Machining Processes

Group #3
Erica Velarde, Sean Clifton
David Pincus, Ruben Sosa

Typical Parts Made with

These Processes

Machine Components
Engine Blocks and Heads
Parts with Complex Shapes
Parts with Close Tolerances
Externally and Internally Threaded Parts

Products and Parts Made By

These Processes

Alternative Processes

Precision Casting
Powder Metallurgy
Powder Injection
Molding
Abrasive Machining
Thread Rolling

The Turning Process

Using Engine Lathes

Operate on all Types of

Materials
Use of single-point tools
Skilled Labor
Low Production Rate

Tool Geometry
Rake Angle
Side Rake Angle
Cutting-Edge
Angle
Relief Angle
Nose Radius

Typical Lathe and Its Various

Components

Lathe Components

Bed: Usually made of cast iron. Provides a heavy

rigid frame on which all the main components are
mounted.
Ways: Inner and outer guide railsn that are
precision machined parallel to assure accuracy of
movement.
Headstock: mounted in a fixed position on the
inner ways, usually at the left end. Using a chuck, it
rotates the work.
Gearbox: inside the headstock, providing multiple
speeds with a geometric ratio by moving levers.

 Spindle: Hole through the headstock to which bar

stock can be fed.
Chuck: 3-jaw (self centering) or 4-jaw (independent)
to clamp part being machined.
Tailstock: Fits on the inner ways of the bed and can
slide towards any position the headstock to fit the
length of the work piece. An optional taper turning
attachment would be mounted to it.
Tailstock Quill: Has a Morse taper to hold a lathe
center, drill bit or other tool.
Carriage: Moves on the outer ways. Used for
mounting and moving most the cutting tools.
Cross Slide: Mounted on the traverse slide of the
carriage, and uses a handwheel to feed tools into
the workpiece.

 Tool Post: To mount tool holders in which the cutting

bits are clamped.
Compound Rest: Mounted to the cross slide, it
pivots around the tool post.
Apron: Attached to the front of the carriage, it has
the mechanism and controls for moving the carriage
and cross slide.
Feed Rod: Has a keyway, with two reversing pinion
gears, either of which can be meshed with the
mating bevel gear to forward or reverse the carriage
using a clutch.
Lead Screw: For cutting threads.
Split Nut: When closed around the lead screw, the
carriage is driven along by direct drive without using
a clutch.

 Quick Change Gearbox: Controls the movement of

the carriage using levers.
Steady Rest: Clamped to the lathe ways, it uses
adjustable fingers to contact the workpiece and align
it. Can be used in place of tailstock to support long
or unstable parts being machined.
Follow Rest: Bolted to the lathe carriage, it uses
adjustable fingers to bear against the workpiece
opposite the cutting tool to prevent deflection.

Lathe Accessories

Carriage and Cross Slide Stops

Devices for Turning Parts with Various Tapers
Milling, Sawing, Gear-Cutting, and Grinding
Attachments
Various Attachments for Boring, Drilling, and
Thread Cutting

Typical Lathe and Its Various

Components

More Tool Geometry

Lathe Operations

Form Tools
Boring
Drilling
Parting
Grooving
Thread Cutting
Knurling

Cutting Operations Performed

on a Lathe

Above Left: Example of Boring

Above Right: Example of Drilling

Below Left: Example of Thread Cutting

Grooving

Below Right: Example of

Types of Lathes

Bench Lathes
Special Purpose Lathes
Tracer Lathes
Automatic Lathes
Automatic Bar Machines
Turret Lathes
Computer-Controlled Lathes

Turret Lathe

Computer-Controlled Lathe

Things to Remember About

Machining Parts on Lathes

Takes considerable amount of time

High Production Costs
Wastes Material
Not as Economical as Forming or Shaping

Machining Processes
Boring, Drilling, Reaming, and Tapping

Boring and Boring

Machines

What is Boring

Performed to enlarge a hole made previously.

Used for circular internal profiles in hollow
workpieces

Boring Machines

Small pieces lathe

Large pieces boring
mill

Horizontal vs Vertical

Boring mills

Perform various
operations: TURNING,
FACING, GROOVING,
CHAMFERING

Horizontal Boring Mill

Vertical Boring Mill

Large pieces can be

machined on a vertical
mill

Jig Boring Machines

Vertical machines

High precision bearings

Used to make jigs and
fixtures
Being replaced by CNC
boring machines

Considerations

Through holes, rather than blind holes,

should be specified.
Smaller length-bore diameter ratios
Interrupted internal surfaces should be
avoided.

Drilling, Drills, and

Drilling Machines

What are Holes used For?

Typical for assembly with fasteners

i.e. screws, bolts, rivets

Weight reduction
Ventilation
Access to inside parts
Appearance

Drilling is a Common
Process!!!
THE COST OF HOLE MAKING IS AMONG THE
HIGHEST MACHINING COSTS IN
AUTOMOTIVE ENGINE PRODUCTION

Properties

Burring on the bottom surface upon

breakthrough requires further machining
Diameters of holes are usually oversize

Quality of drill
Thermal properties

Reaming and honing improve dimensional

accuracy

Standard-Point Twist Drill

Point angle (118-135deg)

Lip-relief angle (7-15deg)
Chisel-edge angle (125-135deg)
Helix angle (15-30deg)
Diameter range from 0.5-150mm

Other Types of Drills

Step Drill

Core Drill

Produces 2 or more different diameters

Makes an existing hole larger

Counterboring & Countersinking

Produce depressions on the surface to

accommodate the heads of screws/bolts

More Drill Types

Center drill

Spot drill

Starts a hole at the desired

location

Spade drill

Produces small hole on the

end of a workpiece

Removable bits, produces

large-diameter or deep holes
Higher stiffness (absence of
flutes)

Straight-flute drill
Gun drill

Gun Drill

Trepanning

Removes a disk to create a hole

Material-Removal Rate

MRR=(pi*D^2)f*N / 4
Pi*D^2 / 4= cross sectional area
F = the distance penetrated per revolution
N = rotational speed

General Troubleshooting
Problem

Probable causes

Drill breakage

Dull bit, chips clogging flutes, feed to

high, lip relief angle too small

Excessive drill wear

Cutting speed to high, ineffective fluid,

rake angle too high, drill burned when
sharpened

Tapered hole

Drill misaligned or bent, lips not equal

Oversize hole

Same as above, machine spindle loose,

chisel edge not central, side force on
workpiece

Poor hole surface finish

Dull bit, ineffective fluid, welding of

workpiece on drill margin, improperly
ground drill, improper alignment

Reaming and Reamers

Considerations

Drilling should be perpendicular to the surface

Interrupted holes should be avoided
Hole bottoms should match standard drill point
angles
Through holes preferred to blind holes
Preexisting holes or dimples help center the drill
Blind holes must be drilled deeper than subsequent
reaming or tapping operations

What is Reaming

An operation used to make an existing hole

dimensionally more accurate and/or to
improve surface finish
For further accuracy and surface finish, holes
may be burnished, ground or honed.

4 Steps to Accuracy
1.
2.
3.
4.

Centering
Drilling
Boring
Reaming

Tapping and Taps

Tapping

Produces threads
May be done by hand
or machine
Chipless tapping is a
process of internal
thread rolling

Milling and Milling Machines

Milling

The Process of cutting away

material by feeding a
workpiece past a rotating
multiple tooth cutter.

Types of Milling

Peripheral Milling

Peripheral Milling is when the cutter is longer than

the width of the cut.
a.k.a.- Slab Milling
The axis of the cutter is usually parallel to the work
piece surface.

Face Milling

the cutter is mounted on a spindle having an

axis of rotation perpendicular to the
workpiece surface.
Leaves feed marks on the machined surface.

End Milling

The cutter generally rotates on an axis

vertical to the workpiece.
It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end
face of the cutter and the periphery of the
cutter body.
Can produce a variety of surfaces at any
depth.

Conventional Milling

a.k.a- Up Milling
The Direction of cutter rotation opposes the
feed motion.

Climb Milling

a.k.a.- Down Milling

The direction of cutter rotation is the same as
the feed motion.

Other Types of Milling

Straddle Milling
Form Milling
Slotting and Slitting

Uses circular cutters

Tool holders

Arbor Cutters

Mounted on an arbor
Used in peripheral, face, straddle and form
milling.

Shank-Type Milling

Cutter and shank are

one peice

Design and Operating

Guidelines

Basic cutters should be used as much as

possible.

Avoid expensive special cutters.

Chamfers should be specified instead of

radii.
Chamfer-A furrow or groove, as in a column.

Avoid internal cavities and pockets with sharp

corners.
Due to the difficulty of doing them.

Troubleshooting

Tool Breakage

Tool material lacks toughness,

improper angles.
Excessive Tool Wear
improper tool material, improper
tool fluids.
Rough Surface Finish
Feed per tooth too high, tool
chipped or worn.
Chatter Marks
Insufficient stiffness of system,
external vibrations.
Breakout
Lead angle too low, feed and
depth of cut too high.

Milling Machines

First Milling Machine

Built in 1820 by Eli Whitney

Column-and-Knee type

Most common milling machines.

Basic Components

Work Table
Saddle
Knee
Overarm
Head

Bed Type

Work table is mounted is mounted directly on

the bed.
Not versatile
High Stiffness
Used for high production work

Other Milling Machines

Planer-Type

Several heads and cutters able to mill different surfaces

Rotary-Table
One or more heads for face milling.

Computer Numerical Control

Able to mill, drill, bore and tap with repetitive accuracy

Profile Milling Machines

5 axes of movement.

Planning and Shaping

Planning

Large workpieces 25m X 15m

Work piece is mounted on a table and travels back and
forth along a straight path.
Cutting speeds can get up to 120 m/min with 150 hp

Shaping

Tool does the moving

Small less than 1m X 2m

introduction
Broaching

and Broaching machines

Sawing
Filing
Gear

Manufacturing by Machining

Broaching and Broaching

machines

Broaching is a similar
technique to shaping
with a long multipletooth cutter and is used
to machine internal an
external surfaces.

Broaching is just as
effective as
Boring
Milling
Shaping
Reaming

Broaching machines
are very expensive but
these machines yield a
very high quantity of
production runs.

Uses a single pass

for finished shapes
or sized
Produces close
tolerances and good
surface finish
Uses a multipoint
cutting tool (broach)
Has the roughing
and finishing teeth
on the same tool

Sawing

Sawing is an old common operation dating back to

around 1000 B.C
Sawing is an efficient bulk removal process and can
produce near net shape materials
The process wastes little material
Most common use of saws
Hacksaws
Circular saws
Band saws
Friction sawing

Samples of various sawing

operations

Hacksaws
Hacksaws were developed in the 1960s.
Good for cutting off bars, rods, and structural
shapes

Power hacksaws

Fast
They work smoothly
and efficiently even
under heavy-duty
operation. With normal
care these machines
are indestructible.

Circular sawing

Circular sawing is a multipoint cutting process in

which a circular tool is advanced against a stationary
workpiece to sever parts or produce narrow slots.
Uses thin circular blades with teeth on periphery
Rotating blade is fed into a stationary workpiece
Produces a narrow cut and a good surface finish

Circular saws also

called cold saws when
cutting metal
They are used for high
production rate sawing
Cold sawing is used in
industry very commonly
particularly for cutting
large crossed sections.

Diamond Saw Blades For Marble

And Limestone

saw blade
for plastics

Types of cold
sawing
machines

Band saw

Uses a flexible steel band with a toothed edge

Workpieces are fed into the cutting edge on vertical
machines

Can produce straight, irregular, or curved cuts

Friction sawing

Workpieces are fed into

a continuously moving
band
Produces fine, accurate
work
Is a finishing operation
in which small amounts
of material are removed

Gear Manufacturing by
Machining

Several processes for making gears

Form cutting (form-milling)

Gear generating (Hobbing, Shaping)

Gear milling
Uses a rotating form
cutter
Gear blanks are
indexed after each cut
Is a low production
process
Gear teeth are
produced individually

Gear generating
This particular machine
removes over 17 lb of
8822 steel from a 100lb, 18-in.-diameter gear
in under 12 min

Gear Hobbing
Is a gear generating
process that uses a
helical hob cutter
Cuts several teeth on a
progressive basis
Is used for high
production runs

CuttingGearTeeth.mov

Gear shaping
Cutters rotate in timed
relationship with the
workpiece
Produces internal
gears, external gears,
and integral gear-pinion
arrangements

References

http://www.manufacturingcenter.com/tooling/archive
s/0604/0604cooling.asp
http://www.mfg.mtu.edu/marc/primers/milling/
http://www.americanmachinetools.com/How_to_use
_a_Milling_Machine_files/Fig8-33.gif
http://www.advantagefabricatedmetals.com/images/
slittingprocess.gif
http://www.eliwhitney.org/inventor.htm
http://www.cncmasters.com/images/bps-1649.jpg
http://www.lagun.com/products/gbm/gbm22e42e.html

http://www.manufacturingcenter.com/tooling/archive
s/0604/0604cooling.asp
http://www.mfg.mtu.edu/marc/primers/milling/
http://www.americanmachinetools.com/How_to_use
_a_Milling_Machine_files/Fig8-33.gif
http://www.advantagefabricatedmetals.com/images/
slittingprocess.gif
http://www.eliwhitney.org/inventor.htm
http://www.cncmasters.com/images/bps-1649.jpg
http://www.lagun.com/products/gbm/gbm22e42e.html

http://www.ohiobroach.com
http://www.broachingmachine.com/
http://class.et.byu.edu/mfg130/processes/me
chanicalreduction.htm
http://www.doringer.com