IPE 4101

Machine Tools and Machining

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 IPE 4101
Machine Tools and Machining

History
of
Machining and Machine Tools

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❑ History of Machine Tool and Machining

Perforated Pointed tool

parts
Artist impression Bow drill (Courtesy:
of ancient [Link])

civilization 4
❑ Machine Tool and Machining (History )
• Cutting evolved as a
process of removing
unwanted material

• Basic elements :
✓ work piece
✓ cutting Tool
✓ machine tool
Egyptian strap lathe- 3rd C. BC
• ‘Lathe’ is one of the oldest (Courtesy: [Link])
machine tool

• Earliest ‘strap lathe’ from

3rd century B.C.
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❑ History of Machine Tool and Machining

• Romans used
continuous motion

• Pulley system
➢ utilising an (Courtesy: [Link])

independent "great
wheel”

• Pole lathe in 13th

century AD.

Pole lathe – 1395

(Courtesy: Mendelsches Bruderbuch)

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❑ History of Machine Tool and Machining

• Beginning 19th century:

✓ cutting wood and metal

• Industrial Revolution:
✓ implementation of steam
Mid-19th C. lathe
power (Courtesy: [Link])

• Rapid development of
metal cutting lathe

• Cutting of metallic objects

Chess pieces
(Courtesy: G & C Miriam Co)

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❑ Machine Tool and Machining (History )

(a) Pointed tool (b) Bow drill (c) Egyptian strap lathe
(Stone age) (4500 BC) (300 BC)

(e) Old tree pole lathe (f) Foot power lathe (e) Electrically driven lathe
(1889 AD) 8 (1907 AD)
(1300 AD)
Machining

High-speed machining (HSM)

High-velocity machining (HVM)
High-performance machining (HPM)
High-efficiency machining (HEM)
Highly profitable cutting (HPC)
Dry machining (DM)
Minimum-quantity lubrication (MQL)
Hard machining (HM)

Figure: Interactions between three advanced methods of machining.

 Machining

Source: G. Byrne, D. Dornfeld, B.

Denkena, Advancing cutting
technology, CIRP Ann. 52/2 (2003)
483507.

Figure: Representation of the factors influencing machining performance for

turning
Machining:
Tool geometry, mechanism of chip formation.
Mechanics of machining.

Cutting temperature; causes, effects, estimation, measurement

and control.

Cutting fluid applications. Failure modes, wear and life of cutting

tools. Cutting tool materials.

Role of geometrical and process parameters and cutting fluid on

machinability. Mechanics of grinding.

Economy of machining and grinding. Special techniques and

advanced technology of machining and grinding.

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 Background
• Metal cutting processes are industrial processes in which metal parts are shaped
by removal of unwanted material.
• Traditional chip-forming processes are turning, boring, drilling, and milling. In
these operations metal is removed as a plastically deformed chip of appreciable
dimensions, and a fairly unified physical analysis can be carried out using basic
orthogonal and oblique cutting models (Fig. 1.1).
Background
• Orthogonal Cutting (2-D Cutting): Cutting edge is
(1) straight,
(2) parallel to the original plane surface on the work piece and
(3) perpendicular to the direction of cutting. For example: Operations:
Lathe cut-off operation, Straight milling, etc.
• Oblique Cutting (3-D Cutting): Cutting edge of the tool is inclined to
the line normal to the cutting direction. In actual machining, Turning,
Milling etc. / cutting operations are oblique cutting(3-D)
Background
EVOLUTION OF MANUFACTURING

The NGM Project: A Key Element in

the Government Manufacturing
Infrastructure Strategy by
B.M. Kramer, US National Science
Foundation, [Link].

Figure: Forces shaping the 21st-century manufacturing environment

Machining

Figure: Possible influences and

importance of machining processes

Source: W. Grzesik, Developments in metal

removal processes, Proc. 4th Intln. Scientifi
Conference
‘Development of Metal Cutting’, Koˇsice,
Slovakia, 2002, pp. 103110.
Background

• The study of metal cutting processes necessarily postdates the

development of modern machine tools. Moreover, advances in the field
have generally resulted form changes in practice, particularly the
introduction of new tool materials.
Metal cutting practice has evolved to accommodate three basic types of
production.
• The first is job shop production, or the production of small or medium lots
of a variety of parts made of many materials.
• The second is the production of small volumes of a few complex parts, as in
aircraft manufacture.
• The third is the mass production of large volumes of identical parts, as in
automotive powertrain and component manufacture.
Metal Cutting Operations and Machine Tools
Four major components of a machining system:
1. Workpiece,
2. Machine tool,
3. Cutting tool, and
4. Fixture.
Basic Machining Operations and Conventional Machine Tools:
• Manufacturing is the backbone of an
industrialized nation

• Metallic manufacturing is the heart of industrial

activities

• ‘Manufacturing’ derived from Latin ‘manus factus’

manus = hand
factus = made

• In modern sense, manufacturing is the process

of converting raw materials to final products

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• Manufacturing encompasses three stages:

✓ Design of product

✓ Selection of raw material

✓ Sequence of processes

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Methods to shape a component

1. By putting materials together (+)

2. By moving material from one region to another (0)

3. By removing unnecessary material (-)

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Methods to generate a required shape

1. By putting materials together (+)

E.g. Welding, Rapid Prototyping

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Methods to generate a required shape

2. By moving material from one region to another (0)

E.g. Rolling, Forging, Extrusion, and Wire drawing
Forging

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Methods to generate a required shape

3. By removing unnecessary material (-)

E.g. Turning, Milling

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◼ Production (of any object) is a value addition process:
➢ raw material of low utility and value (due to its irregular
size, shape and finish) is converted into a high utility
and valued product (with definite size, shape and finish
imparting some desired function ability)

◼ Machining is an essential process (of semi-finishing and

often finishing)
➢ jobs of desired shape and dimensions are produced by
removing extra material from the preformed blanks in
the form of chips with the help of cutting tools moved
past the work surfaces in machine tools.

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Conventional Machining

Turning & Related Operations

Drilling & Related Operations

Milling & Related Operations

Shaping & Related Operations

Grinding & Related Operations

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 Normal Machining
(Turning Process)

• Basic elements of
turning:
✓ work piece
✓ cutting Tool
✓ machine tool

• Workpiece is rotated
while cutting tool is
moved parallel to the
axis of rotation Conventional turning
(Courtesy: Schlichten Drehen)
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 Applications of
Turning Process

• Cylindrical shape is
generated by turning
• Material is removed from
workpiece until the
desired shape and size
achieved
• Turning of various
components :
✓ metallic sleeve,
barrels, tapered guide, Turned metallic components
bearing shafts, (Courtesy: [Link])
camshafts
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 Machine Tool
• Functions :
➢ hold the workpiece
➢ hold the cutting tool
➢ provide relative motion between tool & workpiece

Manual Lathe CNC Lathe

(Courtesy: [Link]) (Courtesy: Mori Seiki)

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Research and development
in
micro machining

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Application in micro manufacturing

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Fabrication of micro pin

Comparison of the micro pin and SEM image of micro pin for bio-
0.5 mm lead of a pencil medical application
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Fabrication of micro shaft

Image of 19 µm micro turned shaft (left) and 80 µm human hair (right)

(Courtesy: Mikrotools Pte Ltd.)

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 What is the rational
to fabricate
such micro turning shafts?

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• The term nanotechnology was coined by a Japanese researcher Norio Taniguchi in 1974 to label
precision machining with a tolerance of a micron or less.
• Nanotechnology is the understanding and control of matter at dimensions between
approximately 1 and 100 nanometres, where unique phenomena enable novel applications’.
Source:[A.P. Malshe, K.P. Rajurkar, K.R. Virwani, et al., Tip-based nanomanufacturing by electrical,
chemical, mechanical and thermal processes, CIRP Annals-Manufacturing Technology 59 (2010),
628651. and Nano-definition, [Link]/[Link], [Link].].
• Nanomanufacturing requires the integration of nanoscale material science with manufacturing
methodologies to solve multi-domain (mechanical, thermofluid, electrical, optical, chemical,
biological, etc.) and multi-scale (nano-, micro-, meso- and macro-) problems.
 Figure (A) shows a second-hand drive mechanism that runs on a watch. It uses the world’s smallest plastic wheel
made from a carbon nanofibre and plastic resin composite.
The wheel of 0.2 mm diameter (Fig. B) was fabricated with a plastic injection moulding technique and special
microparts design and production technology, as well as nanotech-applied technology used in watch manufacturing.

Figure: Exemplary nanomanufacturing products: (A) Nanogear. (B) World’s smallest carbon
nanofibre composite-made wheel.
Source: C.C. Doumandis, Nano-manufacturing: technical advances, research challenges and future
directions, [Link]/forms/NanoManufacturing_review.pdf.
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 Ultra-precision Machining
(Turning)

• A nano machining technology where material removal in

nano scale
Mirror finish
(Courtesy: NUS)

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Ultra-precision Machining
Ultra-precision machines has increased over the years especially for
manufacturing precision components for computers, electronics, nuclear
power plants and for military hardware.
The examples include optical mirrors, computer memory discs and drums for
photocopying machines. Surface finish requirements are in the range of tens
of nanometers, and form accuracies are in the micrometre and sub-
micrometre range
Ultra-precision Machine Tool

(a) NC machining center with

tool changer and GE controls (b) Ultraprecision machine tool
(Fanuc Corporation, 2014)
(Kearney and Trecker Milwaukee-
Matic, 1958)
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Summary

• Fundamental concept of manufacturing and

machining

• Metal cutting (Machining) as the most versatile

process

• Wide variety of applications of metal cutting

components from macro to micro to ultra-precise
levels

• Chronological development of machine tool for the

metal cutting process
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