Metal Cutting

Processes
Dr. Sunil Jha

Content
z Machine tools,
z Cutting tools and tool wear,
z Basics of machining,
z Rigid automation and programmable
automation,
z Grinding and abrasive processes,
z Introduction to non-conventional machining
processes.

1
Introduction
z Rotation and Non-rotational Parts

Machined Parts – (a) Rotational, or (b) non-rotational (block and flat)

Manufacturing of Rotational Parts

TURNING PROCESS

2
Manufacturing of Rotational Parts
TURNING TOOL

Manufacturing of Rotational Parts

MACHINE TOOL (LATHE)

3
Manufacturing of Rotational Parts

MACHINE TOOL (LATHE)

Type of Lathe Machine Tools

z Engine lathe
z Tool room lathe
z Speed lathe
z Turret lathe
z Numerically controlled lathe

4
Turning Operations

(a) Facing
(b) Taper Turning
(c) Contour Turning
(d) Form Turning
(e) Chamfering
(f) Cutoff
(g) Threading
(h) Boring
(i) Drilling
(j) Knurling

Concept of Generatrix & Directrix

5
Work holding Methods in Lathe

Drilling Process

Through Hole Blind Hole

6
Drilling Operations
(a) Reaming
(b) Taping
(c) Counter-boring
(d) Countersinking
(e) Center drilling
(f) Spot facing

Drilling Press

7
Boring Operations

Boring Operations

8
Milling Operations
z For machining Non-Rotational Parts.
z Milling tool possesses a large number of
cutting edges.
z Shaft on which cutter is mounted, known as
Arbour.

Up and Down Milling

Up Milling Down Milling

z Cutting and Feed Motion
opposite direction.
z Chip is thin at beginning.
z Cutter tend to lift work upward
z Greater clamping force
z Safe and commonly used
z Cutting and Feed Motion
Same direction.
z Max chip thickness
encountered in beginning
z Tendency of job being
dragged into cutter.

9
Up and Down Milling - Finish

Up Milling Down Milling

z Poorer surface finish
z Chips can be carried into
newly machined surface
z Possibility of getting tooth mark
on finished surface.
z Good Surface finish
z Chips leave tangentially
along teeth
z Less tendency to show tooth
mark

Milling Operations

Peripheral or plain milling Face milling

10
Milling Operations

Slab Milling Slotting Side milling Saddle milling

Contouring by using End Mill Pocket Milling Surface Milling

Milling Machines

Horizontal Milling Vertical Milling

11
Shaping and Planing

Shaper and Planer

SHAPER

PLANER

12
Broaching
z Feed is obtained by placing the teeth
progressively deeper.
z Shape of broach determines shape of
machined part
z Application in producing internal forms

Shapes Broached

13
Broaching Machine

Sawing

(b)

14
Comparison of Machining Processes

Comparison of Machining Processes

15
Cutting Tool Materials
z Tool material must be strong and hard
enough to withstand high pressures.
z It should be able to retain the strength and
hardness at high operating temperatures.
z It should have sufficient wear resistance
z Tool material should be sufficiently tough to
absorb shock and prevent chipping of
cutting edges.
z It should be able to conduct heat at faster
rates.

Cutting Tool Materials

z It should have good Grindability, Weldability,
Chemical stability and Thermal properties.

z Basic requirements of cutting tool material

are conflicting and no tool material can
satisfy all requirements. This led to
development of wide variety of cutting tool
materials.

16
Cutting Tool Materials
z Carbon Tool Steels
z 0.8-1.3% C, 0.1-0.4% Si, 0.1-0.4% Mn
z Used to Machine soft materials
z Oldest cutting tool material
z Low hot hardness and soften above 250°C

z High Speed Steels

z An alloy steel (18% W, 4% Cr, 1% V, 5% Co)
z Can machine upto 35 m/min

Cutting Tool Materials

z Moly HSS
z 0.8%C, 4% Cr, 2% V, 6% W, 5% Mo
z Max speed 70 m/min

z Cast Non-Ferrous Alloys

z Stellites (40-50% Co,27-32% Cr, 14-29% W, 2-
4% C)
z Max speed 100 m/min

17
Cutting Tool Materials
z Cemented Carbide
z WC powder sintered with Cobalt
z Mainly used for machining of cast iron and non-
ferrous materials.
z If steels are machined fast crater formation take
place due to diffusion.
z For machining of steels; WC was replaced by 10-
40% Titanium Carbide or Tantalum Carbide
z Max speed 250-1500 m/min
z Hot Hardness upto 900°C

Cutting Tool Materials

z Tungsten Carbide
z Tungsten carbide bits are now a days clamped on
to the tool Shank. In earlier days these were
brazed.
z Carbides are very much sensitive to thermal
shocks; therefore cutting fluids are rarely used
during intermittent cutting operations with carbide
tools.

18
Cutting Tool Materials
z Coated Carbide Tools
z A thin layer of Tic, TiN, Alumina is coated.
z Composite or multilayer coating is also used as
they provide prolonged tool life through formation
of stronger bond between coating & carbide
substrate.
z Coating thickness 5-10 microns.
z Can be used to machine variety of materials.

Cutting Tool Materials

z Ceramic Tools
z Made from pure Alumina in the form of inserts tool
tips.
z They are made by very fine alumina powder by
powder metallurgy operations.
z They are harder than carbide but very brittle;
do not soften at elevated temperatures.
z Suitable for very high cutting speeds, low
loads, and continuous machining conditions.

19
Cutting Tool Materials
z Cubic Boron Nitride (CBN)
z By bonding 0.5 mm thick polycrystalline CBN onto
a carbide substrate through sintering under
pressure.
z Retain hardness up to 1000 °C.
z Less chemically reactive
z In hardness second to diamond
z Used in form of tool inserts.
z Cutting speed more than carbides.

Cutting Tool Materials

z Diamond
z Hardest material
z Used to cut non-ferrous materials
z Use is limited because it gets converted into
graphite at high temperature (700 °C). Graphite
diffuses into iron and make it unsuitable for
machining steels.
z Diamond tools are available as inserts.

20
Cutting Fluid
z Act as a coolant and cool the cutting zone
z Act as lubricant to reduce friction at the Tool-
chip and Tool-work interface.
z Advantages
z Long tool life
z Less thermal damage
z Accurate dimension
z Better surface finish

Cutting Fluid - requirements

z Large specific heat & thermal conductivity
z Low viscosity and low molecular size so that
effective penetration at tool-chip interface
z Suitable additives for lubrication
z Non-corrosive to prevent corrosion
z Less expensive and readily available

21
Cutting Fluid - application
z Flood Cooling
z Mist Cooling
z High Pressure Cooling

Unconventional Machining
Processes
z Mechanical Energy Processes
z Electrochemical machining processes
z Thermal energy processes

22
Mechanical Energy Processes

Ultrasonic machining
Water jet cutting

Mechanical Energy Processes

Abrasive jet machining

23
Electrochemical Machining
Processes

Electrochemical Machining Electrochemical Grinding

Electrochemical Machining
Processes

Electrochemical Deburring

24
Thermal Energy Processes

Electric Discharge Machining (EDM)

Thermal Energy Processes

Wire EDM

25
Thermal Energy Processes

Electron Beam Machining

Laser Beam Machining

26