MACHINING OPERATIONS Turning and Related Operations

v
Turning – a machining
process in which a single-
point tool remove material Do Df
Outline from the surface of a
d
rotating work piece. (Lathe)
• Turning and Related Operations f
• Drilling and Related Operations L
v
• Milling N= Rotational Speed
• Machining & Turning Centers πDo
• Other Machining Operations Do − D f = 2d
– Shaping and Planing
f r = Nf Feed rate
– Broaching
L
– Sawing
Tm = Time of machining
• Machinability fr
MRR = vfd Material Removal Rate

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Operations Related to Turning Work Holding

Contour turning Chamfering

Facing Taper turning Form turning

mounting the work between three-jaw chuck
centers using a "dog”

Threading Boring Drilling

Cutoff Knurling
collet face plate for non-cylindrical workparts
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 Engine Lathe Other Lathes & Turning Machine

• Toolroom Lathe and Speed Lathe

• Turret Lathe
– The tailstock is replaced with a
turret
• Chucking Machines – No tailstock
• Automatic Bar Machine – Similar to
chuck machine but with a collet
– A single- and multiple-spindle bar
machines
• NC Lathe
• Boring Machines – the stiffness of a
boring bar
– Horizontal and Vertical

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Drilling and Related Operations Operation Related to Drilling

• Geometry of Twist drill
– Shank, Neck and Drill body
– Helix angle, Point angle, Flute,
cutting edge, Chisel edge, Margin
• Cutting conditions

v
Spindle rpm: N=
πD

Feed rate: f r = Nf f(in/rev) Reaming Tapping

Counterboring
πD f r
2

Metal Removal Rate: MRR = – Countersinking

4
For a through hole For a blind hole – Center drilling
t+A – Spot facing
Machining time: Tm = Tm =
d
fr fr

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 Machine Tool for drilling Milling
A machine operation in which a workpart is fed past a rotating cylindrical
• Drill press tool with multiple edges. (milling machine)
– Upright drill Types:
– Bench drill
– Radial drill
9 Peripheral milling
– Slab, slotting, side and straddle milling Up Milling
– Gang drill –2-6 drills together
– Up Milling (Conventional) & down milling (Climb)
– NC drill
• Vice, Jig and fixture 9 Facing milling
– Conventional, Partial face, end, profile, pocket & contour
Upright drill press Down Milling

Radial drill press

Large drill press designed for large parts

(a) peripheral milling (b) face milling

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Milling Cutting Conditions

• Milling cutters
– Plain milling cutters
– Form milling cutters Radial Rake
Slab slotting side straddle – Face milling cutters Angle
– End milling cutters
Relief
• Cutting conditions Angle

conventional Partial face end milling

face milling milling
v
Spindle rotation speed: N =
πD
profile milling
Feed rate: f r = Nnt f
pocket milling Surface contouring
MRR: MRR = wdf r
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 Milling Machines Machining Centers
• Machining center – highly automated machine tool capable of
performing multiple machining operations under CNC control.
– Automatic tool changer
– Pallet shuttles
– Automatic workpart positioning

horizontal knee-and-column
vertical knee-and-column

ram type knee-and-column milling

machine; ram can be adjusted in and
out, and toolhead can be swiveled CNC turning center

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Other Machining Operations: Shaping and Planing

Mill-Turn Centers
• Highly automated machine tool that can perform turning, milling, and • A single-point tool moves linearly relative to the work part
drilling operations on a workpart
• General configuration of a turning center
• Can position a cylindrical workpart at a specified angle so a rotating
cutting tool (e.g., milling cutter) can machine features into outside
surface of part
– A conventional turning center cannot stop workpart at a defined angular
position and does not possess rotating tool spindles
Shaping - A tool moves Planing – A workpart moves
A part

Stock Turning Milling Drilling

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 Other Machining Operations: Broaching Other Machining Operations: Sawing
• Moves a multiple tooth cutting tool linearly relative to work in
direction of tool axis
Advantages:
- Good surface finish
- Close tolerances
- Variety of work shapes possible
• Cutting tool called a broach
- Owing to complicated and often custom-shaped geometry, tooling power hacksaw –linear reciprocating motion of
is expensive hacksaw blade against work

Internal Broaching:
• Performed on internal surface of a hole
• A starting hole must be present in the part to insert broach at beginning
of stroke
bandsaw (vertical) – linear
continuous motion of bandsaw blade
circular saw
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Machinability

• Machinability – A measure of the success of a machining

operation usually on a workmaterial.
– Tool life
– Force and Power
– Surface finish Next Time:
– Easy of chip disposal
Cutting Tool Technology
– Material Removal rate

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