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Machining

Workshop Practice
ME-105

Department of Mechanical Engineering


College of E&ME, NUST Pakistan
Contents
• Machining Definition
• Core Machining Operations
• Turning
• Milling
• Drilling
• Boring
• Shaping
• Planning
• Broaching
• Machines (Lathe & Mill)
• Machine Tools
MACHINING OPERATIONS
Machining
• Machining: A set of processes used to produce a part through
“controlled” material removal.

• Core machining operations are:


1. Turning Operations
2. Milling Operations
3. Drilling Operations

• Other miscellaneous machining operations include:


1. Sawing
2. Shaping
3. Planing
4. Broaching
5. Knurling
6. Threading
Turning Operation
• Used to remove material from a work piece by rotating it against at a
cutting tool.

• The cutting tool is moved linearly across the rotating work piece
resulting into material removal.

• The linear motion of cutting tool is called feed and it determines the
depth and speed of cutting
• Turning operations are performed on lathe machines.

• Turning operations reduce the diameter of a work piece either uniformly


or to form a taper (known as taper turning).

• Turning operations are performed to produce axis-symmetrical parts.


Turning
Cutting Speed
Cutting speed is defined as the speed at which the work piece
moves with respect to the tool (usually measured in feet per
minute).
Feed Rate
Feed rate is defined as the distance the tool travels during one
revolution of the part. Cutting speed and feed determines the
surface finish, power requirements, and material removal rate.
It is expressed in units of distance per revolution for turning
and boring (typically inches per revolution or millimeters per
revolution
Milling vs Turning
• Firstly in turning the work piece spins and tool stays stationary, whilst in
milling it’s the other way round.

• In turning the tool moves across the lathe bed in forward-backward fashion
and front-to-back but in normal operation never up and down.

• Turning produces round objects, milling produces linear or depth cuts.

• Hobbing is a machining process for gear cutting, cutting splines, and cutting
sprockets on a hobbing machine, which is a special type of milling machine.
The teeth or splines are progressively cut into the work piece by a series of
cuts made by a cutting tool called a hob.
Drilling
• Drilling is a cutting process that uses a drill bit to cut a hole of
circular cross-section in solid materials

• The drill bit is usually a rotary cutting tool

• Used to drill holes by contacting the static work piece with a


rotating cutting tool

• Drilling is performed with drill press machines or lathe machines

• The rotating cutting tool is termed as drill.


Drilling
• Drilling is the process of cutting a hole in a solid material. Usually, a drill
bit is used to make the hole in the solid material. A drill bit is a cutting
tool. It has a rotary mechanism that helps you to cut the hole

• Boring is when you make a hole in your work piece larger. That means if
your work piece already has a hole in it then you can make it larger by
boring that hole. Usually boring is done after drilling.

• To make a hole smooth you have to follow a process. This process is


known as reaming. Reamers are generally used for reaming a hole.
Reamers are edge cutting tools. They will help you to cut and smoothen
the edge of a hole you drilled in your work piece.
Drilling vs Boring vs Reaming
• The main difference between drilling, boring and reaming is that drilling is
when you make a brand new hole in your work piece. But boring is when you
enlarge the hole. When you give a finishing touch to your hole that means you
are reaming. Giving a finishing touch to the hole means making the hole
smoother.

• Next thing about the three processes is that they have individual tools for
them. The process of drilling uses a drill bit. But the boring process uses a
lathe and reaming uses reamers. So there is also a difference in terms of tools.

• The process of boring always comes after the drilling. And reaming comes at
last. The sequence is always the same. You cannot bore until you drill. And you
cannot ream until you bore. So by drilling, you can directly have a hole you
want. But boring and reaming are the helping processes. Or they are the
processes that will make a better hole.
Shaping and Planning

A shaper is a type of machine tool that uses linear relative


motion between the work piece and a single-point cutting tool
to machine a linear tool path.
Its cut is analogous to that of a lathe, except that it is linear
instead of helical.
Shaping and Planning
Planing is a manufacturing process of material removal in which the
cutting tool reciprocates against a stationary work piece producing a
plane or sculpted surface.
The basic and main difference between shaper and planer is that
in shaper machine work piece is fixed at the table and tool is in
reciprocating motion which rub the work piece and cut unwanted
metal. ... But in planer machine tool is act like as stationary body and
work piece move over it
Planing motion is the opposite of shaping. Both planing and shaping
are rapidly being replaced by milling.
The mechanism used for this process is known as a planer.
The size of the planer is determined by the largest work piece that
can be machined on it.
The cutting tools are usually carbide tipped or made of high speed
steel and resemble those used in facing and turning.
Broaching

Broaching is a machining process that uses a toothed tool, called a broach, to


remove material.
There are two main types of broaching: linear and rotary. In linear broaching,
which is the more common process, the broach is run linearly against a surface
of the work piece to effect the cut. Linear
broaches are used in a broaching machine, which is also sometimes shortened
to broach. In rotary broaching, the broach is rotated and pressed into the work
piece to cut an axisymmetric shape.
A rotary broach is used in a lathe. In both processes the cut is performed in one
pass of the broach, which makes it very efficient.
Miscellaneous Operations
LATHE MACHINE
Lathe Machines
Lathe Machine Parts

• Head Stock
• Chuck
• Tool Post
• Compound Rest
• Tail Stock
• Bed
• Lead Screw
• Carriage
THANKS

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