Metal removal processes

Metal Cutting
Process where a stronger metal is used to
cut a softer metal.
One of the most popular and commonly
used manufacturing processes.
Lathe has been used since mid-seventeenth
century.
Metal cutting also includes methods of
machining such as:

 Parts after heat treatment are usually distorted

and hence need machining
Accurate dimension, sharp corners
Desired texture - such as shiny finish, mirrored
surface etc.
With modern machine it can be very
economical
Disadvantages
Higher cost of labor and tools
Scrap metal results
Longer cycle time

Mechanics of Chip Formation

Most important factors in all machining
process:
Geometry of cutting tool
Machining conditions:

Speed of tool
Speed of workpiece
Hardness of workpiece
Hardness of tool

Work holding and fixtures

Coolant, type of process, accuracy issues, etc.
Machine condition - such as stiffness

Indirect effect

Type of chips formed

Temperature rise
Surface finish
Tool wear etc