MACHINING OPERATIONS

AND MACHINE TOOLS

CHAPTER 22
OVERVIEW

• TURNING AND RELATED OPERATIONS

• DRILLING AND RELATED OPERATIONS

• MILLING

• OTHER MACHINING OPERATIONS

 MACHINING

Versatile
• MACHINING
Accurate

“ MANUFACTURING PROCESS”

• To produce diversity of part geometric features.

• Casting
 MACHINING

ROTATIONAL
• MACHINED PARTS
NON ROTATIONAL

• ROTATIONAL
- The workpart has a cylindrical or disk-like shape.
- Cutting tool removes material from a rotating workpart.
- Turning and Boring
- Drilling: related
 MACHINING

ROTATIONAL
• MACHINED PARTS
NON ROTATIONAL

• NONROTATIONAL
- Prismatic.
- The workpart is block-like or plate-like.
- Linear motions of the work part, combined with either
rotating or linear tool motions
- Milling, shaping, planing, and sawing.
MACHINING

(a) Rotational (b) Nonrotational

 MACHINING

RELATIVE MOTION
• PRODUCES A GEOMETRY BETWEEN THE TOOL
AND WORKPART

SHAPE OF THE
CUTTING TOOL

• OPERATIONS BY WHICH PART GENERATING

SHAPE IS CREATED
FORMING
 MACHINING

• GENERATING
- The geometry depends of the feed trajectory
of the cutting tool.
- The path followed by the tool during this feed
motion is imparted to the work surface.
- Variations in depth or width of cutting.
- Ex. Straight turning, taper turning
contour turning
MACHINING

(a) Straight turning (b) taper turning (c ) contour turning

(d) Plain milling (e) profile milling
 MACHINING

• FORMING
- The shape of the part is created by the
geometry of the cutting tool.
- Ex. Form turning, drilling
broaching
- Cutting conditions = primary speed +
feed motion
- Depth of cut: Final penetration into the work.
MACHINING

(a) Form turning (b) drilling (c ) broaching

MACHINING

(a) Thread cutting on a lathe (b) slot milling

TURNING AND RELATED OPERATIONS

• TURNING
• A single point tool removes material from the
surface of a rotating cylindrical workpiece.
• Feed: parallel to the axis of rotation.
• Machine Lathe Power to turn the part
Feed the tool
CUTTING CONDITIONS IN TURNING

Rotational speed, depth of cut, feed, time to machining,

Volumetric rate of material removal
OPERATIONS RELATED TO TURNING

(a) Facing
(b) Taper turning
(c) Contour turning
(d) Form turning
(e) Chamfering
(f) Cutoff
(g) Threading
(h) Boring
(i) Drilling
(j) Knurling
 OPERATIONS RELATED TO TURNING

• FACING: The tool is fed radially into the rotating work on one
end to create a flat surface on the end.
• TAPER TURNING: The tool is feed in angle to create a conical shape.
• CONTOUR TURNING: Instead of feeding the tool along a straight
line parallel to the axis of rotation as in turning
the tool follows a contour.

• FORM TURNING: Forming : The tool has a shape that is imparted to the
work by plunging the tool radially into the
work.
• CHAMFERING: The cutting edge of the tool is used to cut an angle on
the corner of the cylinder.
 OPERATIONS RELATED TO TURNING
• CUTOFF: The tool is fed radially into the rotating work at some location
along its length to cut off the end of the part. (parting)
• THREADING: A pointed tool is fed linearly across the outside surface
of the rotating workpart in a direction parallel to the
axis of rotation at a large effective feed rate.
• BORING: A single point tool is fed linearly, parallel to the axis of
rotation, on the inside diameter of an existing hole in the
part.

• DRILLING: Can be performed by feeding the drill into the rotating

work along its axis.
• KNURLING: Not a machining operations, but it is a metal forming
operation used to produce a regular cross-hatched pattern
into the work surface.
THE ENGINE LATHE
METHODS OF HOLDING THE WORK IN
A LATHE

(a) Between the centers “dog: (b) Chuck (c) Collet (d) Face plate
 BORING MILLS

Horizontal Boring: (a) Boring bar is fed into a rotating work part
(b) Work is fed past a rotating boring bar

Boring bar (WC-Co)

Vertical boring mill

DRILLING AND RELATED OPERATIONS

• DRILLING
• Objective: To create a round hole in a workpart.
• Tool: A rotating cylindrical with two cutting
edges
• Drill
• Machine: Drill press
CUTTING CONDITIONS IN DRILLING

Rotational speed, feed, machining time to drill a through hole

and a blind hole, Rate of material removal
CUTTING CONDITIONS IN DRILLING

• DRILLED HOLES Through holes

Blind holes

(a) Through hole (b) Blind hole

OPERATIONS RELATED TO DRILLING

(a) Reaming
(b) Tapping
(c) Counter-boring
(d) Countersinking
(e) Center drilling
(f) Spot facing
 OPERATIONS RELATED TO DRILLING
• REAMING: Is used to slightly enlarge a hole, to provide a better
tolerance on its diameter. The tool is a reamer
• TAPPING: A tap is used to provide internal screw threads on an
existing hole.

• COUNTERBORING: Provides a stepped hole, in which a larger

diameter ollows a smaller diameter partially into
the hole.
• COUNTERSINKING: Similar to counterboring, except that the step
in the hole is cone-shaped.
• CENTERING: Drills a starting hole to accurately establish its location
for subsequent drilling.
• SPOTFACING: Is used to provide a flat machined surface on the
workpart in a localized area.
THE DRILL PRESS
MILLING

• A workpart is fed past a rotating cylindrical tool

with multiple cutting edges.
• The axis rotation of the cutting tool is
perpendicular to the direction of feed.
• Milling cutter
• Milling machine
• The geometric form created by milling is a plane
surface.
• Types of milling operation Peripheral milling
Face milling
MILLING

• PERIPHERAL MILLING
• Plain milling
• Axis of the tool is parallel to the
surface machined
• Types:
a. Slab milling: the cutter width
extends beyond the workpiece on
both sides.
b. Slotting: the width of the cutter
is less than the workpiece width
(slot).
c. Side milling: cutting the side of
the workpiece.
d. Straddle milling: cutting takes
place on both sides.
MILLING

• PERIPHERAL MILLING

(a) Slab milling (b) Slotting (c ) Side milling (d) Straddle milling
MILLING

• PERIPHERAL MILLING
• Two forms of milling Up milling
Down milling

• Up milling:
- Conventional milling
- The direction of motion of the cutter teeth is
opposite the feed direction.
- “Against the feed”
MILLING
• Down milling:
- Climb milling
- The direction of cutter motion is the same as
the feed direction.
- “With the feed”

(a) Up milling (b) Down milling

MILLING
• Axis of the tool is perpendicular to
the surface machined
• Types:
• FACE MILLING a. Conventional face milling: the
diameter of the cutter is grater
than the workpart width.
b. Partial face milling: the cutter
overhangs the work on only cut into
the part.
c. End milling: The cutter diameter
is less than the work width (slot).
d. Profile milling: Is a form of end
milling in which the outside
periphery of a flat part is cut.
e. Pocket milling: Is used to mill
shallow pockets into flat parts.
f. Surface contouring: A
curvilinear path at close intervals
are created.
MILLING
• FACE MILLING

(a) Conventional face milling (b) Partial face milling (c ) End milling
(d) Profile milling (e) Pocket milling (f) Surface contouring
CUTTING CONDITIONS IN MILLING

Cutting speed, feed, feed rate, Rate of material removal,

Time of machined for slab milling and Face milling
CUTTING CONDITIONS IN MILLING

Slab (peripheral)milling

Face milling:
a. Cutter is centered
b. Cutter is offset to one side
MILLING MACHINE

(a) Horizontal (b) Vertical