INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
MACHINING
Dr. Amit Choudhary
Assistant Professor
Department of Mechanical and Industrial Engineering
IIT Roorkee
Machining Content
• Machining Introduction
• Review of Mechanisms of machining
• Advances in machining processes
– Diamond turning
– Hybrid turning
– Micro-machining
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Manufacturing Processes
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Manufacturing Processes - Tolerance
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Economics of machining and finishing process
• Increase in the cost of
machining and finishing a part
as a function of the surface
finish required.
• This is the main reason that the
surface finish specified on parts
should not be any finer than
necessary for the part to
function properly.
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MACHINING
• Machining is a removal process (subtractive)
• Machining is an essential process of finishing by which jobs are
produced to the desired dimensions and surface finish by
gradually removing the excess material from the preformed blank (
i.e. work material) in the form of chips with the help of cutting
tools moved past the work surface.
• Cutting action involves shear deformation of work material to form
a chip. As chip is removed, a new surface is exposed.
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WHY MACHINING IS IMPORTANT?
• Variety of work materials can be machined.
• Variety of part shapes and special geometry features possible.
• Good dimensional accuracy and surface finish.
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TYPES OF MACHINING
• Conventional Machining:- The material is removed by the direct
contact between tool and work piece. The energy is utilized to
rotate either work piece or tool, and the cutting tool should be
harder than work piece (35-50% more hardness).
Example:- Turning, Boring, Milling, Broaching, Shaping, Slotting,
Grinding
Source: http://www.vssut.ac.in/lecture_notes/lecture1423905443.pdf
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TYPES OF MACHINING
• Non-Conventional Machining:- In non-conventional or advanced machining
process, energy is utilized in its direct form (thermal, mechanical and electrical
etc.) to remove the material. The tool material does not have to be harder than
the work material and the work piece properties such as hardness, shape, and
size are no longer barrier in non-conventional machining.
Example:-
Electrical discharge machining (EDM),
Laser beam Machining (LBM),
Plasma Arc Machining (PAM),
Electron Beam Machining(EBM),
Ion Beam Machining (IBM),
Electro-Chemical Machining (ECM),
Electro-Chemical grinding (ECG),
Electro-Chemical Honing (ECH),
Electro- Chemical Deburring (ECD)
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CONVENTIONAL V/S NON-CONVENTIONAL MACHINING PROCESS
Conventional Machining Non-Conventional Machining
• The cutting tool and work piece are • There is no physical contact
always in physical contact with between the tool and work piece but
relative motion with each other, even in some NCM process tool
which result in friction and tool wear exists.
wear.
• MRR is limited by mechanical • NCM can machine difficult to cut
properties of work material. and hard to cut materials like Ti,
• Relative motion between the tool Ceramics, Nimonics, Inconel etc.
and work is typically rotary or • Many NCM are capable for
reciprocating. Thus the shape of producing complex 3D shapes and
work is limited to the circular or flat cavities.
shapes. In spite of CNC systems,
production of 3D surfaces is still a
difficult task
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CONVENTIONAL V/S NON-CONVENTIONAL MACHINING PROCESS
Conventional Machining Non-Conventional Machining
• Capital cost and maintenance cost is • Capital cost and maintenance cost is
low. high.
• Conventional process mostly uses • Most NCM uses energy in direct
mechanical energy. form like Laser, Electron beam in its
• Surface finish and tolerances are direct forms are used in LBM and
limited by machining inaccuracies. EBM respectively.
• High MRR. • High surface finish (up to 0.1
micron) and fine tolerances can be
achieved.
• Low MRR.
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Turning Process
workpiece
Chuck Chip
N
Rake
Feed face
Tool
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Turning Process
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Turning Process
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Turning Process
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Turning Process
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Mechanism of Machining
Orthogonal Machining Oblique Machining
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Mechanism of Machining
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Mechanism of Machining
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Mechanism of Machining
Mechanism of Chip formation in Machining of ductile materials
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Mechanism of Machining
Primary and secondary deformation zones
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Mechanism of Machining
Chip formation process in machining of brittle materials
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Mechanism of Machining
Piispannen model of card analogy to explain chip formation in machining ductile materials
Piispannen V., “Theory of formation of metal chips”, J. Applied Physics, Vol. 19, No. 10, 1948, pp. 876.
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Mechanism of Machining
Continuous chip formation (Credit: Yang Huo, YouTube Channel)
Y. Guo, W.D. Compton, S. Chandrasekar. In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals.
Proceedings of the Royal Society A 471, 20150194 (2015).
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Mechanism of Machining
Geometric features of ductile material machining
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