TM18 - Machining Operations and Machine Tools PDF

MACHINING OPERATIONS
AND MACHINE TOOLS
1. Turning and Related Operations

2. Boring
3. Drilling and Related Operations
4. Milling
5. Shaping and planing
6. Broaching
7. Machining Operations for Special Geometries
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Classification of Machined Parts
 Rotational - (a) cylindrical or disk-like shape

 Non-rotational (prismatic) - (b) block-like and
plate-like
Classification of Machined Parts
 Rotational – mainly by turning using single

point tools
 Non-rotational – mainly by milling using tools
with multiple cutting edges (but also by shaping
or planning)
 Drilling and boring may be also necessary in
both parts
Classification of Machined Surfaces
 Generating shapes: determined by the feed

trajectory of the cutting tool
 Forming shapes: determined by the geometry

of the cutting tool
 Generated and forming shapes
Generating Shapes
Generating shape: (a) straight turning, (b) taper turning, (c)

contour turning, (d) plain milling, (e) profile milling (contouring)
Forming Shapes
 Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching
Forming and Generating Shapes
 Combination of forming and generating to create shape: (a)

thread cutting on a lathe, and (b) slot milling
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Turning
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
Lathe
Lathe
Spindle Tool post
Headstock Tailstock
Speed Cross
controls slide
Feed
Carriage
controls
Bed
Lathe
Methods of Holding Workpiece
in a Lathe
 Tasks: i) holding the workpiece, ii) referring the

workpiece with respect to the spindle axis
 Made by the following fixtures:
 Between centers
 Self-centering chuck
 Collet
 Face plate
Between Centers
Between Centers
Self-centering Chucks
Other Chucks
 Machinable chuck jaws

 Chuck with jaws independently set
Collet
Face plate
Forces and Power in Turning
Increasing Production Rate
 Reducing tool exchange time
 Reducing workpiece exchange time
 Performing simultaneous operations
 Increasing automation and cutting speed
Increasing Production: Turret
Lathe
 Tailstock replaced by “turret” that holds up to six tools

 Tools rapidly brought into action by indexing the
turret
Increasing Production: Bar
Machine
 These machine tools permit long bar stock to be fed

through headstock
 At the end of the machining cycle, a cutoff
operation separates the new part
Increasing Production: Multiple
Spindle Bar Machines
 More than one spindle, so multiple parts machined

simultaneously by multiple tools
Increasing Production: Multiple
Spindle Bar Machines
 (a) Part; (b) sequence of operations: (1) feed stock to stop,
(2) turn main diameter, (3) form second diameter and
spotface, (4) drill, (5) chamfer, and (6) cutoff
Increasing Production: CNC
Lathe
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Boring vs Turning
 Difference between boring and turning:

 Primary motion is generally performed by cutting
tool
 Boring is generally performed on the inside
diameter of an existing hole
 Boring is generally more accurate than turning
Boring
Horizontal Boring Mill
Column
Column
Headstock
Spindle
Tailstock
Workpiece
Baseplate
Rotary table
Ways
Horizontal Boring Mill
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Drilling
 Creates a round
hole in a workpart
 Cutting tool called a
drill or drill bit
 Machine tool: drill
press
Through Hole vs. Blind Hole
 (a) Through hole - drill exits opposite side of work

and (b) blind hole – drill does not exit opposite side
Operations Related to Drilling
 (a) Reaming, (b) tapping, (c) counterboring
More Operations Related to
Drilling
 (d) Countersinking, (e) center drilling, (f) spot facing
Drill Press
Radial
Drill Press
 Large drill press

designed for large
parts
Vise for Drill Presses
Jig for Drill Presses
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Milling
 Machining operation in which:
 Axis of tool rotation is usually perpendicular to

feed
 Cutting tool called a milling cutter (2 or more
teeth)
 Machine tool called a milling machine
 Interrupted cutting operation
 Basic milling operation creates a planar surface
Two Forms of Milling
 (a) Peripheral milling and (b) face milling
1) Peripheral Milling
 Peripheral milling
 a) slab milling; b) slotting; c) side milling; d)
straddle milling; e) form milling
2) Face Milling
 Face milling
 a) full face milling; b) partial face milling; c) end
milling
Peripheral and/or Face Milling
 d) Profile milling, e) pocket milling, f) surface contouring
Down Milling and Up Milling
Milling Machines
 (a) Horizontal and (b) vertical milling machines
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Shaping and Planing
 Similar operations, both use a single point cutting

tool moved linearly relative to the workpart
Shaping and Planing
 A straight, flat surface is created in both operations

 Interrupted cutting operation
 Subjects tool to impact loading when entering
work
 Typical tooling: single point high speed steel
tools
 Low cutting speeds due to start-and-stop motion
Cutting Conditions
Shaper
Shaper Mechanism
Vertical Shaper (Slotter)
Single-Column Planer
Feed
Double-Column Planer
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Broaching
 A multiple tooth cutting tool is moved linearly

relative to workpiece in direction of tool axis
Broaching
 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 is expensive
Broaching
 (a) External and (b) internal broaching (cross-

hatching indicates surface broached)
Broaching
Example of External Broaching
Broaching Machines
AND MACHINE TOOLS

2. Boring
4. Milling
6. Broaching
Machining Operations for
Special Geometries
 Screw threads
(external and internal)
 Gear teeth
Cutting External Screw Threads
 Single-point thread cutting
 threading die (manual and automatic)
Cutting Internal Screw Threads
 Single-point thread cutting
 Manual tapping
 Manually fed
 Pre-existing
hole
 Automatic tapping
 One tool
 Automatically fed (different strategies)
 Pre-existing hole
Machining Gear Teeth
 Spur gear
 Helical gear
 Bevel gear
 Rack
Principal Operations for
Machining Gear Teeth
 Form milling - use of a form milling cutter
 Gear hobbing - also milling but using a special cutter

called a hob (most diffuse)
 Gear shaping - Cutter has general shape of the gear

but with cutting teeth on one side
Form Milling of Gear Teeth
 The form milling cutter

has teeth with the
shape of the spaces
between teeth on the
gear
 Gear blank is indexed
between each pass to
establish correct size of
the gear tooth
Gear
Hobbing
 Hob has a slight helix and
its rotation is coordinated
with much slower rotation
of the gear blank
 Special milling machines
(called hobbing machines)
accomplish the relative
speed and feed motions
between cutter and gear
blank
Gear Shaping
 To start the process,

cutter is gradually
fed into gear blank
 Then, cutter and
blank are slowly
rotated after each
stroke to maintain
tooth spacing (like
conjugate gears)
 Performed on
special machines
called gear shapers

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MACHINING OPERATIONS

AND MACHINE TOOLS

1. Turning and Related Operations

 Rotational - (a) cylindrical or disk-like shape

 Rotational – mainly by turning using single

 Generating shapes: determined by the feed

 Forming shapes: determined by the geometry

 Generated and forming shapes

Generating shape: (a) straight turning, (b) taper turning, (c)

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

1. Turning and Related Operations

 (a) Facing, (b) taper turning, (c) contour turning

 (d) Form turning, (e) chamfering, (f) cutoff

 (g) Threading, (h) boring, (i) drilling

Spindle Tool post

 Tasks: i) holding the workpiece, ii) referring the

 Machinable chuck jaws

 Reducing tool exchange time

 Reducing workpiece exchange time

 Performing simultaneous operations

 Increasing automation and cutting speed

 Tailstock replaced by “turret” that holds up to six tools

 These machine tools permit long bar stock to be fed

 More than one spindle, so multiple parts machined

1. Turning and Related Operations

 Difference between boring and turning:

1. Turning and Related Operations

 (a) Through hole - drill exits opposite side of work

 (a) Reaming, (b) tapping, (c) counterboring

 (d) Countersinking, (e) center drilling, (f) spot facing

 Large drill press

1. Turning and Related Operations

 Machining operation in which:

 Axis of tool rotation is usually perpendicular to

 (a) Peripheral milling and (b) face milling

 d) Profile milling, e) pocket milling, f) surface contouring

 (a) Horizontal and (b) vertical milling machines

1. Turning and Related Operations

 Similar operations, both use a single point cutting

 A straight, flat surface is created in both operations

1. Turning and Related Operations

 A multiple tooth cutting tool is moved linearly

 (a) External and (b) internal broaching (cross-

1. Turning and Related Operations

 Single-point thread cutting

 threading die (manual and automatic)

 Single-point thread cutting

 Form milling - use of a form milling cutter

 Gear hobbing - also milling but using a special cutter

 Gear shaping - Cutter has general shape of the gear

 The form milling cutter

 To start the process,

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