Machining Processes 1 (MDP 114) First Year, Mechanical Engineering Dept., Faculty of Engineering, Fayoum University Dr. Ahmed Salah Abou Taleb 1.

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Machining Processes 1 (MDP 114) First Year, Mechanical Engineering Dept., Faculty of Engineering, Fayoum University Dr. Ahmed Salah Abou Taleb 1

Aims of the course This course is designed to provide students with a thorough understanding of the fundamentals of cutting tools for machining and materials removal. Turning, boring and related machining processes. Drilling and related hole making processes. Milling, broaching, sawing, shaping and planing, and abrasive machine processes. 2

Course Outlines  Introduction to Machining Processes.  Cutting Tool Materials and Its Characteristics.  Practical Machining Operations: Turning, Shaping, Drilling, Milling, Grinding.  Basic Elements of Machine Tools and Specifications.  Machining Time.  Mechanics of Metal Cutting ; Geometry ; Chip Formation; Wear ; Life; Temperature; Merchant Circle.  Economics in Cutting Process. 3 Part One:

Course Outlines 4  Introduction and Definitions of Metrology  Gauges.  Errors in Measurement.  Linear Measuring Instruments.  Angle Measuring Instruments.  Tests of Straightness and Flatness.  Surface Roughness.  Comparators. Part Two:

Teaching and Learning Methods  Power Point Lectures.  Assignments.  Quizzes.

Weighting of Assessment Final Exam70 Mid Term Exam20 Assignment20 Oral15 Total Marks125

Introduction 7

8

9

Manufacturing Processes CastingForming Fabrication Metal Removal Sand casting Shell mould Die casting Centrifugal Plaster mould Precision Permanent Rolling Drop forging Press forging Upset forging Extrusion Wire drawing Sheet metal Gas welding Electric arc W Ele. Resistance Thermal W Cold welding Brazing soldering Turning Drilling Milling Shaping Grinding Sawing broaching 10

Material Removal Processes A family of shaping operations, the common feature of which is removal of material from a starting workpart so the remaining part has the desired shape. Categories: – Machining – material removal by a sharp cutting tool, e.g., turning, milling, drilling – Abrasive processes – material removal by hard, abrasive particles, e.g., grinding – Nontraditional processes - various energy forms other than sharp cutting tool to remove material

Material Removal Processes The family tree 12

Machining types Turning Drilling Milling Shaping Planning Broaching Grinding Machining types Turning Drilling Milling Shaping Planning Broaching Grinding 13