NAME: AJIMOKO SUNDAY SHOLA

COURSE TITLE: MEE853

ASSIGNMENT: 1

Question 1: Discuss any four traditional metal removal processes.

Answer: Traditional removal processes are the techniques used in manufacturing to shape or
finish materials by removing materials from a workpiece.

The four traditional metal removal are as follows:

1. Turning: Turning is a machining process in which a cutting tool removes material from a
rotating workpiece. The workpiece is typically held in a lathe, and as it rotates, the tool
is fed into it cutting away material to create cylindrical shapes.
Applications: It is used for making bolts, shafts and cylindrical components which is
widely used in the aerospace and automotive industries.

2. Milling: This involves the use of rotating multi point cutting tools to remove material
from a workpiece. The workpiece is typically held stationary while the rotating cutter
moves in multiple axes to shape the material
Application: This is used to create complex shapes, slots and holes. It is used in
industries like Aerospace, Manufacturing and precision engineering.

3. Drilling: This is a cutting process that uses a rotary drill bit to create cylindrical holes in a
workpiece. The drill bit is pressed against the work piece and rotated to cut away
material.
Applications: It is used to create holes for fasteners such as screws and bolts and
material like metal, wood and plastic.

4. Grinding: This is an abrasive machining process that uses a grinding wheel as a cutting
tools. This wheel removes small chips of material from the workpiece to achieve a
smooth finishes or precise dimension.
Applications: It is used for finishing operations such as sharpening tools, creating precise
dimension etc in automotive and aerospace industries
Question 2: Discuss Four Modern Metal Removal Processes.

Answer: The four Modern Metal Removal Processes to be discussed are as follows

1. Electrical Discharge Machining: This removes metal by means of electrical

discharges (sparks) between an electrodes and workpiece. The process involves the
erosion of material through a series of rapidly recurring electrical discharges in a
dielectric fluid.
Applications: This is used very effective on Hard materials such as steel, titanium etc
which are difficult to machine

2. Laser Beam Machining: This uses a high –energy laser beam to vaporizes or melt
material from the workpiece which will result in precise material removal. This
process involves focusing the laser onto the surface of the material which causes
rapid heating and material removal.
Applications: It is used in micro machining, drilling tiny holes. It is used in the
electronics and medical devices industries.

3. Water Jet Machining: This removes material by directing high pressure steam of
water sometimes mixed with abrasive particles onto the workpiece. The velocity of
water jet erodes the material away creating precise cuts without generating heat.
Applications: It is used for cutting intricate shape in materials such as metals,
composites, glass and stones.

4. Plasma Arc Machining: This uses a plasma torch to generate a high temperature
plasma arc which melts and removes material from the workpiece. The process
involves ionizing of gas to create plasma which is then directed towards the
workpiece melting and ejecting the material.
Applications: This is used in cutting thick metals and alloy especially in Shipbuilding
industries, automotive and construction.
Question 3: Compare and Contrast the Four Traditional and Non Traditional Metal Removal
Processes.

TRADITIONAL METAL REMOVAL

TURNING MILLING DRILLING GRINDING
Process Involves rotating A rotating This involves This uses an
the workpiece cutting tool rotating a drill abrasive wheel
while a cutting remove material bit to create to remove very
tool remove from a holes in the fine amount of
material stationary workpiece material
workpiece. Can
be horizontal or
vertical
Material Achieved by Achieved by The drill bit Achieved
Removal shear multiple cutting removes through the
deformation edges on the material abrasive action
tool through a of the grinding
cutting action wheel.
Precision High precision Good precision, Moderate Very high
but limited by suitable for precision often precision,
the tools complex shapes requires capable of
sharpness and reaming for high producing fine
machine precision holes surface finishes.
accuracy.
Tools war Tool experience Similar to Drill wears over Grinding wheels
significant wear turning, tool time especially wear down
due to high wear is a factor in harder slowly but must
friction and materials be dressed to
cutting forces maintain
precision
Application Used in Making Used for Used in creating Used for
cylindrical parts producing slots, holes for bolts finishing
like Shafts and holes and screws or surfaces and
bolts complex surface fasteners sharpening tools
contours.
NON-TRADITIONAL METAL REMOVAL
Electrical Laser Cutting Water Jet Ultrasonic
Discharge Cutting Machining
Machining
Process This uses Uses a focused laser Uses a high Ultilizes high
electrical beam to melt, burns pressure frequency
discharge or vaporize material steams of vibrations of a tool
spark to erode water. in the presence of
material from Sometimes an abrasive slurry
workpiece mixed with an to remove material
abrasive to cut
through
materials
Material No direct Achieved through The force of Achieved from the
Removal contact, intense heat from the water jet slurry combined
material is the laser. erodes the with vibration
removed by material caused the
spark erosion material to be
removed.
Precision Extremely High precision, Moderate Very high
high, capable especially softer precision precision,especially
of producing materials often requires brittle material
intricate and reaming for
delicate high precision
shapes. holes
Tools war Electrodes Minimal tool wear Drill wears Tools wear at a
wears occurs though the nozzle over time slower rates due to
but less may wear over time. especially in low impact.
significant harder
than in materials
traditional
tools
Application It is used and Used for cutting Used in Used for machining
ideal for hard metals,glass,ceramic creating holes hard and brittle
material and for bolts material.
complex screws or
geometries fasteners
such as
 moulds and
dies.

Comparison of Traditional and Non Traditional Metal Removal Processes

[Link]: Non- traditional methods generally offer higher precision and are better
suited for intricate or complex shapes.
[Link]: Traditional methods experience more tool wear due to physical contact,
while non-traditional methods have less wear, through components like electrodes or nozzles
may still degrade
3. Material Flexibility: Non-traditional methods can machine hard, brittle, or difficult-to-
machine materials, unlike traditional method, which are limited by tool material and design
4. Speed: Traditional methods are often faster for simple operations but may require
multiple steps for complex shapes, whereas non-traditional method can directly achieve
complex geometries
5. Cost: Non-traditional methods tend to be more expensive due to the advanced
technology and equipment required.

Both traditional and non-traditional metal removal processes have their place in manufacturing,
depending on the requirements of the task at hand. Traditional processes are typically used for
simpler, high-speed machining tasks, while non-traditional methods are preferred for complex,
high-precision work and difficult-to-machine materials

Question 4: Describe any two type of instruments that are used for the measurement of cutting
forces in turning and milling operations

Answer: Two types of instruments used for the measurement of cutting forces in turning and
milling operations are;

1. Dynamometers: These devices measure the forces exerted on the cutting tool during
machining. They can be of various types, including piezoelectric, strain gauge, and hydraulic
dynamometers. Piezoelectric dynamometers use sensors that generate an electrical charge
proportional to the force applied. Strain gauge dynamometers use strain gauges attached to the
tool holder to measure the deformation caused by cutting forces. Hydraulic dynamometers use
fluid pressure changes to measure force. These instruments are often integrated into the
machine tool setup or mounted directly on the tool holder.

2. Force Sensors: These are specialized sensors that measure forces directly during
machining. In turning and milling, force sensors can be attached to the tool holder or integrated
into the machine tool's spindle. They often use strain gauges or piezoelectric elements to
convert force into an electrical signal that can be read and interpreted. Force sensors provide
real-time data on cutting forces, which helps in monitoring tool wear and adjusting machining
parameters for optimal performance.