Department of Mechanical Engineering
University of Central Punjab
Machining Operations
(Turning and Related Operations)
COURSE TITLE: MANUFACTURING PROCESSES II (MEN3143)
Chapter 22 Course Instructor: Umer Hayat
Summary of Last Lecture
2
Forces Acting on Chip
The Merchant Equation
Power in Machining
Why Cutting Temperatures are Important?
reduce tool life
produce hot chips (safety hazards to operator)
inaccuracies in work part dimensions due to thermal expansion
Overview of Chapter
3
Turning and Related Operations
Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
High Speed Machining
Machining
4
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 (e.g. screw threads, gear teeth, flat surfaces)
Castingcan also produce a variety of shapes, but it lacks the precision and
accuracy of machining
Classification of Machined Parts
5
Rotational - cylindrical or disk-like shape. Achieved by rotation motion
of the workpart. Ex. turning and boring
Nonrotational (also called prismatic) - block-like or plate-like.
Achieved by linear motion of the workpart. Ex. Milling, shaping,
planing and sawing
Figure 22.1 - Machined parts are classified as: (a) rotational, or (b)
nonrotational, shown here by block and flat parts
Machining Operations and Part Geometry
6
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. Feed motion creates shape. Ex.
Straight turning, taper turning, and profile milling
2. Shape of the cutting tool
• Forming – part geometry is created by the shape of the
cutting tool. Cutting edge has the reverse of the shape to be
produced on the part surface. Ex. Form turning, drilling and
broaching
Forming and generating are sometimes combined in one operation,
such as in thread cutting on a lathe and slot milling
Generating
7
Straight turning Taper turning Contour turning
Profile milling
Plain milling
Forming
8
Form Turning Drilling Broaching
Forming and Generating Combination
9
Threading Slot milling
Turning and Related Operations
10
A single point cutting tool removes material from a rotating workpiece
to generate a cylindrical shape
The tool is fed linearly in a direction parallel to the axis of rotation
Performed on a machine tool called a lathe
Variations of turning that are performed on a lathe:
Facing
Taper turning
Contour turning Form turning
Chamfering
Boring
Cutoff
Drilling
Threading
Knurling
Cutting Conditions in Turning
11
Rotational speed N = rotational speed, rev/min
V = cutting speed
Do = origional dia.
Final Diameter of Workpiece Df = final dia. after cut
d = depth of cut
Linear Travel rate fr = feed rate, mm/min
f = feed
L = length of work piece
Machining Time
or
Material Removal Rate
RMR = v f d
Example
12
A turning operation is performed on a cylindrical work part whose
diameter=120 mm and length=450 mm. Cutting speed=2.0 m/s,
feed=0.25 mm/rev, and depth of cut=2.2 mm. Determine (a) cutting
time and (b) material removal rate
Problem 22.3
13
A facing operation is performed on an engine lathe. The diameter of the
cylindrical part is 6 in and the length is 15 in. The spindle rotates at a
speed of 180 rev/min. Depth of cut = 0.110 in, and feed= 0.008
in/rev. Assume the cutting tool moves from the outer diameter of the
workpiece to exactly the center at a constant velocity. Determine (a) the
velocity of the tool as it moves from the outer diameter towards the
center and (b) the cutting time
a) fr = fN = (0.008 in/rev)(180 rev/min) = 1.44 in/min
L = distance from outside to center of part = D/2
Tm = L/fr = D/(2fr) = 6/(2 x 1.44) = 2.083 min
Turning Related Operations
14
Facing
Tool is fed radially inward
to create a flat surface
Taper Turning
Toolis fed at an angle creating a
tapered cylinder or conical shape
Turning Related Operations
15
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
Form Turning
❑ Tool shape is imparted to work
❑ Not a single point tool
Turning Related Operations
16
Chamfering
Toolcut the edge of the part at
an angle called chamfer
Cutoff
Tool is fed radially into rotating
work at some location to cut off end
of part
Turning Related Operations
17
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
Boring
Single point tool is fed linearly, parallel
to the axis of rotation, on inside of an
existing hole
Turning Related Operations
18
Drilling
Drill along the axis
Not a single point tool
Knurling
Produce a regular cross-hatched section
Metal forming process instead of
machining process
19
The Engine Lathe
20
The Engine Lathe
21
Most lathe machines are horizontal but vertical lathe machines are also
used for jobs with large diameter relative to the length and for heavy
work
The size of the lathe is designated by swing and maximum distance
between centers
Swing is the maximum workpart diameter that can be rotated in the
spindle
Maximum distance between centers indicate the maximum length of a
workpiece that can be mounted between headstock and tailstock centers
350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance
between centers of 1.2 m
