Module 04

Material Removal Processes

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Classification of
material removal
processes

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 Material Removal Processes

• A family of shaping operations, the common feature of

which is removal of material from a starting workpart so
that the remaining part has the desired geometry
• Conventional 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

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 04-01
Fundamentals of
Conventional
Machining

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 Conventional Machining

• A material removal process in which a sharp cutting tool

is used to mechanically cut away material so that the
desired part geometry remains
• Most common application: to shape metal parts

• Most versatile of all manufacturing processes in its

capability to produce a diversity of part geometries and
geometric features with high precision and accuracy

– Casting can also produce a variety of shapes, but it lacks the

precision and accuracy of machining

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 Purpose of Conventional Machining

• Most of the engineering components

such as gears,
bearings, clutches, tools, screws and
nuts etc.
dimensional and form accuracy and good
need
serving their purposes
surface finish
• Preforming like casting, forging etc. generally cannotfor
provide the desired accuracy and finish

• For that such preformed parts, called blanks, need semi-

finishing and finishing and it is done by machining and
grinding
• Grinding is also basically a machining process.
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Principle of Conventional Machining

Principle of machining (turning). A metal rod of irregular shape, size and

surface is converted into a finished rod of desired dimension and surface
by machining by proper relative motions of the tool-work pair.
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 Definition of Machining

• Machining is an essential process of finishing

by which jobs are produced to the desired
dimensions and surface finish by gradually
removing the excess material from the
preformed blank in the form of chips with the
help of cutting tool(s) moved past the work
surface(s)

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Machining Requirements

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 Why Machining is Important

• Good dimensional accuracy and surface finish

• Variety of work materials can be machined
• Variety of part shapes and special geometric
features possible, such as:
– Screw threads
– Accurate round holes
– Very straight edges and
surfaces
• Economical, particularly when the number of parts
desired is relatively small

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 Disadvantages with Machining

• Wasteful of material
– Chips generated in machining are wasted material, least
at in the unit operation

• 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

• More and skilled labor required

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 Classification of Machined Parts

• Rotational - cylindrical or disk-like shape

• Nonrotational (also called prismatic) - block-like or
plate-like

Machined parts are classified as: (a) rotational, or (b)

nonrotational, shown here by block and flat parts.

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 Conventional Machining Processes

The three most common types of conventional machining processes: (a) turning,
(b) drilling, and two forms of milling: (c) peripheral milling, and (d) face milling.
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Conventional Machining Processes

Other conventional machining processes

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 Machining Operations and Part
Geometry
• Each machining operation produces a characteristic
part
geometry due to two factors:
1. Relative motions between tool and workpart
• Generating – part geometry determined by feed trajectory
of cutting tool; the path followed by the tool during its feed
motion is imparted to the work surface

2. Shape of the cutting tool

• Forming – part geometry is created by the shape of the
cutting tool
• The cutting edge of the tool has the reverse of the shape
to
be produced on the part surface
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 Generating Shape

Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling.

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 Forming to Create Shape

Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching.

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 Forming and Generating

Combination of forming and generating to create shape: (a)

thread cutting on a lathe, and (b) slot milling.

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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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 Cutting Tool Classification

1. Single-Point Tools
– One dominant cutting edge
– Point is usually rounded to form a nose
– radius
Turning uses single point tools
2. Multiple Cutting Edge Tools
– More than one cutting edge
– Motion relative to work achieved by rotating
– Drilling and milling use rotating multiple edge
cutting
tools

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 Cutting Tools

(a) A single-point tool showing rake face, flank, and tool point; and
(b) a helical milling cutter, representative of tools with multiple
cutting edges.

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 Cutting Conditions in Machining

• Three dimensions of a machining process:

– Cutting speed v – primary motion
– Feed f – secondary motion
– Depth of cut d – penetration of tool below original
work surface
• For certain operations, material removal rate
can be computed as
RMR = v f d
where v = cutting speed; f = feed; d = depth of cut

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Cutting Conditions in Machining

Turning a cylindrical workpiece on a lathe requires you to select

the cutting speed, feed, and depth of cut.

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 Roughing vs. Finishing

• In production, several roughing cuts are usually taken

on the part, followed by one or two finishing cuts
• Roughing - removes large amounts of material from
starting workpart
– Creates shape close to desired geometry, but leaves some
material for finish cutting
– High feeds and depths, low speeds
• Finishing - completes part geometry
– Final dimensions, tolerances, and finish
– Low feeds and depths, high cutting speeds

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Four Basic Types of Chip in Machining

1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip

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 Discontinuous Chip

• Brittle work materials e.g.

cast irons or materials that
contain hard impurities
• Very low or very high
cutting speeds
• Large feed and depth of cut
• Low rake angles

Four types of chip formation in metal cutting: (a) discontinuous

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 Continuous Chip

• Ductile work materials

• High cutting speeds
• Small feeds and depths
• Sharp cutting edge
• High rake angles

(b) continuous

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 Continuous with BUE

• Ductile materials
• Low-to-medium cutting speeds
• Tool-chip friction causes portions of
chip to adhere to rake face
• BUE forms, then breaks off,
• cyclically
Can be reduced
– Decreasing theby
depth of cut
– Increasing the rake angle
– Using a sharp tool
– Increasing cutting speed
(c) continuous with built-up edge

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 Serrated Chip

• Also called segmented or non-

homogeneous chips
• Semicontinuous, saw-tooth
appearance
• Associated with difficult-to-
machine metals at high cutting
speeds; metals with low
thermal conductivity &
strength
• that decreases sharply with
temperature e.g. titanium (d) serrated.
alloys
Some steels may also exhibit
this phenomenon when cut at
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Questions?

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 References

• Fundamentals of Modern Manufacturing ; Materials,

Processes, And Systems, 3rd Ed. By Mikell P. Groover;
John Wiley And Sons

• Degarmo’s Materials And Processes In Manufacturing,

10th Ed. By J.T Black, R.A. Kohser; John Wiley And Sons

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