Machining Operations 2-1

57
Engineering Production 1 (EngM 324) Machining Operations Amr Shehata Fayed, Ph.D. Associate Professor

Transcript of Machining Operations 2-1

Page 1: 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

Presenter
Presentation Notes
What is Machining 13Machining is a process designed to change the size shape and surface of a material through13removal of materials that could be achieved by straining the material to fracture1313Cutting process Removal of the material from the surface of the workpiece (by producing chips)1313Chip Removed material that is separated from the parent material by fracture

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

Presenter
Presentation Notes
Broaching is the machining of metal by means of a tool which is composed of a series of single point cutting edges each slightly larger than the previous one made on bar1313Broaching13It is the process of removing metal with a tool which has ldquoteethrdquo arranged in a row Each tooth is successively higher than the previous tooth and removes more material13Thus the first few sets of teeth remove most of the material while the last few provide a finishing cut with very small amount of material removal13The geometric shape of the last set of teeth is identical to the required geometry of the designed part13In broaching one stroke or cycle of the machine produces a finished part Broaching is used to produce both internal and external features Production rates are high and tolerances of +- 001 mm are possible

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 4
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  • Slide Number 6
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  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 2: Machining Operations 2-1

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

Presenter
Presentation Notes
What is Machining 13Machining is a process designed to change the size shape and surface of a material through13removal of materials that could be achieved by straining the material to fracture1313Cutting process Removal of the material from the surface of the workpiece (by producing chips)1313Chip Removed material that is separated from the parent material by fracture

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

Presenter
Presentation Notes
Broaching is the machining of metal by means of a tool which is composed of a series of single point cutting edges each slightly larger than the previous one made on bar1313Broaching13It is the process of removing metal with a tool which has ldquoteethrdquo arranged in a row Each tooth is successively higher than the previous tooth and removes more material13Thus the first few sets of teeth remove most of the material while the last few provide a finishing cut with very small amount of material removal13The geometric shape of the last set of teeth is identical to the required geometry of the designed part13In broaching one stroke or cycle of the machine produces a finished part Broaching is used to produce both internal and external features Production rates are high and tolerances of +- 001 mm are possible

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 3: Machining Operations 2-1

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

Presenter
Presentation Notes
Broaching is the machining of metal by means of a tool which is composed of a series of single point cutting edges each slightly larger than the previous one made on bar1313Broaching13It is the process of removing metal with a tool which has ldquoteethrdquo arranged in a row Each tooth is successively higher than the previous tooth and removes more material13Thus the first few sets of teeth remove most of the material while the last few provide a finishing cut with very small amount of material removal13The geometric shape of the last set of teeth is identical to the required geometry of the designed part13In broaching one stroke or cycle of the machine produces a finished part Broaching is used to produce both internal and external features Production rates are high and tolerances of +- 001 mm are possible

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 4: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 5: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 6: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 7: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 8: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 9: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 10: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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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
Page 11: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 11
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  • Slide Number 19
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  • Slide Number 26
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  • Slide Number 33
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  • Slide Number 35
  • Slide Number 36
  • Slide Number 37
  • Slide Number 38
  • Slide Number 39
  • Slide Number 40
  • Slide Number 41
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  • Slide Number 43
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  • 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
Page 12: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 13: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 14: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 24
  • Slide Number 25
  • Slide Number 26
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  • 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
Page 15: Machining Operations 2-1

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

Presenter
Presentation Notes
Machine Tool Provides131048708work holding131048708tool holding131048708relative motion between tool and workpiece

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 16: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 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
Page 17: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 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
Page 18: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 49
  • Slide Number 50
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  • Slide Number 52
  • Slide Number 53
  • Slide Number 54
  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 19: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 20: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 21: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 22: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 23: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 8
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  • Slide Number 16
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  • Slide Number 19
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  • 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
Page 24: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 25: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 26: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 27: Machining Operations 2-1

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

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 28: Machining Operations 2-1

Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University

Machining Operations ndash Page 28

Lathe Machine (34)

1

Presenter
Presentation Notes
Quill المكوك

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 29: Machining Operations 2-1

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 30: Machining Operations 2-1

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 31: Machining Operations 2-1

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 32: Machining Operations 2-1

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 33: Machining Operations 2-1

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

Presenter
Presentation Notes
At all types of milling machines the cutting tool13performs a rotational motion that is the cutting13motion The rotation axis of the tool could be13horizontal or vertical depending on machine tool13version1313bull The feeding motion is achieved either by part13or tool or both usually on three perpendicular13directions

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 34: Machining Operations 2-1

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

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 35: Machining Operations 2-1

Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University

Machining Operations ndash Page 35

Presenter
Presentation Notes
Arbor محور العجلة13Saddle سرج - يمتطي صهوة جواد مسرج13Peripheral خارجى ndash محيطى - متعلق بسطح الجسم ndash سطحى

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 36: Machining Operations 2-1

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 37: Machining Operations 2-1

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

Presenter
Presentation Notes
Straddle فرشخة - يستقر عبر شيء مباعدا ما بين رجلية مجازا -

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 38: Machining Operations 2-1

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 39: Machining Operations 2-1

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 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
Page 40: Machining Operations 2-1

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

Presenter
Presentation Notes
spindle عمود دوران - محور دوران - مغزلي الشكل - يستطيل مستدقا - يصبح نحيلا - يصبح طويلا - مغزل

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 26
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  • Slide Number 33
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  • Slide Number 36
  • Slide Number 37
  • Slide Number 38
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  • Slide Number 40
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  • 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
Page 41: Machining Operations 2-1

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

Presenter
Presentation Notes
shank ساق ndash رجل - قطعة

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 18
  • Slide Number 19
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  • 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
Page 42: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • 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
Page 43: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
Page 44: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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 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
Page 45: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • 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
Page 46: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • 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
Page 47: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 40
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  • 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
Page 48: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 41
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  • 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
Page 49: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 40
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  • 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
Page 50: Machining Operations 2-1

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

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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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  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 51: Machining Operations 2-1

Dr Amr Shehata FayedMech Eng Dept College of Engineering Jazan University

Machining Operations ndash Page 51

Drilling

Presenter
Presentation Notes
Drilling13It is one of the most common machining process A large amount of all metal-cutting material removed13comes from drilling operations1313By drilling are creating holes that are right circular cylinders This operation is accomplished most common13by using twisted drills (that is the tool) 1313In order to perform the drilling operation the tool has to have o rotation motion that is the cutting motion and13the tool or work part will achieve the feeding motion which is a translation one on the same direction with13rotation axis

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
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  • Slide Number 53
  • Slide Number 54
  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 52: Machining Operations 2-1

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
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  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 53: Machining Operations 2-1

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
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  • Slide Number 51
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  • Slide Number 53
  • Slide Number 54
  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 54: Machining Operations 2-1

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
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  • Comparisons of various Metal Machining Processes
  • Slide Number 56
  • Slide Number 57
Page 55: Machining Operations 2-1

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
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  • Comparisons of various Metal Machining Processes
  • Slide Number 56
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Page 56: Machining Operations 2-1

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
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  • Comparisons of various Metal Machining Processes
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Page 57: Machining Operations 2-1

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
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