Course Code: ME305A

Course Title: Manufacturing Process -2

Lecture No. 1
Introduction To Material Removal Operations
Lecture delivered by:
Dr. Suresh R

1
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Lecture Objectives

At the end of this lecture, the students should be able to:

• Explain the importance of Machining

• Illustrate the applications of Machining processes
• Classify various machine tools used in manufacturing

2
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Introduction

• The process of converting raw materials, components or parts into

finished goods that meet a customer's expectations or
specifications
• Manufacturing commonly employs a man-machine setup with
division of labor in a large scale production
• Process in which a sequence of operations are performed on the
raw work piece so as to convert it into desired product

Fig.1 Manufacturing as an input-output system 3

Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Classification of Manufacturing Process

• Process type manufacturing

– It involves continuous flow of materials
through a series of processing steps to obtain
finished product, like Chemicals, Oil and Gas
industries, Textile industries
• Fabrication type Manufacturing
– It involves manufacturing of individual parts or
components by series of operations , such as
machining, forming and welding

• Assembly type of Manufacturing

– The parts or components are put together to
get a complete product such as machines,
automobiles, aircrafts, ship building, etc.
4
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Machining Applications
• It is a process by which parts can be produced to the desired
dimensions and surface finish from a blank by gradual removal of
the excess material in the form of chips with the help of a sharp
cutting tool
• Manufacturing industries for making the various types of jobs for
automobiles, machine tools, energy generation sectors
• Machine tool parts, Press tools, tool and dies making applications
• Aircraft, space craft, surgical and orthopedic components

Connecting rods Cam Shaft Turbine 5

Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Aerospace Applications

Landing gear beam

Landing Gear
Aerospace Components
6
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Automobile Applications

Camshaft

Engine block

Bearing

7
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Press Tool Applications

Figure: Press tool dies

8
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Industrial Applications

Industrial components

9
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Machine Tool Applications

Tool Adapter for Machine tool spindle Machine tool bed

machine tools

10
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Surgical Applications

Ti alloys and stainless steels used to Joint

replacement, bone plates and screws

11
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Power Generation Applications

Machining of turbine blades

12
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Selection of Suitable Process

Following factors influence the selection of a suitable machining

process, namely
• Material of work piece
• Shape and size of the work piece
• Degree of dimensional accuracy and geometrical tolerances
• Surface finish required
• Number of products to be produced
• Cost consideration

13
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Classification of Manufacturing Process

14
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Classification of Machine Tools

15
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Metal Removal/Machining Process
The machining process involves removal of extra material from a given
work piece to get it to desired shape and dimensions with better
surface finish.
The machining process are classified as
• Metal cutting
– Single point cutting, Turning, shaping, Planing and Boring
– Multipoint cutting, Milling, drilling, tapping, broaching
• Grinding and finishing
– Surface Grinding, Cylindrical Grinding and Centre-less Grinding
– Lapping, Honing, Super-finishing
• Unconventional machining
– Ultrasonic machining, Electric Discharge Machining, Abrasive Jet Machining,
Laser Beam Machining, etc.
16
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Metal Removal Process
• Produce a desired shape, size and finish of a component by
removing excess material in the form of chips
• Chips may constitute more than 50% of initial work piece

• Machining processes are performed on metal cutting machines,

using various types of cutting tools

• Metal cutting process carried out at high speeds and feeds with
least cutting effort at minimum cost

17
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Metal Cutting process (cont..)
• Removing unwanted material: Cutting/chipping/machining/metal
cutting
• To get desired Shape, Size and Surface finish

Figure: Typical machining example

18
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Why Machining is Important?
• Variety of work materials can be machined
- Most frequently applied to metal processing
• Variety of part shapes and special geometry features possible,
such as:
- Screw threads
- Accurate round holes
- Very straight edges and contour surfaces
• Good dimensional accuracy and surface finish
• Shearing process in which excess materials is removed by cutting
tools

19
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Advantages of Machining Process
• A variety of work materials
• ‘Repeatable’ regular geometries
• Close tolerance (<0.05μm)
• Smooth surface finish (0.8μm)
• Other processes such as casting, forging, and bar drawing
create the general shape
• Provides the final shape, dimensions, finish, and special
geometric details that other processes cannot create

20
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Disadvantages of Machining Process
 Wastage of material
• Chips generated in machining are wasted material, at least in
the unit operation
 Time consuming
• A machining operation generally takes more time to shape a
given part than alternative shaping processes, such as casting,
forging, extrusion and other forming process

21
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Machining Operations

 Most important machining operations:

• Turning
• Drilling
• Milling
 Other machining operations:
• Shaping and Planing
• Broaching
• Sawing

22
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Turning
 Using single point cutting tool removes material from a rotating
workpiece to form a cylindrical shape

Fig.: Turning operation

23
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Turning Operations

Turning Facing Grooving Forming Threading

External

Internal

Figure: Different types of turning operations

24
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Milling
 Rotating multiple-cutting-edge tool is moved slowly relative to work
to generate plane or straight surface
 Two forms: peripheral milling and face milling

Figure: Peripheral milling and Face milling

25
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Milling Operations

Figure: Different types of milling operations

26
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Drilling
 Drilling is used to create a round hole, usually by means of a
rotating tool (drill bit) that has two cutting edges

Figure: Drilling Process

27
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Shaping and Planing
 A single point tool moves linearly relative to the work part
• Shaping –A tool moves
• Planing –A work part moves

Figure: (a) Shaping and (b) Planing

28
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Broaching and Sawing
 Broaching
- Performed by a multiple tooth cutting tool by moving linearly
relative to the work in the direction of the tool axis
 Sawing
-Hacksawing, bands awing and circular sawing

Figure: Broaching tools Figure: Broached components

29
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Abrasive Machining Processes
• Abrasive machining: Material is removed from a work piece using a
multitude of small abrasive particles; Eg.,
Grinding
Honing
Lapping
Polishing
• Different types of grinding
• Surface grinding
• Cylindrical grinding and
• Centerless grinding

30
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Grinding Operations

Figure: Surface grinding Figure: Cylindrical grinding

Figure: Centerless grinding

31
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Honing
• Honing: Produces a precision surface on a metal work piece by
scrubbing an abrasive stone against it along a controlled path
• Applications: Finishing of cylinders for internal combustion engines,
air bearing spindle and gears

Figure Honing Tool

Figure: Honing Process

32
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Factors Affecting Metal Cutting

• Properties of Work material

• Properties of the tool material & geometry of cutting tool
• Interaction between tool and workpiece
• Cutting parameters like cutting speed, feed rate and depth of cut
• Insufficient lubrication between tool and workpiece (cutting
environment)
• Machine tool rigidity

33
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
 Summary

• Machine tools are classified based on the applications as general

purpose, production and special purpose

• Applications of machine tools in various fields as automobile,

aerospace, medical and power generation industries

• Types of machining operations, turning, milling, grinding,

broaching honing etc.

34
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences