SUBJECT CLASS

MANUFACTURING
OF

PROCESS
4 MEETING
TH

TURNING,
DRILLING, AND
MILLING

Dr. rer . oec . Arfan Bakhtiar , S.T.,

M.
Faradhina Azzahra, S.T., M.Sc.
TURNING
AND
RELATED
OPERATIONS
Turning is a machining
process in which a single point
tool removes material from the
surface of a rotating workpiece.
The tool is fed linearly in a
direction parallel to the axis of
rotation to generate a
cylindrical geometry.
CUTTING CONDITIONS IN
TURNING • The rotational speed in turning is related to the
desired cutting speed at the surface of the
cylindrical workpiece by the equation
𝑣
𝑁=
𝜋𝐷0
• N = Rotational speed (rev/min or RPM)
• V = Cutting speed (m/min)
• D0 = Original diameter of the part (m)
• The turning operation reduce the diameter of the
work from its original diameter 𝐷𝑜 to a final
diameter
𝐷𝑓, as determined by the depth of cut d:
𝐷𝑓 = 𝐷0 − 2𝑑
• The feed in turning is generally expressed as
mm/rev. This feed can be converted to a
linear travel rate such as mm/min by the
formula:
𝑓𝑟 = 𝑁𝑓
• fr = feed rate (mm/min)
• f = feed (mm/rev)
• The time to machine from one end of a cylindrical
work
part to the other is given by:
𝑇𝑚 = 𝐿
𝑓𝑟
Tm = machining time (min)
L = length of the cylindrical work part (mm or
in) fr = feed rate (mm/min)

• A more direct computation of the machining time

is provided by the following equation:
𝜋𝐷0𝐿
𝑇𝑚 =
𝑓𝑣
• The volumetric rate of material removal can be
most conveniently determined by the following
equation: 𝑅 = 𝑣𝑓𝑑
𝑀𝑅

RMR = material removal rate (mm3/min or in3/min)

EXERCISE MACHINING TIME IN TURNING

• A turning operation is performed on a cylindrical work part whose diameter = 120 mm and
length = 450 mm. Cutting speed = 2.0 m/s, feed = 0.25 mm/rev, and depth of cut = 2.2
mm.
• Determine the (a) cutting time and (b) material removal rate
OPERATIONS
RELATED TO
TURNING
1. Facing: material.
This operation creates a flat surface on the end of a cylindrical workpiece. The cutting tool completely severs the workpiece at a desired location.
The cutting tool is fed radially, meaning it moves inward towards the center 7. Threading:
of the workpiece, while the workpiece rotates. This operation creates a helical screw thread on the external or internal
2. Taper Turning: surface of a workpiece.
This operation creates a conical shape on the workpiece. This allows for parts to be screwed together or for other threaded
The cutting tool is fed at an angle instead of parallel to the axis of the components to be attached.
workpiece. This angle determines the slope of the taper. 8. Boring:
3. Contour Turning: This operation enlarges an existing hole in a workpiece.
This operation creates a curved surface on the workpiece. A boring bar with a single cutting edge is used to remove material
and
The cutting tool path follows a specific profile to achieve the desired shape. increase the hole diameter.
This can be achieved using various techniques like using a template or CNC 9. Drilling:
control. This operation creates a new hole in a workpiece.
4. Form Turning: A drill bit with a specific diameter is used to create a cylindrical hole.
This operation creates a specific shape on the workpiece by plunging the 10. Knurling:
cutting tool radially into the part. This operation creates a textured pattern on the surface of a workpiece.
The shape of the cutting tool tip determines the final shape created on the This is often used to improve grip and prevent slipping. A knurling tool
workpiece. creates the raised pattern by pressing into the material.
5. Chamfering:
This operation creates a small, angled edge at the corner of a workpiece.
This is often done to reduce stress concentration and
improve machineability.
6. Cutoff:
This operation completely separates a workpiece from the original stock
DRILLING AND RELATED OPERATIONS

• Drilling, is a machining operation used to create a round hole in a work part. This
contrasts with boring, which can only be used to enlarge an existing hole. Most
drilling operations are performed using a rotating cylindrical tool that has two cutting
edges on its working end.
• The tool is called a drill or drill bit, the most common form of which is the twist drill. The
rotating drill feeds into a stationary work part to form a hole whose diameter is equal to
the drill diameter.
• Drilling is customarily performed on a drill press although other machine tools also
perform this operation.
CUTTING CONDITIONS IN
DRILLING
 𝑣
𝑁=
𝜋𝐷
N = spindle (rev/min)
v = cutting speed (mm/min)
D = Drill diameter (mm)

• Feed f in drilling is specified in mm/rev (in/rev). Recommended feeds are

roughly proportional to drill diameter; higher feeds are used with larger-
diameter drills. Since there are (usually) two cutting edges at the drill
point, the uncut chip thickness (referred to as the chip load) taken by each
cutting edge is half the feed.
• Feed can be converted to feed rate using the same equation as for turning:
𝑓𝑟 = 𝑁𝑓
fr = feed rate (mm/min or in/min)
• Drilled holes are either through holes or blind holes, with a twist drill at the
beginning of the operation. In through holes, the drill exits the opposite side
of the work; in blind holes, it does not. The machining time required to drill
a through hole can be determined by the following formula:
𝑡+𝐴
𝑇𝑚 =
𝑓𝑟
Tm = machining or drilling time
(min) t = work thickness (mm)
fr = feed rate (mm/min)

A = an approach allowance that

accounts for the drill point angle
(mm or in)

𝜃
• This allowance is given by 𝐴 = 0.5 𝐷 tan 90 −
2
• In a blind hole, hole depth d is defined as the distance from the work surface to
the depth of the full diameter. Thus, for a blind hole, machining time is given by
𝑑+𝐴
𝑇𝑚 =
𝑓𝑟
Tm = machining or drilling time (min)
d = distance from the work surface to the depth of the full diameter
(mm) fr = feed rate (mm/min)
A = an approach allowance that accounts for the drill point angle (mm or
in)

• The rate of metal removal (mm3/min) in drilling is determined as the product

of the drill cross-sectional area and the feed
𝜋𝐷rate:
2𝑓
𝑟
𝑅𝑀𝑅 =
4
EXERCISE MACHINING TIME IN DRILLING

• A drilling operation is performed to create a through hole on a steel plate that is 15 mm thick.
Cutting speed = 0.5 m/s , and feed = 0.22 mm/rev . The 20-mm-diameter twist drill has a
point angle of 118°.
• Determine the (a) machining time and (b) metal removal rate once the drill reaches
full diameter.
OPERATIONS
RELATED TO
DRILLING
a) Reaming, which is used to slightly enlarge a hole, provide a better tolerance on its diameter,
and improve its surface finish; the tool is called a reamer, and it usually has straight flutes;
b) Tapping, is performed by a tap and is used to provide internal screw threads on an existing
hole;
c) Counterboring, provides a stepped hole, in which a larger diameter follows a smaller diameter
partially into the hole; a counterbored hole is used to seat a bolt head into a hole so the head
does not protrude above the surface;
d) Countersinking, is similar to counterboring, except that the step in the hole is cone shaped for
flat
head screws and bolts;
e) Centering, also called center drilling, drills a starting hole to accurately establish its location
for subsequent drilling (the tool is called a center drill); and
f) Spot facing, is similar to milling and is used to provide a flat machined surface on the work
part in
a localized area.
Most of these operations follow drilling a hole must be made first by drilling, and then the hole is
modified by one of the other, operations centering and spot facing are exceptions to this rule All of
the operations use rotating tools
MILLING AND RELATED
OPERATIONS
• Milling is a machining operation in which a work part is fed past a rotating cylindrical tool with
multiple cutting edges.
• The cutting tool in milling is called a milling cutter and the cutting edges are called teeth.
• The conventional machine tool that performs this operation is a milling machine. The geometric
shape normally created by milling is a plane surface.
• Other work geometries can be created either by means of the cutter path or the cutter shape.
Owing to the variety of shapes possible and its high production rates, milling is one of the most
versatile and widely used machining operations.
• Milling is an interrupted cut operation, which means that the teeth of the cutter enter and exit the
work during each revolution. This interrupted cutting action subjects the teeth to a cycle of
impact force and thermal shock on every rotation. The tool material and cutter geometry must be
designed to withstand these conditions.
TYPES OF MILLING OPERATIONS
TYPES OF MILLING OPERATIONS
PERIPHERAL
a. slab milling , the basic form of peripheral milling in which the cutter width extends beyond the
workpiece on both sides;
b. slotting , also called slot milling , in which the width of the cutter is less than the workpiece
width, creating a slot in the work when the cutter is very thin, this operation can be used to mill
narrow slots or cut a work part in two, called sawmilling ;
c. side milling , in which the cutter machines the side of the workpiece;
d. straddle milling , the same as side milling, only cutting takes place on both sides of the work; and
e. form milling , in which the milling teeth have a special profile that determines the shape of the
slot that is cut in the work.
TYPES OF MILLING OPERATIONS
PERIPHERAL: THE DIRECTION OF CUTTER ROTATION
In up milling, also called
conventional milling, the
direction of motion of the cutter
teeth is opposite the feed direction
when the teeth cut into the work.

In down milling, also called climb

milling, the direction of cutter
motion is the same as the feed
direction when the teeth cut the
work.
TYPES OF
MILLING
OPERATIONS
FACE
MILLING
a. conventional face milling, in which the diameter of the cutter is greater than the work part
width, so the cutter overhangs the work on both sides;
b. partial face milling, where the cutter overhangs the work on only one side;
c. end milling, in which the cutter diameter is less than the work width, so a slot is cut into
the
part;
d. profile milling, a form of end milling in which the outside periphery of a flat part is cut;
e. pocket milling, another form of end milling to cut shallow pockets into flat parts; and
f. surface contouring, in which a ball-nose cutter (rather than square-end cutter) is fed
back and forth across the work along a curvilinear path at close intervals to create a three-
dimensional surface form.
The same basic cutter control is required to machine the contours of mold and die cavities,
in which case the operation is called die sinking.
CUTTING CONDITIONS IN
MILLING PERIPHERAL
CUTTING CONDITIONS IN
MILLING FACE MILLING
• The cutting speed is determined at the outside diameter of a milling cutter. This can
be converted to spindle rotation speed using a formula that should now be familiar:
𝑣
𝑁=
𝜋𝐷0
• The feed f in milling is usually given as a feed per cutter tooth; called the chip load, it
represents the size of the chip formed by each cutting edge. This can be converted to feed
rate by taking into account the spindle speed and the number of teeth on the cutter as
follows:
𝑓𝑟 = 𝑁𝑛𝑡𝑓
fr = feed rate

(mm/min) N = spindle
speed (rpm)
nt = number of teeth on
the cutter
• Material removal rate in milling is determined using the product of the cross-sectional area of
the cut and the feed rate. Accordingly, if a slab-milling operation is cutting a workpiece with
width w at a depth d, the material removal rate is
𝑅𝑀𝑅 = 𝑤𝑑𝑓𝑟
• The time required to mill a workpiece of length L
must account for the approach distance required to
fully engage the cutter. To determine the time to
perform a slab (peripheral) milling operation, the
approach distance A (mm) to reach full cutter depth is
given by
𝐴= 𝑑(𝐷 − 𝑑)
d = depth of cut (mm)
D = diameter of the milling cutter (mm)
𝑇𝑚 = 𝐿 + 𝐴
𝑓𝑟
Tm = time which the cutter is engaged in
the workpiece (min)
• For face milling: First possible case
The cutter feeds from right to left across the workpiece. In order for
the cutter to reach the full width of the work, it must travel an
approach distance given by

𝐴 = 0.5 (𝐷 − 𝐷2 − 𝑤2 )
D = cutter diameter (mm)
w = width of the workpiece (mm)
 If D = w, then Equation reduces to A = 0.5 D.
 If D < w , then a slot is cut into the work and A = 0.5 D

𝐿+𝐴
𝑇𝑚 =
𝑓𝑟
Tm = time which the cutter is engaged in the workpiece
(min)
• The second case is when the cutter is offset to one side
of the work. In this case, the approach distance is given
by
𝐴= 𝑤(𝐷 − 𝑤)
w = width of the cut (mm or in).
• Then,
𝐿+𝐴
𝑇𝑚 =
𝑓𝑟
EXERCISE MACHINING TIME IN PERIPHERAL
MILLING
• A slab milling operation is performed to finish the top surface of a steel rectangular
workpiece 250 mm long by 65 mm wide. The helical milling cutter, which is 75 mm in
diameter and has eight teeth, is set up to overhang the width of the part on both sides.
Cutting conditions are cutting speed = 35 m/min, chip load = 0.225 mm/tooth, and depth of
cut = 6.35 mm.
• Determine: the time to make one pass across the surface
RECAP QUIZ

• What is a blind
hole?
RECAP QUIZ

• What is the difference between peripheral milling and face

milling?
RECAP QUIZ 3

• Describe the difference between up milling and down

milling?