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lec3 Basic concepts of machining process

Uploaded by

Mohamed Ehab
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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‫مرحبا ً بكم في محاضرات‬

‫‪Production Technology‬‬
‫(تكنولوجيا االنتاج)‬

‫الفرقة االعدادية‬
‫أ‪.‬م‪.‬د‪ ./‬دمحم فهمى‬
‫د‪ ./‬عبدالجواد مطر‬
‫قسم التصميم الميكانيكي‬
Basic concepts of machining process
Contents
Cutting Tools
Types of Machine Tooling
Tool Material
Cutting (Cooling) Fluids
Machining methods (Turning)
Processes carried out on a lathe
Machining methods (Milling)
Machining methods Grinding
Cutting Tools
• One of most important components in
machining process

• Performance will determine efficiency of


operation

• Two basic types

Single point and multiple point


Types of Machine Tooling

Single point tools

 Turning Process: This type of tool rotates a work piece while the

cutting tool moves in a linear motion. This process can either be

done manually or automatically


Types of Machine Tooling

Multi-point tools

 Drilling Process: Tool creates or refines round holes in a work

piece.

 Milling Process: This type of tool creates designs by removing

material from the working piece by rotating a cutting tool


Types of Machine Tooling
Types of Machine Tooling
Types of Machine Tooling
Single point tools
Cutting Tool Properties
Hardness Cutting tool material must be 1 1/2 times harder

than the material.

Wear Resistance for minimum wear

Shock Resistance Able to take the cutting loads and forces

Shape and Configuration Must be available for use in

different sizes and shapes.

Thermal resistant To withstand high temperature.


Tool Material
Examples of tool material:

• High speed steel: for high speed and temperature

Commonly used in cutting tools for machining operations

where high heat resistance and hardness are required.


Tool Material

Examples of tool material:

• Carbon steel: for low cutting speeds.

• Ceramics. high-speed cutting of hardened materials. They

are known for their hardness, brittleness, and resistance to

high temperatures and corrosion.


Tool Material
Examples of tool material:

• Diamond. hardness and wear resistance.

• Diamond tools are extensively used in cutting,

grinding, and drilling applications


Cutting (Cooling) Fluids

Function:

- Reduce friction, noise, heat.

- Washing and cleaning.

- Improve surface finish.

- Protection against corrosion.

- Increase tool life.


Cutting (Cooling) Fluids

Examples:

- Mineral Oils

- Synthetic Fluids

- Compressed Air
Cutting (Cooling) Fluids
Cutting (Cooling) Fluids
Cutting (Cooling) Fluids
Cutting (Cooling) Fluids
Machining methods
We cover three of the most common operations including

turning, drilling, and milling.

Machining is a very common manufacturing process. Thus,

it’s possible to machine various types of material using these

three methods.

Metals, plastics, composites, and wood are all possible work

piece materials.
Machining methods - Turning
Turning involves rotation of the work piece while the cutting tool

moves in a linear motion. This results in a cylindrical shape.

A lathe is the machine of choice for all turning operations.

Single point cutting tool removes material from a rotating work-

piece to form a cylindrical shape

Main motion is rotary motion done by work-piece.

Feed motion is linear motion done by cutting tool .


Machining methods - Turning
Examples for turning operations
Turning is the oldest machining method.

Originally called an engine lathe (operated by overhead pulleys & belts).

Engine lathe requires a skilled machinist: all controls are hand operated.

It represents 30-40% of machining process.

It is used for external surfaces and internal surfaces.

Examples: Outside diameter turning A, facing B, grooving C, Parting D,

boring, threading, drilling.


Lathe Components
• Bed: Supports all major components
• Headstock: has motors, pulleys, V-belts that supply power to spindle.
• Tailstock: Can slide along ways. Equipped with a center, (dead when
fixed or live when rotating).
• Carriage: Assembly that consists of cross-slide, tool post & apron

• Gearbox: connects feed rod and lead screw


• Lead screw: used for controlled motion i.e. to cut threads.
• Feed Rod: Connected to headstock. Tears make rotation possible and
provides movement to carriage and cross-slide.
Lathe Components
• Spindle: rotational element in lathe. Can attach chucks or
collets to hold work.
• Quill: Location for mounting tools on tailstock.

• Ways: Guide rails over which the carriage slides.

• Tool post: Mounting fixture for tool.

• Compound rest: Swivel for tool positioning / adjusting.

• Cross-Slide: Moves radially in and out, used for facing.

• Apron: Provides guiding mechanism over lead screw / feed rod.


Processes carried out on a lathe:
Turning :
Produce straight, conical, curved, or grooved work pieces
Examples: shafts, spindles, pins
Processes carried out on a lathe:
Processes carried out on a lathe:
Processes carried out on a lathe:
Facing : Produce flat surface at end of part and ⊥ to its axis
Processes carried out on a lathe:
Face grooving : Produce grooves for applications such as O-ring seats
Processes carried out on a lathe:
Face grooving : Produce grooves for applications such as O-ring seats
Processes carried out on a lathe:
Face grooving : Produce grooves for applications such as O-ring seats
Processes carried out on a lathe:
Face grooving : Produce grooves for applications such as O-ring seats
Processes carried out on a lathe:
Boring :
Enlarge hole/cylindrical cavity made by previous process:
Produce circular internal grooves
Processes carried out on a lathe:
Boring :
Processes carried out on a lathe:
Cutting with forms tools : Produce axisymmetric shapes
Processes carried out on a lathe:
Drilling :
Produce a hole
Processes carried out on a lathe:
Parting : cutting off Cut a piece from the end of a part
Processes carried out on a lathe:
Threading : Produce external or internal threads
Processes carried out on a lathe:
Processes carried out on a lathe:
Machining methods (Milling)

Main motion is rotating motion done by tool.

Feed motion is linear motion done by work piece.

The cutting tool is multi-toothed tool and where the contact occurs

intermittently, less heat generated.

It is fast and fine machining used for all kinds of surfaces.


Operations

During the process cycle, a variety of operations may be performed to

the work piece to yield the desired part shape.

The following operations are each defined by the type of cutter used

and the path of that cutter to remove material from the work piece.
End milling - An end mill makes, slot, pocket, or even a complex
surface contour.
Chamfer milling - A chamfer end mill makes a cut along an edge of
the work piece or a feature to create an angled surface, known as a
chamfer. This chamfer, typically with a 45 degree angle,
Face milling - A face mill machines a flat surface of the work piece in
order to provide a smooth finish. The depth of the face, typically very
small.
Drilling - A drill enters the work piece axially and cuts a hole with a
diameter equal to that of the tool
Boring - A boring tool enters the work piece axially and cuts along an
internal surface to form different features. Boring is commonly
performed after drilling a hole in order to enlarge the diameter or
obtain more precise dimensions.
Tapping - A tap enters the work piece axially and cuts internal
threads into an existing hole.
Machining methods - Grinding

Machining process where the material is removed by a

rotating tool (main motion).

Used for producing smooth surfaces with controlled

roughness and tolerances.

Used for hard surfaces and cutting tools.


Grinding machines
Grinding machines
Grinding machines
Grinding machines
Grinding machines
Grinding machines

Surface grinding (work piece is fixed on a magnet).

Horizontal spindle & reciprocating table.


Grinding machines

Horizontal spindle & rotating table.


Grinding machines

Surface grinding (work piece is fixed on a magnet).


Grinding machines

Vertical spindle & reciprocating table.


Grinding machines

Vertical spindle & rotating table.

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