Material Removal Process

Material removal process is a type of manufacturing process in which

the final product is obtained by removing excess metal from the stock.
 Cutting Process
Casting and metal working are the primary manufacturing
process where the metal is first given an intermediate shape
which is finally brought to its final shapes through metal cutting
process.

Different types of metal removing process

1. Turning
2. Drilling
3. Boring
4. Milling
5. Grinding
6. Shaping and planning
7. Gear cutting
 Metal Cutting
cutting tool or cutter is typically a hardened metal tool that is used
to cut, shape, and remove material from a work piece by means of
machining tools as well as abrasive tools by way of shear
deformation.
Metal Cutting
 Cutting Tools
Two types of cutting tool
1. Single point cutting tool
2. Multipoint cutting tool

Fig: Single point cutting tool Fig: Multi point cutting tool
 Cutting Tool
Some Features of Single point Cutting Tool

Rake angle: It is the angle between the face of the tool called rack
face and the normal to the machining direction

Clearance angle: It is the angle between the machined surface and the
underside of the tool called flank face
 Cutting Tool
Size
It is determined by the width of shank, height of shank and overall length.
Shank
Shank is main body of a tool. It is held in a holder.
Flank
Flank is the surface or surfaces below and adjacent to cutting edge.
Heel
Heel is intersection of the flank and base of the tool.
Base
Base is the bottom part of the shank. It takes the tangential force of cutting.
Face
Face is surface of tool on which chip impinges when separated from workpiece.
Cutting Edge
Cutting edge is the edge of that face which separates chip from the workpiece.
The total cutting edge consists of side cutting edge, the nose and end cutting
edge.
Cutting Tool
 Cutting Tool
According to ASA tool designation System-

αb – Back rake angle

αs – Side rake angle
θe – End relief angle
θs– Side relief angle
Ce– End cutting edge angle
Cs – Side cutting edge angle
R- Nose radius

All the angles are provided in degrees and nose radius in millimeter.
Cutting Tool
 Relief Angle
The purpose of the relief angle is to enable the side of the tool to clear the work
and prevents rubbing action below cutting edge. Small relief angle gives
maximum support below the cutting edge and is necessary while machining
hard and strong workpiece. Too much relief angle weakens the cutting edge and
failure of tool may takes place. Relief angles generally lie between 5° to 15°.

Side Relief Angle

The angle between the portion of the side flank immediately below the side
cutting edge and line perpendicular to the base of tool measured at right angles
to the side flank is known as side relief angle. It is the angle that prevents
interference, as the tool enters the work material.

End Relief Angle

End relief angle is the angle between the portion of the end flank immediately
below the end cutting edge and the line perpendicular to the base of tool,
measured at right angles to end flank. It is the angle that allows the tool to cut
without rubbing on the work piece.
 Rack Angle
The rake angle of a tool affects the angle of shear during the formation of
chip. Larger rake angle provides larger shear angle, lower cutting force,
good surface finish but decreasing the cutting angle and leaves less metal
at the cutting point.

Back Rake Angle

The rake angle of single point cutting tool is useful in determining the
direction of chip flow across the face of the tool and to move the chip
away from the machined work piece surface.

Side Rake Angle

The significance of side rake angle is that it is used to avoid rubbing
action between tool and workpiece.
 Cutting Edge Angle
Side Cutting Edge Angle
It affects the tool life and surface finish. It enables a tool that feed
sideways into a cut to contact the work first behind the tip. Larger side
cutting edge angle tending to separate tool and work and promotes
chatter. While the edge lasts longer for small angle. The most satisfactory
angle is generally 15° but it may varies from 30 to 45°.

End Cutting Edge Angle

End cutting edge angle vary from 8° to 15°. End cutting edge angle
prevents rubbing between the end of the tool and the workpiece. If end
cutting edge angle is less, it will cause vibration because of excessive
tool contact with workpiece. With end cutting edge angle, surface finish
decreases and vice-versa.
 Nose Radius
Nose radius is provided to increase strength of tip of the tool. This is
done by thinning the chip where it approaches tip of tool and by
enlarging the chip over a larger area of the point. It is also provided to
increase the surface finish. If the radius is more, the surface finish will be
good. But due to too large nose radius, contact between tool and work
piece increases, which in turn increase friction and promotes vibration
and chatter.
 Cutting Tool
Cutting speed is defined as the speed at which the work moves
concerning the tool (usually measured in feet per minute).
Cutting speed (V) = π DN/60 × 1000
mm/min
Where D = diameter of the
workpiece (mm)
N = rpm of the work
Feed rate is defined as the
distance the tool travels during
one revolution of the part.
The depth of cut is the distance that the tool bit moves into the
work. usually measured in thousandths of an inch or millimeters.
Depth of cut (t) = D-d/2 mm
where, D = outer diameter, (mm)
d = Inner diameter (mm)
 Lathe Machine (Turning Process)
Lathe is a power driven machine tool used to cut and removes the metal
from a piece of work to the required shape and size. A lathe can perform
many operations.

In lathe machine the work is hold between the centers and rotated while
the feed is given manually through the cutting tool.

Lathe machine may be of different kinds---

1) Engine lathe
2) Turret lathe
3) Capstan lathe
4) Tracer/copy lathe
5) Tool room lathe
6) CNC Lathe
Types of Lathe Machine…Centre Lathe
• Most frequently used lathe
• Work piece generally hold between centers
• Heavy duty
• Power drive for most tool movements
Types of Lathe Machine…Bench Lathe
• A bench top model usually of low power
• Used to make precision machine small work pieces
Types of Lathe Machine…Tool Room Lathe
• Look like engine lathe but having greater accuracy
• Specially used for tool making
• More versatility
• Wider range of speeds and feeds
Types of Lathe Machine…Turret Lathe
• It is production lathe
• Hexagonal turret replaces
tailstock
• Multiple tools set to machine part
• High production rates
Types of Lathe Machine…Capstan Lathe
• It is production lathe
• Used for light duty work pieces
• Small in size as compared to turret lathe
• It also have turret that replaces tailstock
• Multiple tools set to machine part
Types of Lathe Machine…Copy Lathe
• This type of lathe has the ability to follow a template to copy a shape
or contour
• A tracer finger follows the template and guides the cutting tool
• Hydraulic attachment used to copy the shape of a part from a master
• Machine tools with attachments
• Capable of turning parts with various contours
Types of Lathe Machine…CNC Lathe
• Computer Numerical Controls (CNC)
• Wide variety of process capability
• Multiple axis Movement
• Indexing and contouring head
• On- line and off- line programming available
• Equipped with one or more turrets and each turret is equipped with a
variety of tools
• Performs several operations on different surfaces of the work piece
Main Parts of a Lathe Machine
Main Parts of a Lathe Machine… Headstock
Headstock : Holds the jaws for the work piece, supplies power to the jaws
and has various drive speeds

 Clamped on left-hand end of bed

 Headstock holds spindle and fitted

with the chucks

 Hollow cylindrical shaft supported

by bearings

 Provides drive through gears to

work-holding devices

 It’s also called livecentre

 Main Parts of a Lathe Machine… Tailstock
Tailstock : Supports the other end of the work piece

• Tailstock has tapered spindle to hold

the object
• It’s also called dead centre or non-
rotating centre
 Main Parts of a Lathe Machine…Bed
Bed : Supports all major components

• Heavy, rugged casting

• Made to support working parts of lathe
• Guide and align major parts of lathe
 Main Parts of a Lathe Machine… Carriage
Carriage: Slides along the ways and consists of the cross-slide, tool post, apron

 Used to move cutting tool along lathe bed

 Consists of three main parts- Saddle, Cross-slide, Apron

Main Parts of a Lathe Machine…Quick Change Gear Box
Quick change gear box: Transmits motion from the headstock to the feed rod
and lead screw. An index chart or plate is attached at the front of the gear box to
control and maintain the feed and TPI by swiftly moving the lever attached with
the gear box.
 Size of a Lathe Machine
The major elements used for specification should invariably be based on the components that
would be manufactured in the lathe. Thus the following are the basic elements generally specified
for the capability of the lathe machine-

(A) Swing over the bed: this specifies the maximum diameter of the job that can be turned in the
lathe machine, generally restricted to small length jobs
(B) Distance between centres: this would be specifying the maximum length of the job that can
be turned in the lathe.
(C) Length of the bed: this specifies the movement of the carriage lengthwise as well as the
length of the lathe
(D) Swing over the cross slide: this specifies the maximum diameter of the job that can be
machined by the lathe machine with the job across the cross slide, which is generally the case

There are also some other factors that should also be specified to fully describe the lathe machine.
They are-
(a) horse power of the motor
(b) cutting speed range
(c) feed range
(d) screw cutting capacity
(e) accuracy achievable
(f) spindle nose diameter
Size of a Lathe Machine…
 Lathe cutting Process Parameters
Feed is the distance the point of the tool, moves along the bed with each revolution
of the lathe. It depends on the cutting speed, depth of cut, work material, condition
of the lathe (unit- mm/rev)

Depth of cut is the distance from the bottom of the cut to the uncut surface of the
work piece measured at right angles to the machined surface (unit- t=(D-d)/2 mm)
Cutting speed is defined as the distance the work piece rotates and past the cutting
point in one minute as measured on the circumference (unit- unit length/min)
In other words the length of the chip measured in feet that will be removed per
minute
It depends on the type of tool and work piece material, size of the work piece and
desired accuracy, use of cutting fluid
 Lathe Operations
Lathe Machine Operations.mp4 Lathe Machine Operations_1.mp4
Turning: produce straight, conical, curved, or grooved work pieces

Facing: to produce a flat surface at the end of the part or for making
face grooves.

Boring: to enlarge a hole or cylindrical cavity made by a previous

process or to produce circular internal grooves.

Drilling: to produce a hole by fixing a drill in the tailstock

Threading: to produce external or internal threads

Knurling: to produce a regularly shaped roughness on cylindrical

surfaces
Lathe Operations…

Department of Mechanical Engineering, RUET

 Lathe Operations… Turning
Workpiece
Cutting
speed Depth of cut (d) Straight Turning
N
Machined
surface
Chuck Feed Chip
Tool
Depth of cut

4-jaw Axis of job

90° chuck
D1  D2

B  Ax
C

A Eccentric peg
L Cutting
speed (to be turned)
D1 − D2
tan  =
2L Eccentric Turning
Taper Turning
 Lathe Operations…Facing

Chuck Workpiece
d
Machined
Face
Cutting
speed Depth of
cut
Tool Feed
 Lathe Operations…
Knurled surface
Cutting
speed
Knurling
Feed Movement
for depth
Knurling tool
Tool post

Parting

Parting tool Feed

 Lathe Operations…
Chamfer

Chamfering

Feed
Chamfering tool

Drilling – cutting tool – held in TS –feed from TS

Quill
Drill clamp moving
quill
Tail stock
Feed
Tail stock clamp
 Lathe Operations…Threading
To cut a left/right hand thread, carriage must move from left to right or towards the tail
stock and vice-versa. This direction of motion is given by positioning the feed reverse
lever on the headstock. Thread Cutting.mp4
Procedure for cutting left/right hand thread-
i) An undercut is made at the end of the length to be threaded
ii) Compound rest is set at 30º to the left of the cross feed
for German buttress thread and 29º for ACME thread
iii) The direction of the lead screw is reversed so that the
carriage moves towards the tail stock for left hand thread
and opposite for right hand thread
iv) The lead screw is engaged with the feed rod by the
half nut lever for automatic movement of the carriage
v) The TPI is fixed and adjusted through the speed chart
on the headstock
vi) The thread chasing dial indicator is fixed with any of the number on the dial for
even number of thread cutting and for fractional number of thread cutting fixed with the
odd number on the dial
vii) The thread cutting is started at the left end of the threaded section and cutting is
done towards the right end
 Lathe Machine Parts… Half-Nut Lever

The split nut used only during thread cutting when the feed change lever
on the apron is placed in the central or neutral position. This is a nut,
split lengthwise that closes over the ACME thread of the lead screw
when the half nut lever on the apron is moved up. Closing the half nut
causes the carriage to move a fixed distance for each revolution of the
spindle
 Accessories of a Lathe Machine
Accessories are the tools and equipment used in routine lathe machine
operations. Lathe Machine Accessories.mp4
Lathe accessories can be divided into two categories –

i) Work holding, supporting and driving devices-

a. Late centers, chucks,
b. Mandrels, steady and follower rests
c. Lathe dogs, drive plates faceplates

ii) Cutting tool holding devices-

a. Straight and offset tool holders
b. Threading tool holders, boring bars
c. Turret-type tool posts
 Lathe Centers
There are two types of centers-

(i) live center and (ii) dead center

A center which fits into the headstock The center which is used in a tailstock
spindle and revolves with the work is spindle and doesn’t revolve but
called live center. support the free end of the work piece
is called dead center
 Lathe Chucks
Chucks are important device used for holding work pieces. It is attached
to the lathe spindle by means of two bolts with the back plate screwed on
the spindle nose.

There are many type of the chuck, but the following three are commonly
used –

i. Three jaw universal chuck

ii. Four jaw independent chuck
iii. Magnetic chuck
iv. Collet chuck
 Lathe Chucks…
3-jaw universal chuck

4-jaw independent chuck

- The independent chuck generally has four

- The three jaw can move by inserting the
jaws , which are adjusted individually on the
chuck key at any of the 3- holes on the chuck face by means of adjusting screws
periphery of the chuck - Each of the jaw moves in different direction
- The 3- jaw moves in the same direction by inserting the chuck key at the respective
with the same velocity jaw hole
- The centre of the jobs automatically - The centre of the jobs need to be
established determined by the operators
- Generally used for holding cylindrical - Generally used for holding rectangular,
and hexagonal work pieces square or unsymmetrical objects
 Lathe Chucks…

Magnetic Chuck Collet Chuck

- Magnetic chucks use the magnetic force from a

permanent magnet, electromagnet, or electro-
- Collet chuck is used to hold small
permanent magnetic material to achieve chucking tube shaped work pieces
or holding action
- Consistent clamping pressure ensures no variation - It has much faster releasing and
in how tightly or loosely the work piece is held
- Magnetic chucks have shorter setup and take
gripping action with least possible time
down times because the work piece can be placed - It provides maximum tool clearance
right on the magnetic plate
- Suitable for thin and rough objects and not and automatic accurate centering
suitable for small objects due to lack of surface area
 Lathe Accessories… Drive Plate

The drive plate is a circular plate which is bored out and threaded so that it can be
attached to the spindle nose of the head stoke and the w/p is attached by a lathe dog to
the drive plate
It is also carries a hole for the pin which is used only when the work is held in a lathe
dog having straight tail
When bent tail dog is used, this pin is taken out and the bent portion of the tail is
inserted into the hole
 Lathe Accessories… Face Plate

The faceplate is similar to drive plate except that it is larger in diameter

It contains more open slots or T-slots so that bolts may be used to damp
the work piece to the face of the plate
The face plate is used for holding work pieces directly which cannot be
conveniently held in a chuck by using bolt or screw
 Lathe Accessories… Mandrels

The lathe mandrel is a cylindrical bar with center hole at each end. It is
used to hold hollow work piece to machine their external surface
The work piece revolves with the mandrel which is mounted between the
center of the lathe.
 Lathe Attachments…Taper turning Operations
Cutting tapers on a lathe is a common application. Tapers can be done by the following methods-
(a) using a compound slide
(b) using form tools
(c) offsetting the tailstock
(d) using taper turning attachment

(a) Using a compound rest

The compound rest is at the underneath of tool post. The base of the compound rest can be
swiveled to any desired angle of the taper. The tool is then made perpendicular to the work piece
and feed is given manually.

Some of the features of this method are:

(i) Short and steep tapers can be easily done

(iii Limited movement of the compound rest
(iii) Feeding is by hand and non-uniform.
 Lathe Attachments…Taper turning Operations
(b) Using form tools
A broad nose tool having straight cutting edge (form tool) is
set on to the work at half taper angle, and is fed straight into
the work to generate a tapered surface. In this method the tool
angle is set or manufactured before use. This method is
limited to turn short length of taper only. Tool will require
excessive cutting pressure which may distort the work due to
vibration and spoil the work surface.

(c) Offsetting the tailstock

The principle of turning taper by this method is to shift the
axis of rotation of the work piece, at an angle to the lathe axis,
and feeding the tool parallel to the lathe axis. The angle at
which the axis of rotation of the work piece is shifted is equal
to half the angle of the taper.
This method is suitable for turning small taper on long jobs.
The main disadvantage of this method is that the live and dead
centers are not equally stressed and the wear is not uniform.
 Lathe Attachments…Taper turning Operations
(d) Using taper turning attachment Taper Turning Attachment.mp4Tapered Turning Attachment 1.mp4
The principle of turning taper by a taper attachment
is to guide the tool in a straight path set at an angle
to the axis of rotation of the work piece. A taper
turning attachment consists essentially of a bracket
or frame which is attached to the rear end of the
lathe bed and supports a guide bar pivoted at the
centre. The plate having graduations in degrees may
be swiveled on either side of the zero graduation and
is set at the desired angle with the lathe axis. As the
carriage move along the bed, a slide over the bar
causes the tool to move in or out according to the
taper angle setup. The guide plate must be set at half
taper angle and the taper on the work must be
converted in degrees.

If the Large diameter (D), Small diameter (d), and

the taper length (L) are specified, the angle of
swiveling the guide plate can be determined from
equation. Tan ά = (D-d) / 2L
 Lathe Rests

Follower Rest Steady Rest

i) Follower rest is clamped with i) Steady rest is clamped with lathe

carriage of the saddle and moves bed ways
along with it ii) It has three adjustable shoes
ii) It has two adjustable shoes (sometimes with rollers to sustain
(sometimes with rollers to sustain high speed) to hold the work piece
high speed) to hold the work piece iii) It is used to prevent the work
iii) It’s used to prevent the spring form yielding to the pressure of the
cutting tool during machining long
away of jobs while machining
w/p with small diameter or heavy w/p
small jobs
 Lathe Problem#1
Determine the angle at which the compound rest would be swiveled for cutting
a taper on a work piece having a length of 150 mm and outside diameter 80
mm. The smallest diameter on the tapered end of the rod should be 50 mm and
the required length of the tapered portion is 80 mm.

Solution
Given data: D1 = 80 mm,
D2 = 50 mm
L = 80 mm (with usual notations)

tan  = (80-50) / 280

Or  = 10.620

The compound rest should be swiveled at 10.62o

 Lathe Problem#2
A piece of MS bar having 25 mm in diameter and 50 mm long is to be cut at a
speed of 30m/min with a feed rate of 0.25mm/rev. Calculate the cutting time.

Solution

Here,
Job diameter, D= 25 mm
Job length, L= 50 mm
Speed, v= 30 m/min
Feed, f= 0.25mm/rev

Spindle speed, N= v/π×D = 30×1000/ (π×25) = 381.97 rpm

Cutting time, T = L/fN = 50/ (0.25 ×381.97) min = 0.523 min.

Hence, the estimated cutting time is 0.523 min.

 Lathe Problem#3

A lathe machine is used to machine an aluminum

cylinder. Using specific energy values for Aluminum
from table in your text book, calculate MRR and
cutting power at (a) Cutting speed 5 m/s, feed 0.3
mm/rev and depth of cut 1 mm. (b) Cutting speed 1.5
m/s, feed = 0.5 mm/rev and depth of cut 5 mm.
 Special Purposes Drill Machine
Gang drilling machine: This is
almost single purpose and more
productive machine a number (2 to 6)
of spindles with drills (of same or
different size) in a row are made to
produce number of holes
progressively or simultaneously
 Special Purposes Drill Machine
Turret (type) drilling machine: Turret
drilling machines are structurally rigid
column type but are more productive like
gang drill by having a pentagon or hexagon
turret.
 Special Purposes Drill Machine
Multispindle drilling machine: In these high
production machine tools a large number of
drills work simultaneously on a blank through a
jig specially made for the particular job. The
entire drilling head works repeatedly using the
same jig for batch or lot production of a
particular job.