MACHINING OF METALS

COURSE OUTCOMES(CO):
To understand the main classifications of metal machining To learn how to identify the problems occurred during machining process in metallurgical perspective. Able to handle machining precisely and familiarize with the basic machineries such as lathe, milling, grinder etc.
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EBT 207 MACHINING OF METALS Basic principle of tool shops practice and safety precautions. Introduction to machining. Classification of machining operation. Fundamentals and technology of operating the lathes, milling, drilling and grinding machines.

INTRODUCTION TO MACHINING

 Machining is the most manufacturing processes.

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In the machining of metals the ultimate goal is to produce the highest quality part within an established cost. Machining can be defined as the process of removing material from a work piece in the form of chips. The term metal cutting is used when the material is metallic.

 Most machining has very low set-up cost compared to forming, molding, and casting processes. However, machining is much more expensive for high volumes. Machining is necessary where tight tolerances on dimensions and finishes are required. Machining is not just one process; it is a group of processes.
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 The common feature is the use of a cutting tool to form a chip that is removed from the workpart, called swarf. To perform the operation, relative motion is required between the tool and work. This relative motion is achieved in most machining operation by means of a primary motion, called cutting speed and a secondary motion called feed. The shape of the tool and its penetration into the work surface, combined with these motions, produce the desired shape of the resulting work surface.
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 Common machining process involve turning, boring, broaching, drilling, sawing, milling, grinding, tapping, threading, reaming and honing. Machining is a part of the manufacture of almost all metal products. The machinist is involved with making a selection of such variables as tool bit material, geometry of cutting surface and edge, depth of cut, cutting speed, plus the environment surrounding the cutting operation. A room, building, or company where machining is done is called a machine shop.
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 A simple explanation of machinability is a measure of the ease with which a specified finish may be produced on a metal.
Machinability is the ratio of time and expense that is required for a certain quality finish.

The two major factors related to machinability are cutting tool life and rate of metal removal from the workpiece.
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 Working temperature during machining can be source of one of the more serious problems.
On a workpiece that is turned against a single-edged cutting tool bit without coolant, an average of 75% of the heat may be carried away by the chips. Machinist can reduce this temperature at the tool bit by;
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1. Increasing the shear plane angle of the cutting tool. 2. Reducing the cutting speed. 3. Softening the workpiece by heating treating. 4. Selecting an appropriate cutting fluid.

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The Machining section is divided into the following categories: 1. Drilling

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 Drilling, is used to create a round hole.

It is accomplished by a rotating tool that is typically has two cutting edges.

The tool is fed in a direction parallel to its axis of rotation into the workpart to form the round hole. Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but not uncommonly on lathes or mills.

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2. Turning/Lathe

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 Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. In turning, a cutting tool with a single cutting edge is used to remove material from a rotating workpiece to generate a cylindrical shape. The speed motion in turning is provided by the rotating workpart, and the feed motion is achieved by the cutting tool moving slowly in a direction parallel to the axis of rotation of the workpiece.

Lathes are the principal machine tool used in turning.

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3. Milling

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 Milling machines are the principal machine tool used in milling. In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a plane or straight surface. Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece.

The direction of the feed motion is perpendicular to the tool's axis of rotation.
The speed motion is provided by the rotating milling cutter. The two basic forms of milling are 1.Peripheral milling 2.Face milling
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4. Grinding

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 Grinding is a type of machining using an abrasive wheel as the cutting tool.

Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finishes and very accurate dimensions.

It is usually better suited to the machining of very hard materials than is "regular" machining (that is, cutting larger chips with cutting tools such as tool bits or milling cutters), and until recent decades it was the only practical way to machine such materials as hardened steels.

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5. Chip Formation

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 Other conventional machining operations include shaping, planing, broaching and sawing. Miscellaneous operations are operations that strictly speaking may not be machining operations in that they may not be chip producing operations but these operations are performed at a typical machine tool. Burnishing is an example of a miscellaneous operation. Burnishing produces no chips but can be performed at a lathe, mill, or drill press.
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 Other operations falling into miscellaneous categories include shaping, planing, boring, broaching and sawing.

An unfinished workpiece requiring machining will need to have some material cut away to create a finished product.
Machining requires attention to many details for a workpiece to meet the specifications set out in the engineering drawings or blueprints.
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 Beside the obvious problems related to correct dimensions, there is the problem of achieving the correct finish or surface smoothness on the workpiece.

The inferior finish found on the machined surface of a workpiece may be caused by incorrect clamping, dull tool, or inappropriate presentation of a tool.
Frequently, this poor surface finish, known as chatter, is evident by an undulating or irregular finish, and the appearance of waves on the machined surfaces of the workpiece.
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