ME 531 MACHINING MECHANICS

AND ANALYSIS

CHAPTER 1
INTRODUCTION, MACHINING
OPERATIONS AND MACHINE TOOLS
 INTRODUCTION

In 1776, James Watt built the first successful steam engine, and
one of his greatest difficulties in developing this machine was
the boring of the cylinder casting. His first cylinder was
manufactured from sheet metal, but it could not be made steam
tight.
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 INTRODUCTION

John Wilkinson eventually solved the problem when he invented

the horizontal-boring machine. This machine consisted of a
cutting tool mounted on a boring bar that was supported on
bearings outside the cylinder. The boring bar could be rotated
and fed through the cylinder.
Thus generating, with the tool
points, a cylindrical surface
independent of the
irregularities of the rough
casting. This boring machine
was the first effective machine
tool, and it enabled James Watt
to produce a successful steam
engine.
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 INTRODUCTION

• Metal cutting is the process of producing work

piece by removing unwanted material from a block
of metal in the form of chips.

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INTRODUCTION
• Metal cutting is basically adopted because of the
following reasons.
a) To get higher surface finish.
b) To achieve close tolerance.
c) To get complex geometric shapes.
d) Some times it may be economical to produce a
component by machining process.

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Why Machining is Important?
• Variety of work materials can be machined
▫ Most frequently used to cut metals
• Variety of part shapes and special geometric
features possible, such as:
▫ Screw threads
▫ Accurate round holes
▫ Very straight edges and surfaces
• Good dimensional accuracy and surface finish

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Disadvantages with Machining
• Wasteful of material
▫ Chips generated in machining are wasted material.
• Time consuming
▫ A machining operation generally takes more time to
shape a given part than alternative shaping processes,
such as casting, powder metallurgy, or forming/forging.

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Machining in Manufacturing Sequence

• Generally performed after other manufacturing

processes, such as casting, forging, and bar
drawing
▫ Other processes create the general shape of the starting
workpart.
▫ Machining provides the final shape, dimensions, finish,
and special geometric details that other processes
cannot create.

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Machining in Manufacturing Sequence

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Material Removal Processes
A family of shaping operations, the common feature
of which is removal of material from a starting work
part so the remaining part has the desired geometry
▫ Machining – material removal by a sharp cutting
tool, e.g., turning, milling, drilling.
▫ Abrasive processes – material removal by hard,
abrasive particles, e.g., grinding.
▫ Nontraditional processes - various energy forms
other than sharp cutting tool to remove material
such as waterjet cutting, laser cutting.

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Material Removal
• Produce a desired shape by removing segments from
an initially oversized piece.
• Often been referred to as machining.

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 12

Machining
• Machine tools, in general, can be divided into three
groups:
▫ Those using single-point tools
▫ Those using multipoint tools
▫ Those using abrasive wheels
 13

Machining
• Machines using single-point tools
▫ Engine Lathe (Center Lathe, Turning Machine)
A machine tool that rotates a work piece on its axis to carry out
various operations such as drilling, turning, boring, facing, threading,
grooving and parting off.
 14

Machining
▫ Engine Lathe (Center Lathe, Turning
Machine)
 15

Machining
• Machines using single-point tools
▫ Vertical Boring Machine (Vertical Borer)
 16

Machining
• Machines using single-point tools
▫ Horizontal Boring Machine (Horizontal Borer)
 17

Machining
• Machines using single-point tools
▫ Shaping Machine (Shaper)
A machine tool that uses straight or linear motion
between the work piece and a single-point cutting tool to
machine a linear tool path.
 18

Machining
• Machines using single-point tools
▫ Shaping Machine (Shaper)
A machine tool that uses straight or linear motion
between the work piece and a single-point cutting tool to
machine a linear tool path.
 19

Machining
• Machines using single-point tools
▫ Planing Machine (Planer) : A metal working machine
tool that uses straight or linear movement between
the work piece and a single-point cutting tool to
machine a linear tool path.
Planer

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 21

Machining
• Machines using multipoint tools
▫ Drilling Machine (Drill Press)
 22

Machining
• Machines using multipoint tools
▫ Horizontal Milling Machine (Horizontal Miller)
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Machining
• Machines using multipoint tools
▫ Horizontal Milling Machine (Horizontal Miller)
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Machining
• Machines using multipoint tools
▫ Vertical Milling Machine (Vertical Miller)
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Machining
• Machines using multipoint tools
▫ Broaching Machine (Broacher)
 Broaching Machine
• A machine tool that uses a toothed tool or a broach
to remove material. The tool can use two types of
broaching, namely rotary and linear.

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 27

Machining
• Machines using abrasive wheels
▫ Horizontal-spindle surface grinder machine
A machine tool used for grinding, a process whereby an
abrasive wheel is used as the cutting tool.
 28

Machining
• Machines using abrasive wheels
▫ Vertical-spindle surface grinder machine
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Machining
• Machines using abrasive wheels
▫ Cylindrical grinding machine
 30

Machining
• Machines using abrasive wheels
▫ Internal grinding machine
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Machining
• Machines using abrasive wheels
▫ Centerless grinding machine
Machining Operations

• Most important machining operations:

▫ Turning
▫ Drilling
▫ Milling
• Other machining operations:
▫ Shaping and planing
▫ Broaching
▫ Sawing

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 33

Turning

Single point cutting tool removes material from a

rotating workpiece to form a cylindrical shape
 34

Turning
• The feed motion setting on the lathe is the distance moved by
the tool during each revolution of the workpiece. Once chosen,
the feed setting remains constant regardless of the spindle
speed because of the geared drive between the main spindle and
the feed rod. The feed f for all machine tools is defined as the
displacement of the tool relative to the workpiece, in the
direction of feed motion, per stroke or per revolution of the
workpiece or tool. Thus, to turn a cylindrical surface of length lw,
the number of revolutions of the workpiece is lw/f, and the
machining time tm, is given by

where
tm,: Machining time [s]
lw : length of the workpiece [m]
f : feed rate [m/rev]
nw : revolution of the workpiece [rev/s]
Terminology of Single Point Cutting Tools
A single point cutting tool can be understood by its geometry .
Geometry comprises mainly of nose, rake face of the tool, flank,
heel and shank etc. The nose is shaped as conical with different
angles.

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Terminology of Single Point Cutting Tools
A single point cutting tool can be understood by its geometry .
Geometry comprises mainly of nose, rake face of the tool, flank,
heel and shank etc. The nose is shaped as conical with different
angles.

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 Terminology of Single Point Cutting Tools
1. The face is the surface or surfaces over which the chip flows.
2. The flank is the tool surface or surfaces over which the surface produced
on the workpiece passes.
3. The cutting edge is that edge of the face which is intended to perform
cutting. The tool major cutting edge is that entire part of the cutting edge
which is intended to be responsible for the transient surface on the
workpiece. The tool minor cutting edge is the remainder of the cutting
edge.
4. The corner is the relatively small
portion of the cutting edge at the
junction of the major and minor
cutting edges; it may be curved or
straight, or it may be the actual
intersection of these cutting
edges.

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 Terminology of Single Point Cutting Tools
In general, when a tool is applied to a
workpiece, its motion relative to the
workpiece has two components:

1. The motion resulting from the

primary motion of the machine tool,
which can be called the primary
motion of the tool
2. The motion resulting from feed
motion of the machine

The resultant of these two tool

motions is called the resultant cutting
motion and is defined as the motion
resulting from simultaneous primary
and feed motions.
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 Terminology of Single Point Cutting Tools
κr. :the major cutting-edge
angle
ac :the undeformed chip
thickness
ac = af sin κr, where
af is the feed engagement,
(For single-point cutting op.
af =f)

Ac::The cross-sectional area

of the layer of material being
removed (cross-sectional
area of the uncut chip 39
Basic Operations Performed on a Lathe Machine :

1. Turning –Plain turning , Step turning

2. Facing
3. Taper Turning
4. Drilling
5. Boring
6. Reaming
7. Knurling
8. Forming
9. Chamfering
10. Cutting Off (Parting Off)
11. Threading or thread cutting
Turning
Plain turning on lathe machine
Fig.- step turning on lathe machine
Fig.- Facing on lathe machine
Taper turning by set over method
Taper turning by set over method
Taper turning by swiveling the compound
rest
Taper turning by swiveling the compound
rest
Taper turning by form tool
Eccentric turning on lathe machine
FIG.- KNURLING
FIG.- KNURLING
Knurling on lathe machine
Knurling on lathe using knurling tool
Knurling tool
Example
Two thousand bars 80 mm in diameter and 300 mm long
must be turned down to 65 mm diameter for 150 mm of their
length. The surface-finish and accuracy requirements are
such that a heavy roughing cut (removing most of the
material) followed by a light-finishing cut are needed. The
roughing cut is to be taken at maximum power. The light-
finishing cut is to be taken at a feed of 0.13 mm, a cutting
speed of 1.5 m/s, and at maximum power. If the lathe has a 2-
kW motor and an efficiency of 50%, calculate the total
production time in kiloseconds (ks) for the batch of work.
Assume that the specific cutting energy for the work material
is 2.73 GJ/m3, the time taken to return the tool to the
beginning of the cut is 15 s, and the time taken to load and
unload a workpiece is 120 s.
Example
Example
Drilling on lathe machine
Boring on lathe machine
Drilling on lathe
Boring on lathe
Reaming on lathe machine
Reamers
Reaming on lathe using reamer tool
FIGURE – GROOVING AND PARTING
Parting on lathe machine
Grooving on lathe
Forming on lathe machine
Forming on lathe machine
Chamfering on lathe machine
Threading on lathe
Threading on lathe machine

https://www.youtube.com/watch?v=usgYuEwe2AU
Threading on lathe machine
Shaping Operations

https://www.youtube.com/watch?v=SXcfY_r9WnA 78
Shaping Operations

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Drilling Operations

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 Drilling Operations

For through holes:

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Drilling Operations

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Horizontal Milling

https://www.youtube.com/watch?v=kGws9QKhYbI 83
Horizontal Milling

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Horizontal Milling
f :The feed which is equal to the distance
moved by the workpiece during one
revolution of the tool,

f=vf/nt

where vf is the feed speed of the workpiece,

nt is the rotational frequency of the cutter.

The feed engagement af, which is equal to the

thickness of the chip removed by one tooth
and measured parallel to the feed direction
(feed per tooth), is given by f/N, where N is
the number of teeth on the cutter.

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Horizontal Milling

The maximum undeformed chip thickness,

acmax (measured normal to the direction of
primary motion) is therefore given by

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Horizontal Milling

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Horizontal Milling

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Horizontal Milling

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Horizontal Milling

Some horizontal milling

operations.
(a) Form cutting;
(b) slotting;
(c) straddle milling;
(d) angular milling.

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Vertical Milling
 92

Vertical Milling
 93

Vertical Milling
 94

Vertical Milling
 95

Vertical Milling
 96

Broaching
 97

Broaching

Broaching time:
ME 531 MACHINING MECHANICS
AND ANALYSIS

CHAPTER 1
INTRODUCTION, MACHINING
OPERATIONS AND MACHINE TOOLS