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in JNTU World
ld
MACHINING OPERATIONS
or
AND MACHINE TOOLS
1. Turning and Related Operations
W
2. Drilling and Related Operations
3. Milling
4. Machining & Turning Centers
TU
5. Other Machining Operations
6. Shape, Tolerance and Surface Finish
7. Machinability
8. Selection of Cutting Conditions
JN
9. Product Design Consideration
1
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1. Turning & Related Operations
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Turning a machining v
Rotational Speed: N =
process in which a Do
or
single-point tool remove Do D f = 2d
material from the
Feed rate: f r = Nf
W
surface of a rotating
work piece. (Lathe) L
Time of machining: Tm =
fr
TU
Material Removal Rate:
v MRR = vfd
Do Df
d
JN
f
L 2
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Operations related to Turning
ld
Contour turning Chamfering
or
W
Facing Taper turning Form turning
TU
JN
Cutoff Threading Boring Drilling
Knurling
3
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Work Holding
ld
Mounting between
two centers (Dog &
or
Live center)
W
Chuck
TU
Collet
Face plate
JN
4
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Engine Lathe
ld
Headstock
Tailstock
or
Tool
post
W
TU
Carriage Bed
Threaded
JN
Lead Screw
5
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Other Lathes & Turning Machine
ld
or
Toolroom Lathe and Speed Lathe
Turret Lathe
W
The tailstock is replaced with a turret
Chucking Machines No tailstock
Automatic Bar Machine Similar to chuck
TU
machine but with a collet
A single- and multiple-spindle bar machines
JN
NC Lathe
6
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Boring Machining
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Boring Cutting is done inside diameter of the work
or
material
W
TU
Horizontal Boring Machining Vertical Boring Machining
JN
7
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2. Drilling & Related Operations
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Geometry of Twist drill
Shank, Neck and Drill body
or
Helix angle, Point angle, Flute, cutting
edge, Chisel edge, Margin
W
Cutting conditions
Spindle: N =
v Feed rate: f = Nf
r
f(in/rev)
D D 2 f r
TU
Metal Removal Rate: MRR =
t+A 4
Machining time: Tm =
f r For a through hole
A
JN
d
d Tm = For a blind hole
t fr
8
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Twist Drill and Drilling Operations
ld
or
W
TU
JN
From Kalpakjian and Schmid (2003) 9
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Machine Tool for drilling
ld
or
Drill press
Upright drill
W
Bench drill
Radial drill
TU
Gang drill - 2-6 drills together
NC drill
Vice, Jig and fixture
JN
10
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3. Milling
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Up Milling Down Milling
Milling Conventional face
A machine operation in which a
or
work part is fed past a rotating
cylindrical tool with multiple
edges. (milling machine) Partial face
Slab
W
Types
Peripheral milling End
Slab, slotting, side and slotting
straddle milling Profile
TU
Up Milling (Conventional) &
down milling (Climb)
side Contour
Facing milling
Conventional face, Partial
JN
face, End, Profile, Pocket & Pocket
contour millings straddle Face Milling
11
Peripheral Milling
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Cutting conditions
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Milling cutters
or
Plain milling cutters
Form milling cutters Radial Rake
W
Angle
Face milling cutters Relief
Angle
End milling cutters Clearance
TU
Cutting conditions Angle
v
Spindle rotation speed:
N=
D
Feed rate: f r = Nnt f
JN
Material Removal Rate: MRR = wdf r
12
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Milling Machines
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Knee-and-column Milling
Machine
or
Horizontal and Vertical types
Universal and Ram types
Bed-type Mill
W
Planer-type Mills the largest Horizontal Vertical
category
Tracer (profile) Mill
reproduce an irregular part
TU
geometry
CNC Milling machine
Universal Ram
JN
Bed-type mill
13
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Machining Centers
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Machining center highly automated
or
machine tool capable of performing
multiple machining operations under CNC
control.
W
Automatic tool changer
Pallet shuttles
TU
Automatic workpart positioning
CNC turning center
JN
14
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A CNC mill-turn center
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A series of operations without human interactions
or
Stock Turning Milling Drilling
W
A part
TU
JN
From a casting
From a round stock From another casting
15
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5. Other Machining Operations
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Shaping and planing
A single-point tool moves linearly relative to the work part
or
Shaping - A tool moves
Planing A workpart moves
Broaching
W
TU
Performed by a multiple-tooth cutting tool by moving linearly
relative to the work in the direction of the tool axis.
Sawing
JN
Hacksawing, Bandsawing, and Circular sawing
16
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Broaching
ld
or
Semifinishing
teeth
W
TU
Finishing teeth Roughing teeth
JN
17
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Sawing
ld
or
W
Hacksaw - linear reciprocating motion
TU
Bandsaw - linear continuous motion
JN
Saw Blade (Straight & Undercut tooth
or Straight & Raker sets) 18
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