MANUFACTURING PROCESSES

TURNING

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 THEORY OF METAL MACHINING
• Machining is a manufacturing process in which a
sharp cutting tool is used to cut away material to
leave the desired part shape.
• The predominant cutting action in machining
involves shear deformation of the work material
to form a chip; as the chip is removed, a new
surface is exposed.
• Machining is most frequently applied to shape
metals.
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An Orthogonal Cutting

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A Cross-sectional View Of The Machining Process

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 THEORY OF METAL MACHINING
• Machining is not just one process; it is a group of
processes.
• The common feature is the use of a cutting tool
to form a chip that is removed from the
workpart.
• To perform the operation, relative motion is
required between the tool and work.

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 THEORY OF METAL MACHINING
• This relative motion is achieved in most
machining operations by means of a PRIMARY
MOTION, called the CUTTING SPEED, and a
secondary motion, called the feed.
• The shape of the tool and its penetration into the
work surface, combined with these motions,
produces the desired geometry of the resulting
work surface.

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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.
• 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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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 radially 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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 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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 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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 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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 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

lL
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 CUTTING SPEED ( v )

• Cutting speed may be defined as the rate (or

speed) that the material/job moves past the
cutting edge of the tool.
Rough Cut Finish Cut
Material m/min m/min

Cast iron 18 24
Bronze 27 30
Aluminum 61 93

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CUTTING SPEED ( v ) mm/min

v = π Do N (1)

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, 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.

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 Feed Rate ( fr ) mm/min

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

advances along length of work for every
revolution of the spindle.
• This feed can be converted to a linear travel rate
(Feed Rate) ( fr ) in mm/min by the formula

fr = Nf (2)

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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.
• In other words, it is the perpendicular distance
measured from the machined surface to the
unmachined surface of the work piece.
• It is usually expressed in millimeters.
 DEPTH OF CUT ( d ) mm
• The thickness of material removed by one pass of
the cutting tool is called Depth of Cut.

Do - Df (3)
d =
2
d depth of cut mm
Do original dia of the part mm
Df final dia of the part mm 26
 MACHINING LENGTH ( l ) mm
l Tool pre-travel
L a

l = L + a (4)
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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 = = (5)
fN fv
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 MATERIAL REMOVAL RATE ( RMR ) mm3/min

• It is the volume of material removed per unit

time.

(6)

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 MATERIAL REMOVAL RATE ( RMR ) mm3/min

• It is the volume of material removed per unit

time.

volume π [ (Do )2 - (Df )2 ] l

• RMR = =
time 4 TM
π [ (Do )2 - (Df )2 ] l (fN)
• RMR =
4l
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MATERIAL REMOVAL RATE ( RMR ) mm3/min

RMR = π [ (Do – Df ) (Do + Df ) ] l (fN)

(2) (2) l

RMR = π d Davg f N
RMR = vfd because (π DavgN = v )
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 NO. OF PASSES (n)

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

where, d is DOC per pass

Total machining time = n TM

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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 Formula Used

l = 900 mm (1)

v = 2.50 m/s = 2500 mm/s (2)

(5)
f= 0.3 mm/rev
MRR = vdf mm 3/s
d =2 mm

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 TURNING NUMERICAL 1

N = (2500)/125π = 6.366 rev/s (1)

fr = 6.366(.3) = 1.91 mm/s (2)

TM = 900/1.91 = 471.2 s = 7.85 min (5)

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 TURNING NUMERICAL 1

MRR = vfd (6)

= (2500)(.3)(2.0)
= 1500 mm 3/s

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 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 Formula Used

l = 400 mm (5)

Do = 150 mm Ans:-125.7 m/min

f= 0.3 mm/rev

d =4 mm Extra Info

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