Prepared by R.

Batane

Machining processes
Single point cutting/machining Shaping Planing Turning

Multi point cutting/machining Drilling Milling

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Single point cutting/machining

Simple geometry containing one major cutting edge The cutting edge produces the chips that flow past the tool face Examples include; shaping, planing and turning

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Multi point cutting/machining

Geometry of the cutting tool is more complex More expensive than single edged cutting tools

Superior to single point cutting tools in terms of high MMR

Drilling and milling are examples of multi point cutting operations

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Machining
Chip formation : Formation of the chips during cutting depends on: Properties of material; Properties of the tool material; and Tool geometry Tool wear occurs on: Flank surface (flank wear) Top face (crater wear)

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. Metal Cutting Processes

Basic Metal cutting

A B
Adapted from the Hongkong Polytechnique University (2003) MMB 325 7

Types of chips
Discontinuous (segmented) chips: form from hard, brittle materials and two phase materials e.g. lead

Continuous chips: sharp, hot, long continuous chips; dangerous, e.g., steel and aluminum
Built-up edge: chips (some) adhere to the tool, and thus result in a rough surface on the product.

Discontinuous type is preferred due to: good surface finish, and safety Usually Pb and S and added to steel to enhance machinability and discontinuous chips.
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Single point cutting/machining

SHAPING
The primary motion is applied to the tool and the secondary motion is applied to the workpiece in increments Useful for small workpieces
Large components can also be shaped require large ram strokes

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Single point cutting/machining

PLANING The primary motion is applied to the workpiece and the secondary motion is given by the intermittent feed motion applied to the tool The workpiece is clamped to a work-table Difference between Planing and Shaping
The primary cutting motion in shaping is applied to

the tool where as in planing, it is applied to the workpiece

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Single point cutting/machining

METAL REMOVAL RATE (SHAPING AND PLANING) Given by the equation; MRRplaning/shaping = v f dc Where: f = the feed distance per stroke dc = the depth of cut v = the tool velocity
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Turining
Operation to produce cylindrical, Conical, plane (flat) surfaces and screw threads, using a single point tool.

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Multi point cutting/machining

DRILLING Drilling is used to create holes in a workpiece. Performed using drill bits Primary motion is applied by the revolution of the drill bit while the secondary motion is the axial movement of the drill bit along its axis of rotation

2/20/2012 Adapted from CustomPartnet, 2008

Multi point cutting/machining

METAL REMOVAL RATE (DRILLING ) Given by the equation; MRRdrill = N d f /4 Where: f = the drill bit feed per revolution d = the hole diameter N = the drill bit rotational speed
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Multi point cutting/machining

UNDEFORMED CHIP THICKNESS (DRILLING ) Given by the equation; uc=f sin kr /2 Where: f = the feed per revolution kr = the tool cutting edge angle

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DRILLING CALCULATIONS
Calculating the spindle speed (RPM) for a Drilling operation Spindle speed settings on the drill press are done in RPMs To calculate the proper RPM for the tool, use the formula; RPM= CS * 4 /d Where: CS = the cutting speed d = the cutter diameter
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DRILLING CALCULATIONS
Example: A 0.5mm drill is used to drill a piece of 1018 steel with a brinnel hardness of 200.Given that the recommended cutting speed is 70 revolutions per minute, calculate the RPM setting to perform this drilling operation? SOLUTION: RPM = CS * 4 /d = 70 * 4/0.5 = 280/0.5 = 560 RPM
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Milling
Operation using a multiple tooth cutter (tool) to generate flat surfaces as well as complex surfaces. Milling machine is either horizontal or vertical.

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