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Machining Operations and Machine Tools

This document discusses various machining operations and machine tools. It covers topics such as turning operations on lathes, drilling operations, milling operations, and other machining methods. For each operation, it describes the basic process, common tooling used, work holding methods, and important cutting parameters that affect the material removal rate and cycle time. It provides illustrations of different lathe components and configurations, drilling machines, milling machines, and machining centers. The goal is to introduce the fundamental machining processes and associated machine tools.

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367 views18 pages

Machining Operations and Machine Tools

This document discusses various machining operations and machine tools. It covers topics such as turning operations on lathes, drilling operations, milling operations, and other machining methods. For each operation, it describes the basic process, common tooling used, work holding methods, and important cutting parameters that affect the material removal rate and cycle time. It provides illustrations of different lathe components and configurations, drilling machines, milling machines, and machining centers. The goal is to introduce the fundamental machining processes and associated machine tools.

Uploaded by

Anonymous mKdAfWif
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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1

MACHINING OPERATIONS
AND MACHINE TOOLS
1. Turning and Related Operations
2. Drilling and Related Operations
3. Milling
4. Machining & Turning Centers
5. Other Machining Operations
6. Shape, Tolerance and Surface Finish
7. Machinability
8. Selection of Cutting Conditions
9. Product Design Consideration
2
d
f
D
o
D
f
L
1. Turning & Related Operations
Turning a machining
process in which a
single-point tool remove
material from the
surface of a rotating
work piece. (Lathe)
v
vfd MRR
f
L
T
Nf f
d D D
D
v
N
r
m
r
f o
o
=
=
=
=
=
2

Rotational Speed:
Feed rate:
Time of machining:
Material Removal Rate:
3
Operations related to Turning
Facing Taper turning
Contour turning
Form turning
Chamfering
Cutoff
Threading Boring
Drilling
Knurling
4
Work Holding
Mounting between
two centers (Dog &
Live center)
Chuck
Collet
Face plate
5
Engine Lathe
Bed Carriage
Headstock
Tailstock
Tool
post
Threaded
Lead Screw
6
Other Lathes & Turning Machine
Toolroom Lathe and Speed Lathe
Turret Lathe
The tailstock is replaced with a turret
Chucking Machines No tailstock
Automatic Bar Machine Similar to chuck
machine but with a collet
A single- and multiple-spindle bar machines
NC Lathe
7
Boring Machining
Horizontal Boring Machining
Vertical Boring Machining
Boring Cutting is done inside diameter of the work
material
8
2. Drilling & Related Operations
Geometry of Twist drill
Shank, Neck and Drill body
Helix angle, Point angle, Flute, cutting
edge, Chisel edge, Margin
Cutting conditions
D
v
N

=
Spindle:
Feed rate: Nf f
r
=
Metal Removal Rate:
4
2
r
f D
MRR

=
Machining time:
r
m
f
A t
T
+
=
For a through hole
For a blind hole
r
m
f
d
T =
A
t
d
f(in/rev)
9
Twist Drill and Drilling Operations
From Kalpakjian and Schmid (2003)
10
Machine Tool for drilling
Drill press
Upright drill
Bench drill
Radial drill
Gang drill - 2-6 drills together
NC drill
Vice, J ig and fixture
11
3. Milling
Milling
A machine operation in which a
work part is fed past a rotating
cylindrical tool with multiple
edges. (milling machine)
Types
Peripheral milling
Slab, slotting, side and
straddle milling
Up Milling (Conventional) &
down milling (Climb)
Facing milling
Conventional face, Partial
face, End, Profile, Pocket &
contour millings
Up Milling
Down Milling
Slab
slotting
side
straddle
Face Milling
Conventional face
Partial face
End
Pocket
Peripheral Milling
Contour
Profile
12
Cutting conditions
Milling cutters
Plain milling cutters
Form milling cutters
Face milling cutters
End milling cutters
Cutting conditions
Spindle rotation speed:
D
v
N

=
Feed rate: f Nn f
t r
=
Material Removal Rate:
r
wdf MRR =
Relief
Angle
Clearance
Angle
Radial Rake
Angle
13
Milling Machines
Knee-and-column Milling
Machine
Horizontal and Vertical types
Universal and Ram types
Bed-type Mill
Planer-type Mills the largest
category
Tracer (profile) Mill
reproduce an irregular part
geometry
CNC Milling machine
Horizontal
Vertical
Universal Ram
Bed-type mill
14
Machining Centers
Machining center highly automated
machine tool capable of performing
multiple machining operations under CNC
control.
Automatic tool changer
Pallet shuttles
Automatic workpart positioning
CNC turning center
15
A CNC mill-turn center
A part
Stock
Turning
Milling Drilling
A series of operations without human interactions
From a round stock
From a casting
From another casting
16
5. Other Machining Operations
Shaping and planing
A single-point tool moves linearly relative to the work part
Shaping - A tool moves
Planing A workpart moves
Broaching
Performed by a multiple-tooth cutting tool by moving linearly
relative to the work in the direction of the tool axis.
Sawing
Hacksawing, Bandsawing, and Circular sawing
17
Broaching
Finishing teeth
Semifinishing
teeth
Roughing teeth
18
Sawing
Saw Blade (Straight & Undercut tooth
or Straight & Raker sets)
Bandsaw - linear continuous motion
Hacksaw - linear reciprocating motion

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