University of Bahrain

Course: Manufacturing Processes (MENG 312)

Outline:
• Turning and related operations
• Drilling and related operations
• Milling and related operations
• Machining centers and turning centers
• Other machining operations
• High speed machining

Single & Multi-Point Cutting

Operations
Instructor: Prof. Dr. G. Hussain

Department of Mechanical Engineering

 Mechanical 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
 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
 Classification of Machined Parts

 Rotational - cylindrical or disk‑like shape

 Nonrotational (also called prismatic) -
block‑like or plate‑like

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

shown here by block and flat parts.
 Turning
A cutting operation in which single point cutting tool removes
material from a rotating work-piece to generate a cylinder
 Performed on a machine tool called a lathe
 Variations of turning performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Threading
 A Turning Operation

Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert
 Cutting Conditions in Turning

Rotational speed N (rev/min):

Cutting speed at cylinder surface v (m/min)
Final diameter of part:
Feed (mm/rev): f
Feed rate (mm/min): fr

Time to machine:
L: Length of cut/part
Alternatively,
Material Removal rate:

v (m/min); f (m/rev); d (m).

Neglect rotational xtic; v (m3/min)
Example 22.1
 Operations Related to Turning: Facing

Tool is fed
radially inward
- An operation of
reducing
length/thickness of
stock

https://www.youtube.com/watch?v=-J3wN1ruDZM
 Operations Related to Turning: Taper
Turning
 Instead of feeding tool
parallel to axis of
rotation, tool is fed at
an angle thus creating
tapered rotational
shape
Operations Related to Turning: Contour Turning

 Instead of feeding tool

parallel to axis of
rotation, tool follows a
contour that is other
than straight, thus
creating a contoured
shape
Operations Related to Turning: Form Turning

 The tool has a certain shape that is

imparted on the w/p by feeding the tooling
radially
Operations Related to Turning: Chamfering

 Cutting edge cuts an angle on the corner

of the cylinder, forming a "chamfer"
 How is the tool motion?
Operations Related to Turning: Cut Off

 Tool is fed radially into rotating work at

some location to cut off end of part
Operations Related to Turning: Threading

 Pointed form tool is fed linearly across surface

of rotating workpart parallel to axis of rotation,
thus creating threads
Operations Related to Turning: Drilling & Reaming

 Drilling is an operation of making a hole. The

drill (multi-point cutting tool) is fed parallel to
axis of rotation.
 Reaming is an operation of making a drilled
hole accurate and clean.
Operations Related to Turning: 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.
 The purpose of boring is to enlarge the size of
an existing hole
Operations Related to Turning: Knurling

 This is an operation in which regular cross

hatched pattern is imparted on the w/p. This
pattern facilitates holding of a part
 Knurling is not a machining operation, as no
cutting takes place. Instead it is metal forming
operation done in lathe m/c
 Drilling

 Creates a round hole in

a workpart
 Compare to boring
which can only enlarge
an existing hole
 Cutting tool called a drill
or drill bit
 Machine tool: drill press

https://www.youtube.com/watch?v=f5HfRpeT7Fg
 Through Holes vs. Blind Holes
Through‑holes - drill exits opposite side of work
Blind‑holes – does not exit work opposite side

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

 Cutting Conditions in Drilling
-Cutting speed (v) : mm/min
-Feed (f): mm/rev (f~ drill dia)
-Since there are 02 cutting edges, uncut
chip thickness taken by each cutting edge is
half the feed.
-Feed rate (fr) in mm/min: f×N
A
-Time to machine a through hole:
-

-Time to machine a blind hole:

- Material removal rate:

=A× fr
Example 22.2
Operations Related To Drilling: Reaming

 Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish
Operations Related To Drilling: Tapping

 Used to provide
internal screw
threads on an
existing hole
 Tool called a tap
Operations Related To Drilling: Counter-boring
 Provides a stepped
hole, in which a
larger diameter
follows smaller
diameter partially
into the hole
Operations Related To Drilling: Counter-Sinking
 Provides a tapered
step on hole for
screws and bolts
 Boring
 Difference between boring and turning:
 Boring is an operation of enlarging inside diameter
of an existing hole
(inside operation)
 Turning is an operation of reducing outside
diameter of a cylinder (outside operation)
 In effect, boring is internal turning operation

 Types of Boring machines

 Horizontal: The rotational axis of w/p is horizontal
 Vertical - The rotational axis of w/p is vertical
 Horizontal Boring Mill

Fig. Horizontal boring m/c

- Used when Length of part is larger than its diameter; and

the weight is low
https://www.youtube.com/watch?v=v1khAUGQ66M
.
 Vertical Boring Mill
A boring bar made of
cemented carbide

https://www.youtube.com/watch?v=rGsiee2cwp4 A vertical lathe or boring m/c

- Used when Length of part is smaller than its Diameter; and

the part is heavy
 Milling
Machining operation in which work is fed past a rotating tool with
multiple cutting edges to make a flat or contoured surface
Diff b/w Drilling & Milling?
Axis of tool rotation is perpendicular to feed
Creates a planar surface
Other geometries possible either by
cutter path or shape
Other factors and terms:
Cutting tool called a milling cutter,
cutting edges called "teeth"
Machine tool called a milling machine

Interrupted cutting operation:

The cutter teeth enters and exits
the w/p in each revolution. This
interrupted cutting imposes
sudden loads and thermal shocks.
So teeth should be robust
 Two Forms of Milling

https://www.youtube.com/watch?v=AxHexqN0Hr0 https://www.youtube.com/watch?v=VW4AzufWIeQ
&list=PLnqJnnDx5vI_K78gc8G85vwwcF6Ou6TwK

Two forms of milling: (a) peripheral milling, and (b) face

milling.
 Peripheral Milling vs. Face Milling
 Peripheral milling
 Cutter axis is parallel to surface being machined
 Cutting is performed by cutting edges on outside periphery of
cutter
 Face milling
 Cutter axis perpendicular to surface being milled
 Cutting edges on both the end and outside periphery of the cutter
are used in cutting
Types of Peripheral Milling: Slab Milling
 Basic form of peripheral milling in which the cutter
width extends beyond the work-piece on both sides
 Width of cutter larger than width of w/p
 Types of Peripheral Milling: Slotting
 Width of cutter is less than width of w/p,
creating a slot in the work

 If width of cutter is too

small, the tool will
become a saw and the
operations will be called
sawing
Types of Peripheral Milling: Side Milling
Cutter machines the side of a w/p
Types of Peripheral Milling: Straddle Milling
Cutter simultaneously machines the 02 sides of a w/p
 Two Forms of Peripheral Milling

F
Up- Milling Down- Milling
F

- Cutter rotation and feed are in - Cutter rotation and feed are in same
opposite direction direction
- Chip length is large - Chip length is small
- Chip thinner at start than its end - Chip thicker at start than its end
- Tool engages in material for long - Tool engages in material for short time
time - Tool life is longer
- Tool life is smaller - Cutting force presses the part. Result is
- Cutting force is along tangent of low vibration and better surface finish
teeth, so force tries to lift the part
Types of Face Milling: Conventional Face Milling

The cutter overhangs

both sides of w/p

slab milling
High speed face
milling using
indexable inserts
Types of Face Milling: Partial Face Milling

The cutter overhangs

one side of w/p

Any difference b/w partial face milling

& side milling?
face milling

side milling
 End Milling
 Cutter diameter is
less than work width,
so a slot is cut into
part
 Also diameter of tool is
smaller than its height

Difference b/w face & end milling?

- In face milling, cutter dia is larger than
its height but in end milling cutter dia
smaller than its height

slotting
 End milling: Profile Milling
Form of end milling
in which the
outside periphery
of a flat part is cut
 End milling: Pocket Milling
 Another form of
end milling used
to mill shallow
pockets into flat
parts
 End milling: Surface Contouring
 Ball‑nose cutter fed
back and forth
across work along a
curvilinear path at
close intervals to
create a three
dimensional surface
form
 Cutting Conditions in Milling
Rotational speed:
Feed (f): Feed/tooth in mm/tooth/rev
Feed rate: nt: no of teeth
RMR: (Area of cut × fr)
If w is width of cut; d is depth of cut:

Cut time:

Face Milling

Peripheral Milling
 Example 22.3
A peripheral milling operation is performed on a rectangular workpiece that is 320 mm long by 60
mm wide by 56 mm thick. The 65-mm-diameter milling cutter has 4 teeth, is 80 mm wide, and
overhangs the work on either side by 10 mm. The operation reduces the thickness of the piece to
50 mm. Cutting speed = 0.50 m/s and chip load = 0.24 mm/tooth . Determine the (a) machining
time and (b) metal removal rate once the cutter reaches full depth
 A Problem
A face milling operation is used to machine 6.0 mm from the top surface of a rectangular piece of
aluminum 300 mm long by 125 mm wide in a single pass. The cutter follows a path that is centered over
the workpiece. It has four teeth and is 150 mm in diameter. Cutting speed = 2.8 m/s, and chip load = 0.27
mm/tooth. Determine (a) the actual machining time to make the pass across the surface and (b) the
maximum metal removal rate during cutting.

Solution:
 Shaping and Planing
 Similar operations
 Both use a single point cutting tool

(a) Shaping, and (b) planing.

 Shaping and Planing
 A straight, flat surface is created in both
operations
 Interrupted cutting
 Subjects tool to impact loading when
entering work
 Low cutting speeds due to start‑and‑stop
motion
 Typical tooling: single point high speed steel
tools
 Broaching
 Moves a multi-tooth cutting tool linearly
relative to work in direction of tool axis
 Broaching
Advantages:
 Good surface finish
 Close tolerances
 Variety of work shapes possible
 High material removal rate
Cutting tool called a broach
 Owing to complicated and often
custom‑shaped geometry, tooling is expensive
 Internal Broaching

 Performed on internal surface of a hole

 A starting hole must be present in the part to
insert broach at beginning of stroke

Work shapes that can be cut by internal broaching; cross‑hatching

indicates the surfaces broached.
 High Speed Machining

Table 1: Comparison of cutting speeds used in conventional vs. high-speed machining for
selected work materials

The high-speed range varies from material to material

High Speed Machining
High Speed Machining
High Speed Machining
 High Speed Machining

Requirements for high-speed machining :

(1)High-speed spindles using special bearings designed for high rpm

operation;
(2)High feed rate capability, typically around 50 m/min (2000 in/min);
(3)CNC motion controls
(4) Balanced cutting tools, toolholders, and spindles to minimize vibration
effects;
(5) Coolant delivery systems that provide flow pressures greater than that in
conventional machining;
(6) Chip control and removal systems to cope with the much larger metal
removal rates in HSM.
 High Speed Machining
Applications :

(1)Aircraft
(2)Automotive
(3)Computer
(4)Medical
(5)Dies & molds

Benefits:
(1)Reduced cost
(2)Higher productivity
(3)Good finish
(4)Compressive stresses
 Taylor Tool Life Equation
Relationship is credited to F. W. Taylor
n
Tool life: length of cutting time vT C
that a tool can be used. where v = cutting speed; T
= tool life; n is the slope of
the plot; C is the intercept
on the speed axis at one
minute tool life
C
n and C are parameters
that depend on feed,
n depth of cut, work
material, tooling material,
and the tool life criterion
used
 Homework

22.1 to 22.4; 22.10, 22.11, 22.14, 22.15