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Machining Processes Overview

The document discusses various machining processes and metrology. It covers 7 topics related to metal cutting mechanics, basic machine tools like lathes and milling machines, unconventional machining methods, and metrology. Machining involves removing material in the form of chips through relative motion between a cutting tool and workpiece. It allows for very accurate and flexible shaping of parts at low tooling costs. Key requirements for metal cutting are a relative motion between tool and workpiece, and for the tool to be harder than the workpiece.

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HarishVenkatesan
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13 views11 pages

Machining Processes Overview

The document discusses various machining processes and metrology. It covers 7 topics related to metal cutting mechanics, basic machine tools like lathes and milling machines, unconventional machining methods, and metrology. Machining involves removing material in the form of chips through relative motion between a cutting tool and workpiece. It allows for very accurate and flexible shaping of parts at low tooling costs. Key requirements for metal cutting are a relative motion between tool and workpiece, and for the tool to be harder than the workpiece.

Uploaded by

HarishVenkatesan
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Machining Processes and

Metrology
MEE2006

School of Mechanical Engineering


Vellore Institute of Technology-632014
Module Topics
1 Metal Cutting - Mechanics of metal cutting - cutting tool materials, temperature, wear, and tool life
considerations, geometry and chip formation, surface finish and machinability, optimization.

2 Basic Machine Tools - Lathe and its types - Constructional details including accessories and
attachments, operations, types of lathe, Constructional and operational details of Shaping - Planing -
Slotting – Drilling - Boring – Reaming – Tapping – Broaching.
3 Milling machine - Cutters - Milling operations - Indexing – Gear Generation: Gear generating
principles - Gear Hobber - Gear finishing methods - Bevel gear generator.

4 Grinding machine- Operations and applications of surface, cylindrical and centreless grinding
processes, dressing, truing and balancing of grinding wheels, grading and selection of grinding
wheels, micro-finishing (honing, lapping, super-finishing).
5 Unconventional methods - Electro-chemical, electro-discharge, ultrasonic, LASER, electron beam,
water jet machining.

6 Introduction to Metrology - Linear and angular measurements – taper measurement, threads,


surface finish, inspection of straightness, flatness and alignment-– Comparators - Gear testing.

7 Advances in Metrology - Precision Instrumentation based on Laser Principals, Coordinate measuring


machines, Optical Measuring Techniques: Tool Maker’s Microscope, Profile Projector. Nano-
measurements: Scanning Electron [Link] Force Microscopy-Transmission Electron
Microscopy.
8 Contemporary Discussion

2
Manufacturing Processes

• Subtractive (Material Removal)

• Additive (Material Build-up)

• Formative (Material distribution)

Mechanics of metal cutting 3


Manufacturing Process Selection

1. Material

2. Tolerances

3. Geometry, strength and endurance

4. Surface finish

5. Production volume

Mechanics of metal cutting 4


Machining
Removing material in the form of chips

Very accurate
• highest of all manufacturing processes
• small amounts of materials removed
• precise tools, dies, moulds can be made

Highly Flexible
• shape is programmed
• many different parts can be made on one machine
• any arbitrary shape can be machined

Low cost tooling


• contour is generated by path of tool, rather than its shape, in most cases
• cutting tools are mass-produced in
• standardized shapes
5
Basic requirements for metal cutting

• There should be a relative motion between the cutting tool and the
workpiece.

• The cutting tool should be harder than the workpiece

• There should be sufficient power available to overcome the cutting


forces
 Solid state physics
 Physical metallurgy
 Engineering mechanics
 Thermodynamics
 Theories of wear and lubrication

Mechanics of metal cutting 6


What is required?

1. Rapid removal of metal

2. Satisfactory surface finish

3. Low-cost tools, maintenance

4. Minimum down time of the machines

Mechanics of metal cutting 7


Machining Operation

1. Workpiece
2. Tool
3. Chip
4. Cutting fluid

Mechanics of metal cutting 8


Ref: [Link]
Mechanics of metal cutting 9
Shear Zone

The region between the


lower surface, where
elongation of the grain
structure begins and in
the upper section where
it ends

Mechanics of metal cutting 10


Stress – Force – Material removal
P
Ps

𝑃𝑛 = 𝑃 𝑐𝑜𝑠𝜃
P
ϴ n
𝑃𝑠 = 𝑃 𝑠𝑖𝑛𝜃
Pn
ϴ
𝑃
n 𝑆𝑛 = 𝑐𝑜𝑠 2 𝜃
𝐴
𝑃 𝑃 m
𝑆𝑠 = 𝑠𝑖𝑛𝜃 𝑐𝑜𝑠𝜃 = 𝑠𝑖𝑛2𝜃
𝐴 2𝐴
m
Maximum shear stress 2ϴ = 90 °
ϴ = 45 °

P
Mechanics of metal cutting 11

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