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The document provides an introduction and overview of machining processes. It defines machining as the removal of unwanted material from a workpiece to achieve a desired size, shape and surface quality. The document then covers the historical background of machining and provides a classification of traditional machining processes including machining by cutting, abrasion and erosion. It discusses advantages and limitations of traditional processes and the rise of non-traditional machining methods.

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OKELLO JOB LAZARUS
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25 views31 pages

0 - Iroduction To Machining

The document provides an introduction and overview of machining processes. It defines machining as the removal of unwanted material from a workpiece to achieve a desired size, shape and surface quality. The document then covers the historical background of machining and provides a classification of traditional machining processes including machining by cutting, abrasion and erosion. It discusses advantages and limitations of traditional processes and the rise of non-traditional machining methods.

Uploaded by

OKELLO JOB LAZARUS
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Introduction to Machining

By

Hassan El-Hofy

Professor
College of Engineering, Alexandria University
Outline
 Definition
 Histological Background
 Classification of Machining Processes
Machining by cutting
Machining by abrasion
Machining by Erosion
 Disadvantages of traditional machining
 Why non traditional methods?
Outline

Non traditional machining


n Mechanical methods
 Chemical & electrochemical erosion
 Thermal erosion
 Hybrid machining

Micromachining
Machining

 Is the removal of the unwanted


material (machining allowance)
from the workpiece so as to
obtain a finished product of the
desired size, shape and surface
quality
Historical Background
 Cylinder
 Roller
 First drilling m/c 4000 BC.
 First deep hole drilling (1452-1519).
 First turning 1840.
 Lead screw, back gears and the tool
post to the previous design 1771-1831.
Historical Background
 Planers and shapers (1824-1905)
 First milling machine 1818
 Cylindrical grinding 1874
 First gear shaper 1896
 Gear hobbing 1879
 Gear planers 1908
Historical Background
 Copying techniques, cams and automatic
mechanisms raised the product accuracy.
 In 1953 NC, CNC and DNC enhanced
the product accuracy and uniformity.
 Machine tools form around 70 % of the
production machines
 M/c tools = high production accuracy
compared to the metal forming machine
tools.
Machining
Processes

Cutting (C) Abrasion (A) Erosion (E)

Circular Various Bonded Loose CHM


Shapes Shapes Abrasives Abrasives
ECM
ECG
EDM
Turning Milling Grinding Polishing LBM
Boring Planing Honing Buffing AJM
Drilling Shaping Superfinishing Lapping WJM
Broaching Abrasive flow PBM
Gear cutting USM

Traditional Nontraditional
Machining by Cutting
 The tool is penetrated into the w.p by a
depth of cut.
 Cutting tools have definite number of
cutting edges of a known geometry.
 The machining allowance is removed in
the form of visible chips.
 The shape of the workpiece produced
depends on the tool and workpiece
relative motions.
Metal Cutting System

Chip

Cutting speed
Depth of cut
Tool
Cut surface

Workpiece
Machining by Cutting

Form Generation Form &


Generation

Shaping Turning Thread cutting


Planing Shaping Slot milling
Drilling Planing Gear hobbing
Form turning Pocket milling
Form milling Contour milling
Tool motion
Workpiece
motion Stationary Linear Rotary Spiral

Shaping Drilling
Broaching
Planing Milling

Turning

Hobbing
Form Cutting

Feed

Feed
Generation Cutting
Depth of cut

Feed

Feed

Turning Shaping
Form + Generation Cutting

Feed

Feed
Machining by Cutting

Multi
Single
point
Point

Drilling
Turning Reaming
Boring Milling
Shaping Broaching
Planing Hobbing
Sawing
Filing
Machining by Abrasion
Wheel rotation

Abrasives
Bond

Workpiece
Surface Grinding

Grinding
wheel

Workpiece
Lapping
Low pressure

Lab
Oil + Loose
abrasives

Workpiece
Machining by Abrasion

Grinding Surface Modern


Finishing Abrasion

Surface Honing USM


Creep feed Lapping AJM
Cylindrical Superfinishing AWJM
Centerless Polishing AFM
Buffing MAF
Abrasion Machining
 The energy required to remove a unit
volume is 10 times higher than in
machining by cutting (High friction).
 Abrasive machining tackles materials
harder than 400 HV
 Produces smooth surface finish
 Enables close control of the material
removal.
 Normally used for finishing operations.
W.P Tool motion
motion

Stationary Linear Rotary Spiral

Lapping Honing
Polishing
Surface grinding

Superfinishing Centerless Cylindrical


grinding grinding
Cylindrical
grinding
Ultrasonic Machining
Oscillation + feed Abrasive slurry

Tool
Workpiece
Disadvantages of
Traditional Machining
 The high cost due to the large energy
used to remove a unit volume from the
workpiece material.
 Workpiece distortion due to the heat
generated during cutting and abrasion.
 Undesirable cold working and the
residual stresses which may require
post processing to remedy their harmful
effects.
 Limitations related to the size and
complexity of the workpiece shape.
Machining by Erosion

Electrochemical Thermal

CHM
EDM
ECM
EBM
LBM
PBM
Erosion Machining
Molten metal
Laser beam
Tool (-)

Workpiece (+)

Workpiece
ECM
LBM
Electrochemical Machining
Micro Machining
Micro Machining
Water Jet Machining
Water Jet Machining

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