Manufacturing Technology I

ME 307
Material Removal Processes
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
THEORY OF METAL MACHINING
1. Overview of Machining Technology
2. Theory of Chip Formation in Metal Machining
3. Force Relationships and the Merchant
Equation
4. Power and Energy Relationships in Machining
5. Cutting Temperature
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 3nd Ed., by
Mikell P. Groover, JOHN WILEY & SONS, INC.,
2007. (Chapter 21, pages 481-486)

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Material Removal Processes
A family of shaping operations, the common
feature of which is removal of material from a
starting workpart so the remaining part has the
desired geometry
Machining material removal by a sharp
cutting tool, e.g., turning, milling, drilling
Abrasive processes material removal by
hard, abrasive particles, e.g., grinding
Nontraditional processes - various energy
forms other than sharp cutting tool to remove
material
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Fig 21.1 Classification of material removal processes
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Schematic illustration of the cutting process
After K. Holmberg, A. Matthews. Coating Tribology: Properties, Techniques and
Applications in Surface Engineering, Elsevier, Amsterdam, 1994. (fig.7. 9)
Machining is a manufacturing process in which a sharp cutting
tool is used to cut away material to leave the desired part
shape.
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
Figure 21.2 (a) A cross-sectional view of the machining process, (b)
tool with negative rake angle; compare with positive rake angle in (a).
Machining
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Why Machining is Important
Variety of work materials can be machined
Most frequently used to cut metals
Variety of part shapes and special geometric
features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good dimensional accuracy (tolerances of 0.025
mm are achievable)
Good surface finishes (Roughness values less
than 0.4 microns achievable in conventional machining)
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Disadvantages with Machining
Wasteful of material
Chips generated in machining are wasted
material, at least in the unit operation
Time consuming
A machining operation generally takes more
time to shape a given part than alternative
shaping processes, such as casting, powder
metallurgy, or forming

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Machining in Manufacturing Sequence
Generally performed after other manufacturing
processes, such as casting, forging, and bar
drawing
Other processes create the general shape
of the starting workpart
Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot create
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Machining Operations
Most important machining operations:
Turning
Drilling
Milling
Other machining operations:
Shaping and planing
Broaching
Sawing
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape rotating
workpiece to generate a cylindrical shape,
Tool feed is parallel to the axis of rotation of the
workpiece.
Figure 21.3 Three most common machining processes: (a) turning,
Turning
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
The Turning Operation
Figure 21.2 Schematic illustration of the turning operation showing various features.
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Basic principles of the turning operation
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Used to create a round hole, usually by means of
a rotating tool (drill bit) with two cutting edges
Tool feed is parallel to its axis of rotation.
Figure 21.3 (b) drilling,
Drilling
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Drilling Operation
After Ghosh, A. and Mallik, A.K. Manufacturing Science
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Rotating multiple-cutting-edge tool is moved
across work to cut a plane or straight surface
Two forms: peripheral milling and face milling
Tool feed is perpendicular to its axis of
rotation.
Figure 21.3 (c) peripheral milling, and (d) face milling.
Milling
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Machining with multipoint tools
After Ghosh, A. and Mallik, A.K. Manufacturing Science
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Cutting Tool Classification
1. Single-Point Tools
One dominant cutting edge
Point is usually rounded to form a nose
radius
Turning uses single point tools
2. Multiple Cutting Edge Tools
More than one cutting edge
Motion relative to work achieved by rotating
Drilling and milling use rotating multiple
cutting edge tools
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Figure 21.4 (a) A single-point tool showing rake face, flank, and tool
point; and (b) a helical milling cutter, representative of tools with
multiple cutting edges.
Cutting Tools
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Cutting Conditions in Machining
Three dimensions of a machining process:
Cutting speed v primary motion
Feed f secondary motion
Depth of cut d penetration of tool
below original work surface
For certain operations, material removal
rate can be computed as
R
MR
= v f d (mm
3
/s)
where v = cutting speed m/s; f = feed
mm (mm/rev for turning); d = depth of cut
mm
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Cutting Conditions for Turning
Figure 21.5 Speed, feed, and depth of cut in turning.
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Roughing vs. Finishing
In production, several roughing cuts are usually
taken on the part, followed by one or two
finishing cuts
Roughing - removes large amounts of material
from starting workpart
Creates shape close to desired geometry,
but leaves some material for finish cutting
High feeds and depths, low speeds
Finishing - completes part geometry
Final dimensions, tolerances, and finish
Low feeds and depths, high cutting speeds
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e



For Turning:
Roughing cuts f = 0.4---1.25 mm/rev;
d = 2.5---20 mm
Finishing cuts f = 0.125---0.4 mm/rev;
d = 0.75---2.0 mm
Cutting Fluid
is often applied to the machining operation to cool
and lubricate the cutting tool.
Determining whether to use a cutting fluid
choosing the proper cutting fluid,
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Characteristics of the typical operation of
machining
Operation Sectional
area of cut
off layer,
mm
2

Energy for
material
removing
10
-3
, J./cm
3

Cutting
speed,
m/s
Productivity,
sm
3
/s
MRR
Turning 1,0 0,50,7 1,57,5 510
-2
510
Broaching 0,5 2,53,7 0,010,1 410
-3
110
-1
Milling 0,3 5,07,5 26 210
-3
1,0
Reaming 0,1 1230 0,151,6 510
-3
510
-1
Grinding 0,00005 5570 2550 510
-3
210
-2
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Machine Tools
A power-driven machine that performs a
machining operation, including grinding
Functions in machining:
Holds workpart
Positions tool relative to work
Provides power at speed, feed, and depth
that have been set
The term is also applied to machines that
perform metal forming operations
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Conventional Machine Tools Used for the
Three Common Machining Operations
Operati
on
Machine tool Definitions of speed, feed, and depth of
cut
Turning Lathe Work rotates for speed motion.
Tool is fed parallel to work axis.
Depth of cut is tool penetration beneath
original work surface.
Drilling Drill press Work is held stationary.
Tool rotates and feeds in direction
parallel to tool axis. Drill bit diameter
determines hole diameter.
Depth of cut is depth of hole.
Milling Milling
machine
Tool rotates for speed motion.
Work is fed in direction perpendicular to
tool axis.
Depth of cut is tool penetration beneath
original surface.
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e