Basic Introduction of Machining processes. Disclaimer: I don't own any of the contents in the slides.

1. CLASSIFICATION OF MANUFACTURING PROCESS:
 CASTING, FOUNDRY OR MOULDING PROCESSES
 FORMING OR METAL WORKING PROCESSES
 MACHINING (METAL REMOVAL) PROCESS
 JOINING AND ASSEMBLY
 SURFACE TREATMENTS (FINISHING)
 HEAT TREATMENTS
MACHINING PROCESS

2. MACHINING PROCESS (MATERIAL REMOVAL):
Machining processes and metal removal processes are linked with the removal of
a specific portion to get the desired shape, size and finish. The additional
unwanted material is removed in the form of chips from the blank material by
cutting tool so as to obtain the final desire features.
The cutting tools are mounted in machines, which provide the movements to the
tool with respect to the job to accomplish desired process.
Material removal is most expensive method because more energy is consumed
and also lot of waste material is generated in these processes.
Machining is widely used because it delivers very good dimensional accuracy and
accurate surface finish.
MACHINING PROCESS

3. 7 Basic Machining
Process:
1) Shaping (Rarely used)
2) Drilling.
3) Turning.
4) Milling.
5) Sawing.
6) Broaching.
7) Abrasive Machining.
MACHINING PROCESS

4. 8 Machine Tools have been developed to accomplish these basic machining process:
1) Shapers/Planers to carry out shaping operations.
2) Drill Presses (Drilling machine) to carry out Drilling, Reaming, Tapping, Counterbore/Countersink.
3) Lathes to carry out Turning, Facing, Threading, Forming, Cut off parting etc.
4) Boring Machine for Boring operation.
5) Milling Machines to carry out Milling Keyways, Grooves and Slot
6) Saws for Cutting the blank length.
7) Broaches for Broaching
8) Grinders for Cylindrical, pedestal, surface grinding etc.
MACHINING PROCESS

5. SHAPER MACHINE
Reciprocating type of machine tool with single point cutting tool is used
to produce flat surfaces.
MACHINING PROCESS

6. SHAPER MACHINE
Three significant feature of shaper machine:
•Ram
•Tool head
•Table
Forward stroke – Cutting stroke, Return stroke – Idle stroke
Tool head fed at an angle – inclined surfaces
Shaper are used for machining Keyways, Slots, Grooves etc.
MACHINING PROCESS

7. SHAPER MACHINE
Tool Head
RAM Driving Mechanism:
Crank and slotted link mechanism
Whitworth quick return mechanism
Hydraulic drive Shaper
MACHINING PROCESS

8. DRILLING MACHINE
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole
of circular cross-section in solid materials.
MACHINING PROCESS

9. DRILLING MACHINE
Drilling Machine are used produce holes, reaming operation, Tapped holes,
Couterbore, Countersinking etc.
Reaming Tapping
Portable Drilling M/C
MACHINING PROCESS

10. MACHINING PROCESS

11. LATHE
Lathe is one of the most important machine tools in the metal working industry.
A lathe operates on the principle of a rotating work piece and a fixed cutting tool.
Lathe machine is also known
as “the mother/father of the
entire tool family”.
MACHINING PROCESS

12. LATHE
LATHE OPERATION: TURNING
Turning is a form of machining, a material removal process, which is used to create
Cylindrical/Spherical parts by cutting away unwanted material. The turning process requires
a turning machine or lathe, work piece, fixture, and cutting tool. There are variations
of turning performed on a lathe such as facing, contour turning, chamfering, cutoff
and threading.
MACHINING PROCESS

13. LATHE
LATHE OPERATION: FACING
Facing is the operation where you reduce the length of a workpiece and finish a surface by
Cutting to a depth along the length of the workpiece and moving the tool perpendicular to the
axis of the workpiece. It is not restricted to workpieces with cylindrical profiles alone.
MACHINING PROCESS

14. LATHE
LATHE OPERATION: THREAD CUTTING
Thread cutting on the lathe is a process that produces a helical ridge of uniform section on the
workpiece. This is performed by taking successive cuts with a threading toolbit the same shape as
the thread form required.
MACHINING PROCESS

15. LATHE
OTHER OPERATIONS DONE ON LATHE:
 Taper turning
 Shoulder turning
 Chamfering
 Grooving
 Knurling
 Under cutting
 Filing
 Spinning
 Forming
 Polishing
 Spring winding
 Boring
 Drilling
MACHINING PROCESS

16. LATHE
TYPES OF LATHE M/C’s:
 Speed Lathe
 Engine Lathe
 Bench Lathe
 Tool room Lathe
 Capstan & Turret Lathe
 Special purpose Lathe
 Automatic Lathe
 CNC Lathe
MACHINING PROCESS

17. BORING MACHINE
When internal surface of a hollow part is turned, a single point cutting tool is used for enlarging
a hole, the operation is called BORING.
The bar on which single point tool is mounted is called BORING BAR
MACHINING PROCESS

18. BORING MACHINE
Major Types of Boring Machines:
• Horizontal Boring Machine
• Vertical Boring Machine
MACHINING PROCESS

19. BORING MACHINE
HORIZONTAL BORING MACHINE:
The work is supported on a table which is stationary and tool revolves in a horizontal axis.
Can perform boring, reaming, turning, threading, facing, milling , grooving and many other
Operations with suitable tools.
MACHINING PROCESS

20. BORING MACHINE
VERTICAL BORING MACHINE:
The work rotates on a horizontal table about a vertical axis and the tool is stationary.
Machine may look like a vertical lathe.
Larger diameter and heavy work pieces, can be set up more quickly than in lathe.
Multiple tooling may be adapted with its turret type tool post, increasing the rate of production
MACHINING PROCESS

21. BORING MACHINE
Other Types of Boring Machines:
 JIG Boring
MACHINING PROCESS

22. MILLING MACHINE
It is a machine which is used to remove metals from the workpiece with the help of a revolving
cutter called milling cutter.
It is used to machined the flat, rough and irregular surfaces and this is done by feeding the
workpiece against a rotating milling cutter.
MACHINING PROCESS
Horizontal Milling Machine
Vertical Milling Machine

23. MILLING MACHINE
HORIZONTAL MILLING MACHINE:
The horizontal milling machine has a spindle that is parallel to the shop
floor and an over arm that extends over the work-piece.
The over arm supports the arbor, which holds the milling cutter. On the
horizontal mill, The arbor is the component that rotates the
milling cutter.
MACHINING PROCESS
ARBOR

24. MILLING MACHINE
HORIZONTAL MILLING MACHINE OPERATIONS:
Slab milling: A milling operation that uses a cylindrical mill on
an axis parallel to the worktable to create a flat surface.
Slotting: A milling operation that cuts a narrow ridge into
the surface of a work-piece.
Slitting: A rotary tool-steel cutting tool with peripheral teeth, us
ed in a milling machine to remove material from the
work-piece through the relative motion of work-piece and cutter.
Form milling: A milling operation that uses a mill with
a unique shape to create that shape into the work-piece.
Straddle milling: Face milling of two parallel vertical surfaces of
a work-piece simultaneously by using two side-milling cutters.
MACHINING PROCESS
SLAB MILLING SLOTTING
SLITTING FORM MILLING
STRADDLE MILLING

25. MILLING MACHINE
VERTICAL MILLING MACHINE:
The most common type of milling machine, a vertical milling machine
features a vertically oriented spindle that holds, as well as rotates,
the cutting tool against the stationary workpiece. The spindle is
capable of moving up and down, all while pressing against the
workpiece to remove material.
MACHINING PROCESS
ARBOR & COLLET

26. MILLING MACHINE
VERTICAL MILLING MACHINE OPERATIONS:
Conventional milling: The diameter of the cutter is greater
than the work part width, so that the cutter overhangs the
work on both sides.
Partial face milling: The cutter overhangs the work on only
one side.
End milling: The cutter diameter is less than the work width,
so a slot is cut into the part.
Surface contouring: A ball-nose cutter (rather than square
end cutter) is fed back and forth across the work along a
Curvilinear path at close intervals to create a
three-dimensional surface form.
Pocket milling: Another form of end milling,
this is used to mill shallow pockets into flat parts.
MACHINING PROCESS
CONVENTIONAL MILLING

27. MILLING MACHINE
OTHER TYPES OF MILLING MACHINES:
 Knee-Type Milling Machine
 Ram-Type Milling Machine
 Manufacturing or Bed -Type Milling Machine
 Planer-Type Milling Machine
 CNC Milling
MACHINING PROCESS

28. MILLING CUTTING TOOLS
MACHINING PROCESS
Ball End Mills
Shell End Mills

29. SAW
A hand tool for cutting wood or other hard materials, typically
with a long, thin serrated blade and operated using a
backwards and forwards movement.
Different Types of Saws:
MACHINING PROCESS
HAND SAW POWER SAW

30. SAW
MACHINING PROCESS
CHAINSAW
BAND SAW
CIRCULAR SAW
JIG SAW

31. BROACHING
Broaching is a machining process that uses a toothed
tool called a broach ,to remove material.
Broaching is a similar technique to shaping with a long
multiple-tooth cutter.
MACHINING PROCESS
VERTICAL BROACHING MACHINE
HORIZONTAL BROACHING MACHINE
BROACH

32. BROACHING
HORIZONTAL BROACHING MACHINE:
These machines are designed for pull broaching, surface
broaching, continuous broaching, and rotary broaching
MACHINING PROCESS
HORIZONTAL BROACHING MACHINE

33. BROACHING
VERTICAL BROACHING MACHINE:
These machines can be designed for push broaching,
pulldown broaching, pull-up broaching, or surface broaching.
MACHINING PROCESS

34. PRODUCTS OF BROACHING
MACHINING PROCESS

35. GRINDING/ABRASIVE MACHINING
It is the most common form of abrasive machining,
It is the process of removing material by abrasive action of a revolving wheel on
the surface of a work-piece in order to bring it to required shape and size.
• Cutting by abrasive tool whose cutting elements are grains of abrasive
material known as grit. (Aluminium oxide, Silicon Carbide, Boron Carbide etc.)
• Grits have sharp cutting points, high hot hardness, and chemical
stability and wear resistance.
• The grits are held together by a suitable bonding material to give shape
of an abrasive tool.
MACHINING PROCESS

36. GRINDING/ABRASIVE MACHINING
CLASSIFICATION:
Surface grinding machine
Cylindrical grinding machine (External Cylindrical grinder)
Internal grinding machine
Bench grinder.
MACHINING PROCESS
Surface Grinding Machine Cylindrical Grinding Machine
Bench Grinder
Internal Grinding Machine

37. GRINDING/ABRASIVE MACHINING
Surface Grinding Machine:
Surface grinding is normally used to grind plain flat surfaces.
It is performed using either the periphery of the grinding wheel or the flat face of
the wheel. Because the work is normally held in a horizontal orientation, peripheral
grinding is performed by rotating the wheel about a horizontal axis, and face
grinding is performed by rotating the wheel about a vertical axis.
MACHINING PROCESS

38. GRINDING/ABRASIVE MACHINING
Cylindrical grinding machine (External Cylindrical grinder):
This machine is used to produce external cylindrical surface.
The surfaces may be straight, tapered, steps or profiled.
The machine is similar to a centre lathe in many respects.
The workpiece is held between head stock and tailstock centers.
A disc type grinding wheel performs the grinding action with its
peripheral surface.
MACHINING PROCESS

39. GRINDING/ABRASIVE MACHINING
Internal Grinding Machine:
• The workpiece is usually mounted in a chuck. A
magnetic face plate can also be used.
• A small grinding wheel performs the necessary
grinding with its peripheral surface. Both transverse
and plunge grinding can be carried out
MACHINING PROCESS

40. GRINDING/ABRASIVE MACHINING
Bench Grinders:
A bench grinder is a benchtop type of grinding machine used to
drive abrasive wheels. A pedestal grinder is a similar or larger
version of grinder that is mounted on a pedestal, which may be
bolted to the floor or may sit on rubber feet. These types of
grinders are commonly used to hand grind various cutting
tools and perform other rough grinding.
MACHINING PROCESS

41. NON-CONVENTIONAL MACHINING
MACHINING PROCESS
Electrical discharge Machining (EDM)
Laser beam Machining (LBM)
Electron Beam Machining (EBM)
Electrochemical Machining (ECM)
Electrochemical Grinding (ECG)
Plasma Arc Machining (PAM)
Chemical Machining (CM)
Ultrasonic Machining (USM)
Abrasive jet machining
Water jet Machining

42. SURFACE FINISH
MACHINING PROCESS
INTRODUCTION:
Surface finish, also known as surface texture or surface topography, is the nature of a surface as
defined by the three characteristics of lay, surface roughness, and waviness.
It comprises the small, local deviations of a surface from the perfectly flat ideal (a true plane).
Surface texture is one of the important factors that control friction and transfer layer formation during
sliding.
LAY: Lay is the direction of the predominant surface pattern, ordinarily determined by the production
method used. The term is also used to denote the winding direction of fibres and strands of a rope.
SURFACE ROUGNESS Surface roughness, commonly shortened to roughness, is a measure of the total
spaced surface irregularities. In engineering, this is what is usually meant by "surface finish.”
A Lower number constitutes less of these irregularities on the surface.
WAVINESS: Waviness is the measure of surface irregularities with a spacing greater than that of surface
roughness. These irregularities usually occur due to warping, vibrations or deflection during machining.

43. SURFACE FINISH
MACHINING PROCESS
SYMBOLIC REPRSENTATION
SURFACE ROUGNESS SYMBOLS
Figure (a) above is an example of a drawing symbol as used on a drawing
and figure (b) shows the meaning of each of the numbers and also the
location of the lay symbol.
What Does Ra Mean?
As described in ASME B46.1, Ra is the arithmetic average of the absolute values of
the profile height deviations from the mean line, recorded within the evaluation
length. Simply put, Ra is the average of a set of individual measurements of a
surfaces peaks and valleys.

44. SURFACE ROUGNESS
MACHINING PROCESS