Me570 Metal Cutting Lecture Notes

ME 535 METAL CUTTING
Chapter 1: MACHINE TOOLS AND MACHINING OPERATIONS

Prof. Dr. Ömer Anlağan / 2006
MACHINE TOOLS
AND
MACHINING OPERATIONS
1
MACHINING IS THE REMOVAL

OF THE UNWANTED METAL FROM A
WORKPIECE IN THE FORM OF CHIPS
SO AS TO OBTAIN A FINISHED
PRODUCT OF DESIRED SIZE, SHAPE,
AND FINISH.
2
ME 535History
METALofCUTTING
machining
Before 18th century main material used was

wood.
Development of metal machining starts with
invention of steam engine (1776).
The production of cylinders of the engine was
a problem.
Wilkinson invented horizontal boring machine
to cope with this problem.
3
ME 535 METALofCUTTING
Fundamentals machining
The principle used in all machine tools is

generating the surface required by providing
suitable relative motions between cutting tool
and the work piece.
Metal removed is called chip.
Two types of relative motion must be
provided by a metal cutting machine tool:
Primary and feed motion.
4
ME
Fundamentals
535 METALofCUTTING
machining
The primary motion is the main motion

provided by a machine tool or manually to
cause relative motion between the tool and
the work piece so that the face of the tool
approaches to the work piece material.
Usually the primary motion absorbs most of
the total power required to perform a
machining operation.
5
ME
Fundamentals
535 METALofCUTTING
machining
The feed motion is a motion that may be

provided to the tool or work piece by a
machine tool which, when added to the
primary motion, leads to a repeated or
continuous chip removal.
This motion may proceed by steps or
continuously; in either case it usually absorbs
a small proportion of the total power required.
6
Relative motion
between
tool and workpiece
Primary motion Secondary motion
Cutting motion Feed motion
Cutting speed Feed speed
7
Classification of the chip removing

methods according to relative motion
8
9
ISO MACHINE TOOL AXIS

DEFINITION
10
ISO MACHINE TOOL AXIS
11
CLICK ON TO FILM TO RUN & PAUSE
MACHINE TOOL
AXIS MACHINE TOOL WITH SPINDLE WITH NO
SPINDLE
Perpendicular to
the work holding
Axis of spindle, (+Z) as tool goes away from
Z surface, (+Z) as
work-piece
tool goes away
from work-piece
MACHINE
TOOL WITH MACHINE TOOL WITH
ROTATING ROTATING TOOL
WORKPIECE
HORIZONTAL VERTICAL
AXIS AXIS
Horizontal and Horizontal and
X
Radial and parallel to work parallel to work
Parallel to and
parallel to cross holding surface, holding surface,
positive in the
slide, (+X) when (+X) to the right (+X) to the right
principle direction
tool goes away when viewed when viewed
of cutting (primary
from the axis of from spindle from spindle
motion)
spindle towards work- towards
piece column.
Y Apply right hand rules
12
MERIGHT
535 METAL
HANDCUTTING
RULE
13
MERIGHT
535 METAL
HANDCUTTING
RULE
Vertical Machine Horizontal Machine
14
CUTTING TOOL
SİNGLE POİNT MULTI POİNT ABRASIVE

CUTTİNG TOOL CUTTİNG TOOL TOOL
15
Typical single-point cutting tool
16
Machine Tools using single-point

cutting tool
Lathes
Shapers
Planers
Boring M/C’s
17
Machine Tools using multiple-

point cutting tool
Drilling M/C’s
Milling M/C’s
Broaching M/C’s
Hobbing M/C’s
18
Machine Tools using abressive

wheel
Grinding M/C’s
Honing M/C’s
19
Machine Tool Provides

work holding
tool holding
relative motion between tool and workpiece
20
LATHES
21
A typical lathe is composed of;
The Bed
Headstock Assembly
Tailstock Assembly
Carriage Assembly
Quick-change Gear Box
Lead Screw and Feed Rod.

22
A typical turning machine
23
An Engine Lathe
24
Kinds of Lathes
Engine lathe
Tool-room lathe
Turret lathe
CNC lathes
Automatic screw machines
Swiss-type automatic screw machines
25
For cutting tools used in

Lathes , geometry depends
mainly on the properties of
the tool material and the work
material.
26
The standard terminology is shown

in the following figure
27
Operations that can be performed

on a lathe
Turning
Boring
Facing
Parting (Cutoff)
Treading
28
Typical lathe operations
29
Turning is the machining operation

that produces cylindrical parts
30
Turning
The process of
machining external
cylindrical surfaces.
• Usually performed
on a lathe
31
It can be defined as the machining

of an external surface
with the work-piece rotating,
with a single-point cutting tool, and
with the cutting tool feeding parallel to
the axis of the work-piece and at a
distance that will remove the outer
surface of the work.
32
Turning process and adjustable

parameters
33
Turning process
34
Turning process
35
Another Turning Process
36
There are 3 primary factors in any

basic turning operation these are;
speed
feed
depth of cut
37
Average cutting speed is ;
π . n w .(d w + dm)
V max =
2
nw:rotational frequency of workpiece

dw:diameter of workpiece
dm:diameter of machined surface
38
Metal removing rate is ;
Z w = π .f.a p .n w .(d m + a p )
f:Feed
ap:back engagement
nw:rotational frequency of
workpiece
39
Boring involves the enlarging of an

existing hole, which may have
been made by a drill or may be the
result of a core in a casting
40
Typical Boring operation
41
Metal removing rate is;
Z w = π .f.a p .n w .(d m + a p )
f:Feed
ap:back engagement
nw:rotational frequency of
workpiece
42
Facing is the process to produce

a flat surface in turning
43
Typical Facing operation is shown below
44
The maximum cutting speed is ;
v max = π .n w .d m
45
Metal removing rate Zw,max is ;
Z w, max = π .f.a p .n w .d m
f:Feed
ap:back engagement
46
Parting is the operation by which

one section of a work-piece is
severed from the remainder by
means of a cutoff tool.
47
Typical Parting operation
48
Lathe provided the first method for

cutting threads by machines.They
often are used for cutting threads
on special work-pieces.
49
Typical Threading operation
50
Threading operation
51
Vertical Boring Machine

essentially is the same as a
vertical turret lathe; but it usually
has main tool heads instead of a
turret.
52
A typical Vertical Boring Machine
53
Horizontal Boring
Machine
They are very versatile and
thus particularly useful in
machining large parts.
54
The essential features are as follows:
A rotating spindle that can be fed

horizontally.
A table that can be moved and fed in two
directions in a horizontal plane.
A headstock that can be moved vertically
55
A typical Horizontal Boring Machine
56
SHAPERS
57
Shaping is used to produce a

flat surface.
58
ME 535
Shaping
METAL
& Planing
CUTTING
Are among the oldest single-point machining

processes.
Have largely been replaced by milling and
broaching.
In shaping, the work piece is fed at right
angles to the cutting motion between
successive strokes of the tool.
59
ME 535
Shaping
METAL
& Planing
CUTTING
A shaper and a planer from 18th century 60

Shapers are classified according to

their general design features
Horizontal Vertical Special

Pull-cut Regular
Push-cut Keyseater
61
A typical horizontal shaper
62
A typical vertical shaper
63
PLANERS
64
Planers are used to produce

flat surfaces on workpieces that
are too large to be accommodated
on shapers.
65
Planers are classified according to

their general design features
Double-housing type planers

Edge planers
Open side planers
Pit planers
66
A typical planer
67
Machines Using Multipoint-

Cutting Tools
68
Drilling Machine
(Drill Press)
is used to produce holes
69
ME 535 METAL
Drilling
CUTTING
Process used to produce

holes.
About 25% of all
machining processes is
drilling
70
Drilling Machine consist of
Powerhead
Column
Spindle
Table
Base
71
A Drilling Machine
72
Other Drilling Machines
73
Several operations can be

performed on a drilling machine
Center Drilling
Reaming
Spot Facing
74
Center Drilling
Produces a shallow, conical hole

with clearence at the bottom.
75
Center Drilling operation
76
Center Drilling operations
77
Reaming
is intented for finishing a

previously drilled hole.
78
Reaming operation
79
Spot Facing
is designed to provide a flat
surface around the end of a
hole and perpendicular to its
axis.
80
Spot Facing Operation
81
f
ac = ⋅ sinκr
2
ac :undeformed chip thickness
f:feed
Кr :Major cutting edge angle
82
Machining time is;

lw
tm =
f.nt
lw:lenght of specimen
f:feed
nt:rotational frequency of the tool
83
Metal Removal Rate is;

π .f.d .nt 2
m
Zw =
4
f:feed
dm:diameter of the machined surface
84
If an existing hole of diameter

dw is enlarged
π .f.(d −d ).nt
2
m
2
w
Zw =
4
f:feed
85
MILLING
86
Milling
A process by which a surface is generated

by progressive chip removal.
Performed on a wide variety of milling
machines.
The cutting tool is used is known as milling
cutter.
87
Milling
End Milling Face Milling

88
Milling is designed to provide

a flat surface around the end of
a hole and perpendicular to its
axis.
89
Major components of a Milling

machine
90
There are two types of Milling Mach.

Horizontal Milling Machines
Vertical Milling Machines
91
Milling operation
92
Milling operation with coolant
93
Horizontal Milling
Machines
In Horizontal Milling Machine the
milling cutter is mounted on a
horizantal arbor driven by the
main spindle.
94
A typical Horizontal Milling

Machine
95
Slab Milling Operation
is used to generate a horizantal

surface on the workpiece.
96
Slab Milling operation
97
In Slab Milling operation feed is ;
V
f = ntf
f:feed
Vf:Feed speed of the workpiece
nt:rotational frequency of the cutter
98
Max. Undeformed chip thickness

2Vf a
ac, max = ⋅ e
N.nt d t
N:number of teeth on the cutter
ae:Working Engagement
dt:Diameter of the tool 99
Time for machining is;

lw + a e (d t - a e )
tm =
Vf
lw:Lenght of the specimen
dt:Diameter of the tool
Vf :Feed speed of the workpiece
100
Metal Removal rate is;
Z w = a e .a p .V f
ap:Width of cut
101
Vertical Milling Machines
In Vertical Milling Machine the

milling cutter is mounted on a
vertical arbor driven by the
main spindle.
102
A Vertical Milling Machine
103
Face Milling Operation
is used to generate surface that is

at right angle to the cutter axis.
104
Face Milling Operation
105
Face Milling Operations
106
In Face Milling feed is ;

V
f = ntf
f:feed
107
Max. Undeformed chip

thickness is;
a
c, max
f V
= N.n
t
N:Number of teeth on the cutter
108
Machining time if the path of the

tool axis passes over the workpiece ;
tm = (lw + dt).Vf
109
Milling time analysis

Slab milling:
Approach distance, A :
A= d (D-d)
Time to mill workpiece, Tm:
Tm = (L + A)/fr
Face milling:
Allow for over-travel O where A = O:
Full face A = O = D/2
Partial face A=O= w (D – w)
Machining time:
Tm = (L + 2A)/fr
110
Machining time if the path of the tool

axis does not passes over the workpiece ;
tm =
(
lw + 2 ae(dt - ae) )
Vf
111
Some Vertical Milling

operations shown below
112
Horizantal Surface Operation

with Vertical Milling Machine
113
Slot Operation with Vertical

Milling Machine
114
Dovetail Operation with Vertical

Milling Machine
115
T-Slot Operation with Vertical

Milling Machine
116
BROACHING
117
Broaching is the machining of

metal by means of a tool which is
composed of a series of single point
cutting edges each slightly larger
than the previous one,made on bar.
118
ME 535 METAL
Broaching
CUTTING
Finishes an entire surface in a single pass.

Is used in production to finish holes, splines
and flat surfaces.
Is one of the most productive of the basic
machining processes.
119
Broaching on a vertical broach
120
The average metal-removal rate (Zw)

can be estimated by dividing the
total volume of metal removed by the
machining time.
121
In Broaching operation
machining time is;
lt
tm =
v
lt:Lenght of the Broach
V:Cutting Speed
122
Undeformed chip thickness is;
ac=af=f
af:Feed engagement
f:Feed
123
ABRASIVE
MACHINING
PROCESSES
124
Abrasive Machining is the basic

process in which chips are formed by
very small cutting edges that are
integral parts of abrassive particles.
125
The abrasive machining process

has two unique characteristics.
Cutting edge is very small, very fine

cuts are possible.
Extremely hard abrasive particles can
be produced therefore very hard

materials can be machined
126
There are two types of operations

that can be performed in all grinding
machines;
Transverse Grinding
Plunge Grinding
127
ME 535 METAL
AbrasiveCUTTING
machining:
Grinding
A material removing process that involves the

interaction of abrasive grits with the work piece at
high speeds and shallow penetration depths.
Abrasive machining is the oldest machining
operation.
Cutting edges are very small and can cut
simultaneously.
Very fine and smooth surfaces can be obtained
128
ME 535 METAL
AbrasiveCUTTING
machining:
Honing
A stock removal process

that uses fine abrasive
stones to remove very
small amounts of metal.
Cutting speed is much
lower than that of grinding.
Used to size and finish
bored holes.
129
In transverse grinding the abrassive

wheel moves into the work, or the
work into the abrassive wheel.
130
In plunge grinding the basic

movement is of the wheel being fed
radially into the work while the latter
revolves on centers.
131
There are 4 types of grinding

machines
Horizontal-Spindle Surface-grinder
Machine
Vertical-Spindle Surface-grinder
Machine
Cylindrical-grinding Machine
Internal-grinding Machine
132
Horizontal-Spindle Surface-
grinder Machine
has a horizontal spindle that provides

primary motion to the wheel.The feed
motion is the reciprocation of the
worktable on which the work is
mounted. 133
A horizontal-spindle surface-
grinder machine
134
A typical transverse grinding

process with horizontal-spindle
surface-grinder machine
135
In transverse grinding metal

removal rate is;
Z = f.ap.vtrav.
f:Feed
ap:Back Engagement
Vtrav.:Traverse Speed
136
The machining time is;

bw
tm =
2.f.nr
bw:Witdh of the workpiece
F:Feed
nr:Frequency of reciprocation
137
A typical plunge grinding process

with horizontal-spindle surface-
grinder machine
138
In plunge grinding metal

removal rate is;
Z = f.ap.vtrav.
f:Feed
ap:Back Engagement
139

at
tm = + ts
2.f.nr
at:tool depth of workpiece
f:Feed
ts:Sparking-out time
140
Vertical-Spindle Surface-
grinder Machine
Employs a cup-shaped abressive
wheel and performs an operation
similar to face milling operation.
141
Grinding with a vertical-spindle

surface-grinder machine
142
In vertical-spindle surface-grinding
operation metal removal rate is;
Z = f.ap.vtrav.
f:Feed
ap:Back Engagement
143

at
tm = + ts
2.f.nw
f:Feed
nw:Frequency of reciprocation worktable
ts:Sparking-out time 144
Grinding with a cylindrical-

grinding machine
145
In traverse grinding on a cylindrical

grinder max.metal removal rate is ;
Zwmax = π .f.dw.vtrav.
f:feed per stroke of the machine table
dw:diameter of the work surface
Vtrav.:traverse speed
146

at
m t = + ts
2.f.n r
f:Feed
In plunge grinding on a cylindrical

grinder max. metal removal rate is ;
Zwmax ≅ π .ap.dw.vf
ap:back engagement
dw:diameter of the work surface
Vf.:feed speed
148

at
tm = + ts
vf
vf:Feed speed
149
Internal-grinding Machine
is commonly used for producing

internal cylindrical surfaces.
150
Grinding with a internal-grinding

machine is shown below
151
In traverse grinding on an internal

Zwmax = π .f.dm.vtrav.
f:feed per stroke of the machine table
Vtrav.:traverse speed
152

at
tm = + ts
2.f.nr
f:Feed
In plunge grinding on a internal

Zwmax = π .ap.dm.vf
ap:back engagement
Vf.:feed speed
154

a
t
m t = +t s
v
f
vf:Feed speed
155
For a given work material

machined under given conditions,
the energy required to remove a
unit volume of material (ρs) can be
measured.
156
This factor mainly depends on the

work material.
157
The power required to perform any

machining operation is ;
Pm = Ps Zw
Ps:Specific cutting energy
Zw:Metal removal rate
158
The electrical power consumed

by the machine tool is;
Pm
Pe =
η m
Pm: Power required to perform machining

operation
ηm: Overall efficiency of the machine tool
159
160
161
162

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ME 535 METAL CUTTING

Chapter 1: MACHINE TOOLS AND MACHINING OPERATIONS

MACHINING IS THE REMOVAL

Before 18th century main material used was

The principle used in all machine tools is

The primary motion is the main motion

The feed motion is a motion that may be

Primary motion Secondary motion

Cutting motion Feed motion

Cutting speed Feed speed

Classification of the chip removing

ISO MACHINE TOOL AXIS

ISO MACHINE TOOL AXIS

Vertical Machine Horizontal Machine

SİNGLE POİNT MULTI POİNT ABRASIVE

Typical single-point cutting tool

Machine Tools using single-point

Machine Tools using multiple-

Machine Tools using abressive

Machine Tool Provides

relative motion between tool and workpiece

A typical lathe is composed of;

Quick-change Gear Box

Lead Screw and Feed Rod.

A typical turning machine

Automatic screw machines

Swiss-type automatic screw machines

For cutting tools used in

The standard terminology is shown

Operations that can be performed

Typical lathe operations

Turning is the machining operation

It can be defined as the machining

Turning process and adjustable

Another Turning Process

There are 3 primary factors in any

Average cutting speed is ;

nw:rotational frequency of workpiece

Metal removing rate is ;

Boring involves the enlarging of an

Typical Boring operation

Metal removing rate is;

Facing is the process to produce

Typical Facing operation is shown below

The maximum cutting speed is ;

Metal removing rate Zw,max is ;

Parting is the operation by which

Typical Parting operation

Lathe provided the first method for

Typical Threading operation

Vertical Boring Machine

A typical Vertical Boring Machine

The essential features are as follows:

 A rotating spindle that can be fed

A typical Horizontal Boring Machine

Shaping is used to produce a

Are among the oldest single-point machining

A shaper and a planer from 18th century 60

Shapers are classified according to

 Horizontal  Vertical  Special

A typical horizontal shaper

A typical vertical shaper

relative motion between tool and workpiece

Quick-change Gear Box

Lead Screw and Feed Rod.

Automatic screw machines

Swiss-type automatic screw machines

A rotating spindle that can be fed

Horizontal Vertical Special

Double-housing type planers

Cutting edge is very small, very fine