MANUFACTURING PROCESSES

Machining

Dra. Martha Guerrero & Dra. Adriana Salas

Machining
Machining is the broad term used to describe removal
of material from a workpiece, it covers several
processes, which we usually divide into the following
categories:
Cutting, generally involving single-point or multipoint
cutting tools, each with a clearly defined geometry.
Abrasive processes, such as grinding.
Nontraditional machining processes, utilizing electrical,
chemical, and optimal sources of energy.
Machining categories
MILLING

CHIP FORMATION
TURNING
DRILLING

GRINDING
Drilling
 Drilling
Drilling is easily the most
common machining process.
One estimate is that 75% of all
metal-cutting material
removed comes from drilling
operations.
Drilling involves the creation of
holes that are right circular
cylinders.
This is accomplished most typically
by using a twist drill, something
most of you will have seen before. Cross section of a hole being
cut by a common twist drill
Drilling
The chips must exit through the flutes to the outside of
the tool. As can be seen in the last figure, the cutting front
is embedded within the workpiece, making cooling
difficult.
The cutting area can be flooded, coolant spray mist can be
applied, or coolant can be delivered through the drill bit
shaft.
Drilling Characteristics
Thecharacteristics of drilling that set it apart from
other powered metal cutting operations are:
The chips must exit out of the hole created by the
cutting.
Chip exit can cause problems when chips are large and/or
continuous.
The drill can wander upon entrance and for deep holes.
For deep holes in large workpieces, coolant may need to
be delivered through the drill shaft to the cutting front.
Of the powered metal cutting processes, drilling on a drill
press is the most likely to be performed by someone who
is not a machinist.
Drill Press Work Area
A view of the metal-cutting area of a drill press is shown in
next page.
The workpiece is held in place by a C-clamp since cutting
forces can be quite large.
It is dangerous to hold a workpiece by hand during drilling
since cutting forces can unpredictably get quite large and wrench the
part away.
Wood is often used underneath the part so that the drill bit can
overshoot without damaging the table.
The table also has holes for drill overshoot as well as weight
reduction.
A three-jaw chuck is used since three points determine a circle in
two dimensions.
Drill Press Work Area
Four-jaw chucks are rarely
seen since offset of the bit
is not necessary. The next
section contains
illustrations of drill bit
chucks. To get an idea of
the differing configurations
of three and four-jaw
chucks, please see the
equivalent lathechucks.
General Classifications
Classification Based on Construction
1. Solid Drills: Those made of one piece of material such as
high speed steel
2. Tipped Solid Drills: Those having a body of one material
with cutting lips made of another material brazed or
otherwise bonded in place
3. Composite Drills: Those having cutting portions
mechanically held in place
General Classifications
Classification Based on Methods of Holding or Driving
1. Straight Shank Drills: Those having cylindrical shanks
which may be the same or different diameter than the body
of the drill; the shanks may be made with or without driving
flats, tang, grooves or threads
2. Taper Shank Drills: Those having conical shanks suitable
for direct fitting into tapered holes in machine spindles,
driving sleeves or sockets; tapered shanks generally have a
driving tang
3. Taper Shank Square Drills: Those having tapered shanks
with four flat sides for fitting a brace
4. Shell Core Drills: Core drills mountable on arbors
specifically designed for the purpose; commonly used with
shell reamer arbors
General Classifications
5. Straight Shank Drills: Those made
with threaded shanks generally used
in close center multiple spindle
applications or portable angle drilling
tools
6. Beaded Shank Bits: Drills with flat
shanks having raised beads parallel to
the axis
General Classifications
Classification Based on Number of Flutes
1. Two-Flute Drills: The conventional type of twist drill used
for originating holes
2. Single-Flute Drills: Those having only one flute commonly
used for originating holes
3. Three-Flute Drills (Core Drills): Drills commonly used
for enlarging and finishing, drilled, cast, or punched holes; they
will not produce original holes
4. Four-Flute Drills (Core Drills): Used interchangeably
with three-flute drills; they are of similar construction except
for the number of flutes
General Classifications
Classification Based on Hand of Cut
1. Right-Hand Cut: When viewed from the cutting point
the counterclockwise rotation of a drill in order to cut;
the great majority of drills are made "right hand.
2. Left-Hand Cut: When viewed from the cutting point
the clockwise rotation of a drill in order to cut.
Drills and Drilling operations

VIDEO
Turning
Turning
Turning is another of the basic machining processes.
Turning produces solids of revolution which can be
tightly tolerance because of the specialized nature of the
operation.
Turning is performed on a machine called a lathe in
which the tool is stationary and the part is rotated.
Lathes are designed only for turning operations, so that
precise control of the cutting results in tight tolerances.
The workpiece is mounted on the chuck, which
rotates relative to the stationary tool.
Engine Lathe
Turning

Turning refers to cutting.

Turning

The term "facing" is used to describe removal of material

from the flat end of a cylindrical part, as shown above.
Facing is often used to improve the finish of surfaces that have
been parted.
 Turning machines
The turning machines are, of course, every kinds of lathes.
Lathes used in manufacturing can be classified as engine,
turret, automatics, and numerical control, etc.
Turning machines
They are heavy duty machine tools and have power
drive for all tool movements.
They commonly range in size from 12 to 24 inches
swing and from 24 to 48 inches center distance, but
swings up to 50 inches and center distances up to 12 feet
are not uncommon.
Many engine lathes are equipped with chip pans and
built-in coolant circulating system.
Turret Lathes
In a turret lathe, a longitudinally feedable, hexagon turret replaces
the tailstock.
The turret, on which six tools can be mounted, can be rotated about
a vertical axis to bring each tool into operating position, and the
entire unit can be moved longitudinally, either annually or by power,
to provide feed for the tools.
When the turret assembly is backed away from the spindle by means
of a capstan wheel, the turret indexes automatically at the end of its
movement thus bringing each of the six tools into operating
position.
The square turret on the cross slide can be rotated manually about
a vertical axis to bring each of the four tools into operating position.
Turret Lathes
On most machines, the turret can be moved transversely, either
manually or by power, by means of the cross slide, and longitudinally
through power or manual operation of the carriage.
In most cased, a fixed tool holder also is added to the back end of
the cross slide; this often carries a parting tool.
Through these basic features of a turret lathe, a number of tools can
be set on the machine and then quickly be brought successively into
working position so that a complete part can be machined without
the necessity for further adjusting, changing tools, or making
measurements.
Turret Lathes
Single-Spindle Automatic Screw
Machines
There are two common types of single-spindle screw machines,.
One, an American development and commonly called the turret type
(Brown & Sharp), is shown in the following figure.
The other is of Swiss origin and is referred to as the swiss type.
The Brown & Sharp screw machine is essentially a small automatic
turret lathe, designed for bar stock, with the main turret mounted
on the cross slide.
All motions of the turret, cross slide, spindle, chuck, and stock-feed
mechanism are controlled by cams.
The turret cam is essentially a program that defines the movement
of the turret during a cycle.
These machines usually are equipped with an automatic rod feeding
magazine that feeds a new length of bar stock into the collect as
soon as one rod is completely used.
Single-Spindle Automatic Screw
Machines
 CNC Machines
Nowadays, more and more Computer Numerical Controlled
(CNC) machines are being used in every kinds of
manufacturing processes.
In a CNC machine, functions like program storage, tool offset
and tool compensation, program-editing capability, various
degree of computation, and the ability to send and receive data
from a variety of sources, including remote locations can be
easily realized through on board computer.
The computer can store multiple-part programs, recalling
them as needed for different parts. A CNC turret lathe in
Michigan Technological University is shown in the following
picture.
CNC Machines
Videos about Turning

Video I:
Cutting tools geometries and materials
Materials
Video II:
Geometries

CNC Machine Video

Milling
 Milling
Milling is as fundamental as
drilling among powered metal
cutting processes.
Milling is versatile for a basic
machining process, but because
the milling set up has so many
degrees of freedom, milling is
usually less accurate than
turning or grinding unless
especially rigid fixturing is
implemented.
For manual machining, milling is
essential to fabricate any object
that is not axially symmetric.
Milling machines
There is a wide range of different milling machines,
ranging from manual light-duty Bridgeports to huge
CNC machines for milling parts hundreds of feet long.
Below is illustrated the process at the cutting area.
Column-and-Knee Manual Mill
The figure illustrates a
typical column-and-knee
type manual mill.
Such manual mills are
common in job shops that
specialize in parts that are
low volume and quickly
fabricated.
Such job shops are often
termed "model shops"
because of the prototyping
nature of the work.
 Column-and-Knee Manual Mill
The parts of the manual
mill are separated below.
The knee moves up and
down the column on
guideways in the column.
The table can move in x
and y on the knee, and the
milling head can move up
and down.
Milling equipment
The milling machine is one of the most versatile machine
tools in existence.
In addition to straight milling of flat and irregularly shaped
surfaces, it can perform gear and thread cutting, drilling,
boring and slotting operations which are normally
handled on machine tools designed specifically for these
specific operations.
Milling Cutters
A milling cutter is a cutting tool that is used on a
milling machine.
Milling cutters are available in many standard and
special types, forms, diameters, and widths.
The teeth maybe straight (parallel to the axis of
rotation) or at a helix angle.
The helix angle helps a slow engagement of the
tool distributing the forces.
The cutter may be right-hand (to turn clockwise)
or left-hand (to turn counterclockwise).The
figure shows a typical end milling cutter.
Features of Milling Cutters
Someof the terms used to identify the major features
of a milling cutter are given in the figure.
Types of Milling Cutters

Video