1. MACHINING OPERATIONS AND MACHINE TOOLS
SME Video – Machining Processes
Basic Holemaking (vts_01)
Cutting Tool Materials (vts_20)
Turning
Drilling
Milling
Machine Tools
In-class Assignment
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

2. Classification of Machining
Sharp cutting tool
Shape metal parts
Geometries with high precision and accuracy
Casting lacks precision and accuracy
(a) rotational (b) nonrotational (prismatic parts)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

3. Generating Shape straight turning taper turning contour turning
profile milling
plain milling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

4. Forming to Create Shape
form turning
drilling
broaching
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

5. Forming and Generating
thread cutting on a lathe
slot milling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

6. Turning Operation Titanium nitride coated carbide cutting insert
(photo courtesy of Kennametal Inc.)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

7. Generating Shape in Machining
(a) Facing
(b) Taper turning
(c) Contour turning
(d) Form turning
(e) Chamfering
(f) Cutoff
(g) Threading
(h) Boring
(i) Drilling
(j) Knurling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

8. Engine Lathe
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9. Methods of Holding the Work in a Lathe
three‑jaw chuck
"dog”
collet
face plate
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

10. Multiple Spindle Bar Machine
(1) feed stock to stop
(2) turn main diameter
(3) form second diameter and spotface
(4) drill
(5) chamfer
(6) cutoff
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

11. Horizontal Boring Boring bar made of cemented carbide (WC-Co)
Indexable cemented carbide inserts
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

12. Through Holes vs. Blind Holes
Through‑holes - drill exits opposite side of work
Blind‑holes – does not exit work
through‑hole
blind hole
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

13. Operations Related to Drilling
(a) Reaming
(b) Tapping
(c) Counterboring
(d) Countersinking
(e) Center drilling
(f) Spot facing
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

14. Two Forms of Milling Slab milling Slotting Side milling
Peripheral milling
Face milling
Slab milling
Slotting
Side milling
Straddle milling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

15. Conventional face milling
(a) Up milling
(Conventional milling)
(b) Down milling
(Climb milling)
High speed face milling using indexable inserts
(photo courtesy of Kennametal Inc.)
Conventional face milling
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

16. Milling End milling Profile milling Pocket milling Surface contouring
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

17. Milling Machine Horizontal knee-and-column milling machine
Vertical knee‑and‑column milling machine
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

18. (photo courtesy of Cincinnati Milacron)
Machining Centers
Highly automated machine tool
CNC control (three, four or five axes)
Minimal human attention
Automatic tool‑changing
Pallet shuttles
Automatic workpart positioning
(photo courtesy of Cincinnati Milacron)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

19. Broaching Advantages: Good surface finish Close tolerances
Complicated geometry
Disadvantages:
Tooling is expensive
External broaching
Starting hole
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Internal broaching

20. Power Hacksaw Power hacksaw Band saw Circular saw
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

21. SME Video
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

22. In-class Assignment 1
An orthogonal cutting operation is performed using a rake angle of 15, chip thickness before the cut = in and width of cut = in. The chip thickness ratio is measured after the cut to be 0.55.
Determine
(a) the chip thickness after the cut
(b) shear angle
(c) friction angle (research formula)
(d) coefficient of friction (research formula)
(e) shear strain.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

23. Test 2 Review Discussion
100 multiple choice
2 problems with calculations similar to in-class examples
2 challenge problems with calculations similar to in-class assignments
Production scheduling problems will not be on the test
Machine-machine diagrams will not be on the test
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

24. Extra Credit – hand in before test 2
In an orthogonal cutting operation, the rake angle = ‑5, chip thickness before the cut = 0.2 mm and width of cut = 4.0 mm. The chip thickness ratio = 0.4.
Determine
(a) the chip thickness after the cut
(b) shear angle
(c) friction angle (research formula)
(d) coefficient of friction (research formula)
(e) shear strain.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

25. Production Scheduling Machine-Machine Diagrams
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

26. Time Permitting Content
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

27. Turning Turret lathes Tailstock replaced by “turret” Chucking machines
No tailstock
Applications: short, light‑weight parts
Bar machines
Collet permits long bar stock through headstock
Cutoff operation separates the new part
Highly automated (a.k.a. automatic bar machine)
Automatic screw machine
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

28. Vertical Boring Mill
A vertical boring mill – for large, heavy workparts
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

29. Drilling Creates a round hole in a workpart
Boring can enlarge an existing hole
Cutting tool called a drill or drill bit
Machine tool: drill press
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

30. Milling Slab (peripheral) milling Face milling (centered)
Face milling (offset)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

31. Indexable tools (face mills)
High Speed Machining
Conventional vs. high speed machining
Indexable tools (face mills)
Work material
Conventional speed
High speed
m/min
ft/min
Aluminum
600+
2000+
3600+
12,000+
Cast iron, soft
360
1200
4000
Cast iron, ductile
250
800
900
3000
Steel, alloy
210
700
Source: Kennametal Inc.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

32. HSM Higher production rates Shorter lead times
Rather than functions of spindle speed
Rapid traverse speeds and high feed rates
Automatic tool changes
High rpm bearings
Advanced CNC motion controls
Balanced cutting tools to minimize vibration
Coolant delivery systems (high pressures)
Chip control and removal systems
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

33. Milling Machine Universal machine Ram type (top of machine omitted)
Simplex bed type milling machine
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

34. Operation of Mill-Turn Center
(a) example part with turned, milled, and drilled surfaces
(b) sequence of operations on a mill‑turn center
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

35. Shaping and Planing (a) Shaping (b) Planing
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
V-groove
Square groove
T-slot
Dovetail slot
Gear teeth

36. Drilling Vise Fixture Drill jig Upright drill press Radial drill press
(Willis Machinery and Tools)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e