Machining Processes

1.MACHINING OPERATIONS AND MACHINE TOOLS-

(basically subtractive manufacturing)_

● Turning and Related Operations

● Drilling and Related Operations

● Milling

● Machining Centers and Turning Centers

● Other Machining Operations

● Machining Operations for Special Geometries

● High Speed Machining

2. Machining-
▪ 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: metal parts

▪ Most versatile of all manufacturing processes for producing a

variety of part shapes and geometric features with high precision
and accuracy

▪ Casting can also produce a variety of shapes, but in general is

not as accurate as machining

3. Classification of Machined Parts-

▪ Rotational - (a) cylindrical or disk‑like shape
▪ Nonrotational - (b) block‑like and plate‑like

4.Machining Operations and Part Geometry

▪ Each machining operation produces a characteristic part geometry due to
two factors:

1. Relative motions between tool and workpart

• Generating – part geometry determined by feed trajectory

of cutting tool

2. Shape of the cutting tool

• Forming – part geometry is created by the shape of the

cutting tool

5.Generating Shape

▪ Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling
6.Forming to Create Shape-
▪ Forming to create shape: (a) form turning, (b) drilling, and (c) broaching

7.Forming and Generating

▪ Combination of forming and generating to create shape: (a) thread

cutting on a lathe, and (b) slot milling
8.Turning

▪ Single point cutting tool removes material from a rotating workpiece to

generate a cylindrical shape

▪ Performed on a machine tool called a lathe

▪ Variations of turning performed on a lathe

▪ Facing

▪ Contour turning

▪ Chamfering

▪ Cutoff

▪ Threading

9.Turning Operation-
10.Operations Related to Turning-
▪ (a) Facing, (b) taper turning, (c) contour turning(d) Form turning, (e)
chamfering, (f) cutoff(g) Threading, (h) boring, (i) drilling

11. Engine LAthe-

12.Methods of Holding Workpiece in a Lathe

▪ (a) Holding the work between centers, (b) chuck, (c) collet, and (d) face
plate

13.Other Production Turning Machines-

1.Turret lathe-
▪ Tailstock replaced by “turret” that holds up to six tools
▪ Tools rapidly brought into action by indexing the turret
▪ Tool post replaced by four‑sided turret to index four tools
▪ Applications: high production work that requires a sequence of cuts on the
part

2.Chucking machine-

● Uses chuck in its spindle to hold workpart

● No tailstock, so parts cannot be mounted between centers
● Cutting tool actions controlled automatically
● Operator’s job: to load and unload parts
● Applications: short, light‑weight parts

3.Bar machine-

● Similar to chucking machine except collet replaces chuck, permitting long

 bar stock to be fed through headstock
● At the end of the machining cycle, a cutoff operation separates the
new part
● Highly automated
● Computer numerical control
● Applications: high production of rotational parts

4.Automatic screw machine

● Same as automatic bar machine but smaller

● Applications: high production of screws and similar small hardware
items

5.Multiple spindle bar machine

● More than one spindle, so multiple parts machined simultaneously by

multiple tools
● Example: six spindle automatic bar machine works on six parts at a
time
● After each machining cycle, spindles (including collets and workbars) are
indexed (rotated) to next position
 6. Six Spindle Bar Machine

(a) Part; (b) sequence of operations: (1) feedstock to stop, (2) turn
main diameter, (3) form second diameter and spotface, (4) drill, (5)
chamfer, and (6) cutoff

14.Boring
Difference between boring and turning:

▪ Boring is performed on the inside diameter of an existing hole

▪ Turning is performed on the outside diameter of an existing

cylinder

▪ In effect, boring is internal turning operation

▪ Boring machines

▪ Horizontal or vertical - refers to the orientation of the axis of

rotation of machine spindle

16. Vertical Boring Mill

▪ Applications: Large, heavy workparts that have low L/D ratio

17. 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

18.Through Hole vs. Blind Hole-

▪ (a) Through hole - drill exits opposite side of work and (b) blind hole – drill
does not exit opposite side
19.Operations Related to Drilling
(a) Reaming, (b) tapping, (c) counterboring

20.More Operations Related to Drilling-

▪ (d) Countersinking, (e) center drilling, (f) spot facing

21.Drill Press-
▪ Upright drill press stands on the floor
 ▪ Bench drill similar but smaller and mounted on a table or bench

22.Radial Drill Press

▪ Large drill press designed for large parts (photo courtesy of Willis
Machinery and Tools)

23.Milling
▪ Machining operation in which work is fed past a rotating tool with
multiple cutting edges

▪ Axis of tool rotation is perpendicular to feed

 ▪ Cutting tool called a milling cutter

▪ Cutting edges called teeth

▪ Machine tool called a milling machine

▪ Interrupted cutting operation

▪ Basic milling operation creates a planar surface

▪ Other geometries possible

24. Two Forms of Milling

(a) Peripheral milling and (b) face milling

25.Peripheral Milling vs. Face Milling

▪ Peripheral milling

▪ Cutter axis parallel to surface being machined

▪ 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
26.Types of Peripheral Milling

▪ (a) Slab milling, (b) slotting, (c) side milling, (e) straddle milling, and (e)
form milling

27.Types of Face Milling

▪ (a) Conventional face milling, (b) partial face milling, and (c) end milling(d)
Profile milling, (e) pocket milling, and (f) surface contouring

▪
28. Face Milling

▪ High speed face milling operation using

indexable inserts (photo courtesy of
Kennametal Inc.)

29.Knee-And-Column Milling Machines

▪ (a) Horizontal and (b) vertical knee-and-column milling machines

30.Machining Center
▪ Highly automated machine tool that can perform multiple machining
operations under CNC control in one setup with minimal human attention

▪ Typical operations are milling and drilling

▪ Three, four, or five axes

▪ Other features:

▪ Automatic tool‑changing

▪ Pallet shuttles

▪ Automatic workpart positioning

31.CNC Machining Center

32.CNC TurningCenter-Industrial Robot to Load and

Unload Parts

33.Mill-Turn Centers
▪ Highly automated machine tool that can perform turning, milling, and
drilling operations in one setup

▪ General configuration of a turning center

 ▪ Can position a cylindrical workpart at a specified angle so a
rotating cutting tool (e.g., milling cutter) can machine features
into outside surface of part

▪ Conventional turning center cannot stop workpart at a

defined angular position and does not include rotating tool
spindles

34.Operation of Mill-Turn Center

▪ (a) Part and (b) sequence of operations : (1) turn second diameter, (2)
mill flat, (3) drill hole, and (4) cutoff

35.Shaping and Planing

▪ Similar operations, both use a single point cutting tool moved linearly
relative to the workpart
▪ A straight, flat surface is created in both operations

▪ Interrupted cutting operation

▪ Subjects tool to impact loading when entering work

▪ Typical tooling: single point high speed steel tools

▪ Low cutting speeds due to start‑and‑stop motion

 ▪
▪ Shaper-

▪
▪ Planer

36.Broaching
▪ A multiple tooth cutting tool is moved linearly relative to work in
direction of tool axis
▪ Advantages:

▪ Good surface finish

▪ Close tolerances

▪ Variety of work shapes possible

▪ Cutting tool called a broach

▪ Owing to complicated and often custom‑shaped geometry, tooling is

 expensive

▪ (a) External and (b) internal broaching (cross-hatching indicates surface

broached)

37.Sawing
▪ Cuts narrow slit in work by a tool consisting of a series of narrowly
spaced teeth

▪ Tool called a saw blade

▪ Typical functions:

▪ Separate a workpart into two pieces

▪ Cut off unwanted portions of part

▪ Cut outline of flat part

▪ (a) Power hacksaw, (b) bandsaw (vertical), and (c) circular saw
38.Machining Operations for Special Geometries
▪ Screw threads

▪ Gear teeth

39.Cutting Screw Threads

▪ Methods for producing external threads

▪ Single-point threading

▪ Threading die

▪ Thread chasing using self-opening threading dies

▪ Thread milling

▪ Methods for producing internal threads

▪ Tapping - using a solid tap

▪ Collapsible taps - cutting teeth retract for quick removal from

 hole

Cutting External Screw Threads-

▪ (left) Single-point thread cutting and (right) threading die

▪
▪ Thread Milling Using a
Form-Milling Cutter

40.Principal Operations for Machining Gear Teeth

▪ Form milling - use of a form milling cutter

▪ Gear hobbing - also milling but using a special cutter called a hob

▪ Gear shaping - two forms

▪ Single point tool to gradually shape each gear tooth spacing

▪ Cutter has general shape of the gear but with cutting teeth on
one side

▪ Gear broaching - for internal and external gears

41.Form Milling of Gear Teeth

▪ The form milling cutter has teeth with the shape of the spaces between
 teeth on the gear

▪ Gear blank is indexed between each pass to establish correct size of the
gear tooth

42.Gear
Hobbing

▪ Hob has a slight helix and its rotation is coordinated

with much slower rotation of the gear blank

▪ Special milling machines (called hobbing machines) accomplish the relative

speed and feed motions between cutter and gear blank

43.Gear Shaping
▪ To start the process, cutter is gradually fed into gear blank

▪ Then, cutter and blank are slowly rotated after each stroke to
maintain tooth spacing

▪ Performed on special machines called gear shapers

44.Gear Broaching
▪ Applicable for both external gears and internal gears (teeth on inside of
gear)

▪ Cost of tooling (broach) is high due to its complex geometry

▪ For internal gears, broach consists of a series of gear-shaped cutting

teeth of increasing size to form the gear teeth in successive steps as
broach is drawn through starting hole

▪ For external gears, broach is tubular with inward-facing cutting teeth