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Conventional Machining: Presented by Ahmad Juang P

Conventional machining operations include turning, drilling, milling, boring, broaching, shaping, and planning. Turning is used to produce rotational parts and involves rotating the workpiece against a single-point cutting tool to cut away material. Drilling involves using a rotating tool to produce holes in the workpiece. Milling uses a rotating cutter to cut flat, shoulder, and irregular surfaces on a workpiece. Boring is used to produce smooth, cylindrical surfaces inside holes. Broaching uses a multi-tooth tool to cut internal or external surfaces in one pass. Shaping and planning are used to produce flat surfaces on large or oddly shaped workpieces. Conventional machining can introduce residual stresses and is best for

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Maulana Hasan
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116 views

Conventional Machining: Presented by Ahmad Juang P

Conventional machining operations include turning, drilling, milling, boring, broaching, shaping, and planning. Turning is used to produce rotational parts and involves rotating the workpiece against a single-point cutting tool to cut away material. Drilling involves using a rotating tool to produce holes in the workpiece. Milling uses a rotating cutter to cut flat, shoulder, and irregular surfaces on a workpiece. Boring is used to produce smooth, cylindrical surfaces inside holes. Broaching uses a multi-tooth tool to cut internal or external surfaces in one pass. Shaping and planning are used to produce flat surfaces on large or oddly shaped workpieces. Conventional machining can introduce residual stresses and is best for

Uploaded by

Maulana Hasan
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Conventional Machining

Presented by
Ahmad Juang p
Introduction
• What is conventional machining?

• Various machining operations


Basic Process

Image courtesy - Wiki


Turning

Fig-2 Basic scheme of Turning

• To produce rotational, axis-symmetric parts.


• Feed motion
• Feed relative to work piece.

Image Courtesy:- Ghosh and Mallik; Manufacturing Science


Turning Operations
• Facing
• Parting
• Grooving
• Drilling
• Screw cutting

Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel

Ref: Manufacturing Engineering and Technology


Ref:-Manufacturing
Serope Kalpakjian
Science
and Steven
- GhoshR.and
Schimid
Mallik
Effect of Turning on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials

• Physical
• Little effect

• Chemical
• Little effect

Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie


• Advantages
• Increased production with medium and high turret lathes.

• Disadvantages
• Limited to rotational parts.
• High equipment cost.
• Significant tool wear.
• Low production rate.
• Large amount of scrap.

Ref: Manufacturing Science - Ghosh and Mallik


Drilling

• Drilling Operations
• Reaming
• Tapping
• Counterboring Fig-3 Basic scheme of Drilling
• Countersinking
• Centering
• Spot facing

Ref: Manufacturing Engineering and


Image
Technology
Courtesy:-
- Serope
Ghosh and
Kalpakjian
Mallik; and
Manufacturing
Steven R. Schimid
Science
Workpiece Materials
•
Aluminum alloys
• Magnesium alloys
• Copper alloys
• Stainless steels
Effect of Drilling
• Cast iron on Work Material Properties
• Plastics
• Mechanical
• Very thin layer of highly stressed and disturbed material on new
surface.

• Physical
• Little effect

• Chemical
• Increased probability of corrosion at stressed surface
Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie
Advantages
• High production rate.

Disadvantages
• Skilled labor is required according to the hole location and
accuracy.
Milling

Fig-4 Basic scheme of Milling

Image Courtesy:- Ghosh and Mallik; Manufacturing Science


Milling Operations
• Slab Milling
• Face Milling
• End Milling

Fig-5 Slab Milling Fig-6 Face Milling

Image Courtesy:- Ghosh and Mallik; Manufacturing Science


Workpiece Materials
• Aluminum
• Brass
• Magnesium
• Nickel
• Steel
• Thermostat plastics
• Titanium
• Zinc

Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie


Advantages
• Variety of shapes can be obtained

Disadvantages
• Skilled labor is required
• Low to medium production rate
• Limited shape complexity
• High equipment cost
• Significant tool wear
• Large amount of scrap

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
Boring

Fig-7 Boring operation

Image Courtesy:- http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm


Boring Operations
• Single-Edge Boring
• Multi-Edge Boring
• Step Boring
• Reaming

Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel
Ref: Manufacturing Processes Reference Guide – Robert
Ref:H.www.coromant.sandvik.com/boring
Tadd, Dell K. Allen and Leo Alting
Effect of Boring on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials
• Physical
• Little effect
• Chemical
• Little effect

Advantages
• Finish machining of cylindrical surfaces on very large workpieces.

Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alting
Broaching

Broaching Operations
Fig-8 Broaching Tool

• Surface Broaching
• Pull down Broaching
• Push Broaching
• Pot Broaching

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond
Image Courtesy:-
F. Veilleux
wiki
Workpiece Materials
• Aluminum
• Brass
• Bronze
• Plastic
• Malleable Iron

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux
Advantages
• External and internal flat surfaces
• Good surface finish
• High production rate
• Less skilled labor is required
• Reduced cycle times
• Increased tool life
• Reduced maintenance
• Complex and irregular shapes.

Disadvantages
• Costly tooling

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
Shaping

Fig-9 Basic scheme of Shaping

Image Courtesy:- Ghosh and Mallik; Manufacturing Science


Fig-10 Shaper Mechanism

Image Courtesy:- http://www.roymech.co.uk/images9/shaper_mechanism_6.gif


Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on
relatively small surfaces.

Disadvantages
• Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik


Planing

Fig-11 Basic scheme of Planing

Image Courtesy:- Ghosh and Mallik; Manufacturing Science


Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on large
surfaces.

Disadvantages
• Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik


References
• Books
• Manufacturing Science by Amitabha Ghosh and Asok Kumar Mallik, East-
West Press Pvt Ltd.
• Tool and Manufacturing Engineers Handbook, Volume 1 – Machining by
Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux, Society
of Manufacturing Engineers Publications Committee
• Troubleshooting Manufacturing Processes by Laroux K. Gillespie, Society
of Manufacturing Engineers Publications Committee
• Manufacturing Engineering and Technology by Serope Kalpakjian and
Steven R. Schimid, Pearson Education
• Manufacturing Processes Reference Guide by Robert H. Tadd, Dell K. Allen
and Leo Alting, Industrial Press
• Websites
• http://www.roymech.co.uk/images9/shaper_mechanism_6.gif
• http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm
• http://www.coromant.sandvik.com/boring
Thank you

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