Machining Operations 2-1
Transcript of Machining Operations 2-1
Engineering Production 1 (EngM 324)
Machining Operations
Amr Shehata Fayed PhDAssociate Professor
Machining Operations ndash Page 2
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
What is Machining
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
Machine tools are kind of machines on which metal
cutting or metal forming processes are carried out
Machining Operations ndash Page 3
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material removal is essentially done on machine tools
which may be Lathe Milling Drilling Shaping Planing
Broaching and Grinding machines
Mechanism
Metal ahead of the cutting tool is compressed This
results in the deformation or elongation of the crystal
structure resulting in a shearing of the metal
Machining Operations ndash Page 4
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Why Machining
Benefits
Excellent dimensional tolerances
External and internal geometrical features
Surface finish
Removal of heat treat distortion
Economical for small quantities
Machining Operations ndash Page 5
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
However there are some
Limitations
Material waste
Time consuming
Energy capital and labor intensive
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
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- Slide Number 49
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- Slide Number 53
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- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 2
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
What is Machining
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
Machine tools are kind of machines on which metal
cutting or metal forming processes are carried out
Machining Operations ndash Page 3
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material removal is essentially done on machine tools
which may be Lathe Milling Drilling Shaping Planing
Broaching and Grinding machines
Mechanism
Metal ahead of the cutting tool is compressed This
results in the deformation or elongation of the crystal
structure resulting in a shearing of the metal
Machining Operations ndash Page 4
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Why Machining
Benefits
Excellent dimensional tolerances
External and internal geometrical features
Surface finish
Removal of heat treat distortion
Economical for small quantities
Machining Operations ndash Page 5
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
However there are some
Limitations
Material waste
Time consuming
Energy capital and labor intensive
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 3
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material removal is essentially done on machine tools
which may be Lathe Milling Drilling Shaping Planing
Broaching and Grinding machines
Mechanism
Metal ahead of the cutting tool is compressed This
results in the deformation or elongation of the crystal
structure resulting in a shearing of the metal
Machining Operations ndash Page 4
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Why Machining
Benefits
Excellent dimensional tolerances
External and internal geometrical features
Surface finish
Removal of heat treat distortion
Economical for small quantities
Machining Operations ndash Page 5
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
However there are some
Limitations
Material waste
Time consuming
Energy capital and labor intensive
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 4
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Why Machining
Benefits
Excellent dimensional tolerances
External and internal geometrical features
Surface finish
Removal of heat treat distortion
Economical for small quantities
Machining Operations ndash Page 5
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
However there are some
Limitations
Material waste
Time consuming
Energy capital and labor intensive
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 5
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
However there are some
Limitations
Material waste
Time consuming
Energy capital and labor intensive
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 6
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 7
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Diagrammatic Representation of Material Removal Operations
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 8
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples machining such as turning drilling and milling also grinding and nontraditional processes
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 9
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Purpose of Machining
Most of the engineering components such as gears bearings clutches tools screws and nuts etc need-
dimensional and form accuracy
good surface finish for serving their purposes
Machining to high accuracy and finish essentially enables a product to
fulfill its functional requirements
improve its performance
prolong its service
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 10
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Principle of Machining
The basic principle of machining is typically illustrated in Fig1
A metal rod of irregular shape size and surface is converted into a finished rod of desired dimension and surface by machining by proper relative motions of the tool-work pair
Fig 1 Principle of machining (turning)
Blank Product
ToolFeed vo
vc
t
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 11
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machining
Machining refers to cutting operations that are based on the removal of material from an originally rough-shaped workpiece for example via casting forging extrusion etc
In the literature such operations are called-
metal cutting
material removal and
chip removal techniques
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 12
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The essential basic requirements for machining work are schematically illustrated in Fig 2
Fig 2 Requirements for machining
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 13
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Requirements
The blank and the cutting tool are properly mounted (in
fixtures) and moved in a powerful device called machine
tool enabling gradual removal of layer of material from
the work surface resulting in its desired dimensions and
surface finish
Additionally some environment called cutting fluid is
generally used to ease machining by cooling and
lubrication
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 14
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Definition of Machine Tools
A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which
energy is expended to produce jobs of desired size
shape and surface finish by removing excess material
from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s)
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 15
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machine Tools basically produce geometrical surfaces like flat cylindrical or any contour on the preformed blanks by machining work with the help of cutting tools
Basic Functions of Machine Tools
firmly holding the blank and the tool
transmit motions to the tool and the blank
provide power to the tool-work pair for the machining action
control of the machining parameters ie speed feed and depth of cut
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
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- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
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- Slide Number 30
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- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 16
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Classification of Machine Tools according to the Surface Generated
Machine tools for cylindrical work
Lathe and turret lathe
Boring machines
Cylindrical grinder and
Surface grinder
Machine tools for flat surface work
Planning
Shaping
Slotting and
Broaching
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Machining Operations ndash Page 17
An Introduction to Machining
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Elements of Machine Tools
Structure which is formed by bed column and frame
Slides and tool structure
Spindles and spindles bearing
Kinematics of machine tool drives
Two motions are required to perform the machining operation See next figures
Cutting motion (its accuracy depends on the design of main spindle)
Feed motion (its accuracy depends on the design of the bed)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 18
Relative Motion between Tool and Workpiece
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 19
Machining Parameters
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 20
Cutting Parameter Relationships
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 21
Cutting Parameters Definitions
Cutting Speed
It is the distance traveled by the work surface in
unit time with reference to the cutting edge of the
tool
The cutting speed v is simply referred to as speed
and usually expressed in mmin
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 22
Feed
It is the distance advanced by the tool into or along the workpiece each time the tool point passes a certain position in its travel over the surface
In case of turning feed is the distance that the tool
advances in one revolution of the workpiece
Feed f is usually expressed in mmrev Sometimes
it is also expressed in mmmin and is called feed
rate
Cutting Parameters Definitions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 23
Cutting Parameters Definitions
Depth of cut
It is the distance through which the cutting tool is
plunged into the workpiece surface
Thus it is the distance measured perpendicularly
between the machined surface and the unmachined
(uncut) surface or the previously machined surface of
the workpiece
The depth of cut d is expressed in mm
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 24
Selection of Cutting Speed and Feed
It is based on the following parameters
Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 25
Selection of Cutting Speed and Feed
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 26
b) Cutting and feed motionsa) Schematic view
Lathe Machine (14)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 27
Lathe Machine (24)
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
spindle chuck tool-post
carriage
tail-stock
carriage wheel cross-slide wheel
tail-stock wheel
lead-screw
feed f
depth of cut d
feed f
depth of cut d
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 28
Lathe Machine (34)
1
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 29
Lathe Machine (34)
How It Works
External turnning
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 30
Some common machining operations done in center lathes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 31
Now Turning Operations
Applications
usually to form round or taper cylindrical profiles
Work-pieces
rotating usually cylindrical shape
Cutters
single-point cutter move in linear direction
Machines
Turning machine or lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 32
Milling Machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 33
Milling Cutting and Feed Motions
In order to perform a flat surface by milling operation a relative motion has to be between the milling tool and part In this respect the milling tool will have a rotation motion that is the main cutting motion and either the tool or part has to perform a translation motion that is the feeding motion
Milling tool
Machined surface
SwarfsPart
Feed Motion
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 34
a) Schematic view of horizontal milling machine
b) Cutting and feed motions
Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 35
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 36
Slab MillingCutter width extends
beyond the work piece on both sides
Slotting (Slot milling)Cutter width is less than the work piece width creating a slot If the cutter is very thin it can be used to cut a work part into two called saw milling
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 37
Straddle millingSimilar to side milling but cutting takes on both sides of the work part simultaneously
Side millingCutter machines the side of the work piece
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Horizontal Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 38
Form Milling
The cutter has the desired form of the part
Milling of a concave half circle Milling of a gear
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 39
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 40
Face Milling
The cutter with a relatively large diameter removes a layer from the upper side of the part
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 41
End millingCutters diameter is less than the work partrsquos width
Profile milling (also contouring or shaping)
Outside periphery of flat part is cut
Feed
CM
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 42
Pocket Milling
The cutter removes material creating a cavity (rectangular
circular etc)
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 43
Slot Milling T-Slot Milling
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Milling Operations on a Vertical Milling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Gazan University
Machining Operations ndash Page 44
Horizontal flat surface Vertical flat surface
Profile surface
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 45
Then Milling Operations
Applications
for Flat or formed profiles
Work-pieces
Move linearly
Cutters
Multiple cutting edges Rotating about its own axis
Machines
Milling machines (Horizontal Vertical and universal Milling Machines)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 46
Grinding Machine (Surface Grinding)
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 47
Grinding Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Slide Number 19
- Slide Number 20
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 48
Then Grinding Operations
Applications
For better surface finishing
better accuracy or close tolerances
For hardened materials
Very little metal removal
Cutters
Grinding wheels
Machines
Surface grinding machines ( for flat or formed profiles)
Cylindrical Grinding machines
Universal grinding machines
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
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- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 49
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
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- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 50
a) Schematic view
b) Cutting and feed motions
Drilling Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
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- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 51
Drilling
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
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- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 52
Shaping Machine
a) Schematic view
b) Cutting and feed motions
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
- Slide Number 8
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- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 53
Shaping Machine
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
- Slide Number 7
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- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 54
Schematic View of a Planning Machine
What are the cutting and feed motions of it
Cutting motion is the table (workpiece)
Feed motions is the tool
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 6
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- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 55
Comparisons of various Metal Machining ProcessesWork-pieces Cutters Applications Remarks
Turning Rotating Move linearlySingle point
Round or Cylindrical shapes
Turning Lathe
Milling Linear RotatingMulti-point
Flat of formed profiles Milling
Surface Grinding
Linear Rotating Grinding wheel
Better finishingBetter accuracyFor hardened surface
Small metal removal
Cylindrical Grinding
Rotating RotatingGrinding wheel
Better finishingBetter accuracyFor hardened surface
Drilling Station Rotating amp move linearly along the axis
Cylindrical holes Along the axis
Reaming station Rotating amp move linearly
Better finishing
Boring Station or rotating
Single pointRotating or linear
Better straightness Jig borerMilling or Lathe
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
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- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 56
Comparison of Machining Processes
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
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- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Comparisons of various Metal Machining Processes
- Slide Number 56
- Slide Number 57
-
Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University
Machining Operations ndash Page 57
Comparison of Machining Processes
- Engineering Production 1(EngM 324)Machining Operations
- Slide Number 2
- Slide Number 3
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- Comparisons of various Metal Machining Processes
- Slide Number 56
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