting tool with straight cutting edges (Reamer)
used to size or smooth holes.
 A reamer follows the original hole and cannot shift its centre.
 Reamer
 Possesses several cutting edges on outer periphery
 May be classified as solid reamer and adjustable reamer
 Reaming operation serves to make the hole smooth, straight
and accurate in diameter.
 Reamers cannot remove much material, but at the same time,
enough material should be available all round.
 Srock Allowance:
 Needed to work efficiently.
 For holes up to 12.5 mm in diameter, about 0.38–0.4 mm of
material is left as reaming allowance.
 Various Drilling and Boring
Operations
 Step Drilling:
 More than one diameter is drilled at a time on the drill body
 It saves an extra operation.
 Counter Boring:
 It is an operation of enlarging the mouth (end) of a drilled hole
 It is done to set bolt heads and nuts below the surface so that
they may not project out from the surface level.
 A counter boring tool similar to an end mill or a single
blade ground to give two cutting edges is used and
 is guided by a pilot pin to ensure that the counter-bore is
concentric with the drilled hole.
 Counter Sinking:
 This is the operation of making a cone shaped enlargement of
the end of a drilled hole for making a conical seat for a flat
head screw.
 Counter sinking provides a tapered entrance to the hole. A
special counter sinking tool with a pilot is used.
 Drilling Machine
 Drill Press
 Light duty machine and is capable of
drilling a hole of 12mm dia (max).
 Upright drill press stands on the floor.
 Bench drill is similar but smaller and
mounted on a table or bench.
 Part is kept on the table and
clamped in appropriate position.
 Hole is drilled by lowering the
spindle of the drilling head.
 Workpiece has to be moved so

as to align the center of the

hole exactly below the spindle.

 Radial Drill
 Large drill press designed for larger and
heavier workpieces.
 Table is integral part of the base.
 Hole is drilled at required

postion by combined
movement of the radial arm
and drilling head.
 Shaping
 It is a process of producing small straight, flat surfaces: horizontal,
vertical, or inclined.
 Shock initiated machining process: Subject tool to impact loading.
 How the process works:
 Workpiece is rigidly held in a vice or clamped directly on the
table.
 A single point cutting tool is held in the tool holder, which is
mounted on the ram.
 The ram reciprocates and thus cutting tool held in tool holder
moves forward and backward over the workpiece.
 Tool performs the cutting operation during its forward
stroke.
 The backward stroke remains idle and no cutting takes
place during this stroke.
 Both the forward and backward strokes form one working
cycle of the shaper.
 The feed is given to the workpiece after one working cycle, and
 The depth of cut is adjusted by moving the tool downward towards the
workpiece.
 The time taken during the idle stroke is less as compared to
forward cutting stroke.
 This is obtained by quick return mechanism.
Shaping: Quick Return Mechanism
 The pinion receives its motion from an individual
motor and transmits the motion to the bull gear.
 A radial slide bolted to the centre of the bull
gear carries a sliding block.
 It is mounted on the crankpin and fitted within
the slotted link (rocker arm).
 Rocker arm is pivoted at its bottom end
and connected to ram block by a pin.
 With the rotation of bull gear, crank pin will
rotate on the crank pin circle, and
simultaneously move up and down the slot in
the slotted link giving it a reciprocating
movement to the ram.
 Planning
 Planning is similar to shaping:
 A shock initiated machining process,
 Low cutting speed due to start-and-stop motion, and
 Used to produce straight, flat surfaces on the workpieces
 Parts are too large and heavy to be accomodated on the
shaping machine table.
 Basic difference from shaping:
 During planning,
Planning  the cutting tool remains stationary and the work piece
travels back and forth under the cutting tool.
 The feed is given to the cutting tool and not to the table.
 Heavier cuts and coarse feed can be employed.
 Several tools can cut simultaneously.
 Table is driven either by gears or by hydraulic means.
 Advantages of planning and shaping
 Suitable for low quantity production.
 Flat surfaces and straight profiles can be obtained on relatively
Shaping small surfaces.
 Disadvantage of planning and shaping
 Complex parts require skilled labor.
Machining Calculations: Shaping and
Planning
 Number of (double) Stroke per min - Ns N s  (1000Vc ) / [Lc (1  Q )]
 Vc = cutting speed, m/min
 Lc = Stroke Length, mm
= Lw + (A + O)
 Lw = Length of the workpiece, mm
 Q = Quick Return Ratio
= (Time of Return Stroke)/(Time of Cutting Stroke)

 Feed Rate - fr (mm/min) fr  Ns f

f = feed (mm) per (double) stroke
Lw 


 Machining Time - Tm (min) Tm 

Nsf
 Lw’ = Total length of travel of the workpiece, mm
= W + (A/ + O/)
 W = Width of the workpiece, mm

 Material Removal Rate – MRR (mm3/min)

MRR  dLc f r
 d = depth of cut, mm
 Milling
 A machining operation in which work is fed past a rotating tool
with multiple cutting edges.
 How the process works:
 Workpiece is rigidly clamped on the table of the machine
or in a chuck or an index head
 A revolving multiteeth cutter is mounted either on a
spindle or on an arbor.
 Job or workpiece is fed slowly past the cutter.
 Axis of tool rotation is perpendicular to feed

 Other factors and terms:

 Interrupted cutting operation

 Cutting tool called a milling cutter, cutting edges

called "teeth"
 Creates flat surfaces or curved profile and many other

intricate shapes
Peripheral milling  With a great accuracy and

 Having a very good surface finish.

 Basic Milling Methods
 Two distinct methods of milling:
 Up-milling or conventional milling:
 The cutting tool (milling cutter) and the workpiece move in

opposite direction at the point of their contact.

 Chip thickness is minimum at the start of the cut and

maximum at the end of the cut.

 Cutting force varies from zero to maximum value per

tooth movement of the milling cutter.

 Disadvantages:

 Tendency of the cutting force is to lift the workpiece

Process being safe, from the fixture.

up-milling is the  Poor surface finish.

most common
method of milling
 Basic Milling Methods
 Down-milling or Climb milling:
 The cutting tool (milling cutter) and the workpiece move in

the same direction at the point of their contact.

 Teeth cut downward instead of upward.

 Chip thickness is maximum at the start of the cut and

minimum at the end of the cut.

 Advantages:

 Used to increase the number of pieces per sharpening

 Better surface finish.

 Lower power consumption

Friction being less,  Saws cut long thin slots more satisfactorily.
less heat is
generated during
down-milling.
Types of Milling Processes
 Broadly classified into peripheral and face
milling.
 Peripheral Milling
 Cutter axis is parallel to surface being
machined
 Cutting edges are on outside periphery
of cutter
 Face Milling
 Cutter axis is perpendicular to surface
being milled
 Cutting edges are on both the end and
outside periphery of the cutter
 Milling Processes
 Slab Milling
 Basic form of peripheral milling in which the cutter width
extends beyond the workpiece on both sides. (tool axis
parallel to machined surface)

 Slotting
 Width of cutter is less than workpiece width, creating a
slot in the work. (tool axis parallel to machined surface)

 Conventional Face Milling

 Cutter overhangs work on both sides. (tool axis
perpendicular to machined surface)
 Machining Calculations: Milling
 Spindle Speed - N (rpm)
v
 v = cutting speed N 
 D = cutter diameter π D
 Feed Rate - fr (mm/min)
 f = feed per tooth fr  N nt f
 nt = number of teeth

L  d D d 
 Machining Time – Tm (min)
 Slab Milling: Tm 
 L = length of cut fr
 d = depth of cut
L D
 Face Milling: Tm 
 w = width of cut fr
L  2 w  D w 
 2nd form is multi-pass Tm 
fr

 Mat’l Removal Rate – MRR (mm3/min) MRR  w d fr

 Milling Operation
 Workpice Materials
 Aluminum
 Brass
 Magnesium
 Nickel
 Steel
 Thermostat plastics
 Titanium
 Zinc

 Advantages
 Variety of shapes can be obtained
 Disadvantages
 Skilled labor is required
 Low to medium production rate
 Limited shape complexity
 High equipment cost
 Significant tool wear
 Large amount of scrap