Manufacturing

processes and systems

Lecture 1: Brief overview of manufacturing processes

Created by: Csaba Felhő

Turning: the cutting process
Undeformed chip cross section

alternate angles
b: uncut chip width

The tool after one rotation of the h: uncut chip thickness

workpiece
Turning: tools
Turning: machining steps
Turning: fixtures
Lathe dog and driver plate
Face plate
three-jaw chuck

Rotating centre

steady centre
Turning: machines
 Drilling: the cutting process

Feed per
tooth

Tool edge
Chisel edge
Twist drill geometry
Drilling: tools
Drilling: machines
Drilling: video
Planing and shaping: cutting
process
Planing and shaping
Planing and shaping:
machines
Broaching: the process
Broaching: shapes
Broaching: machines
Broaching: tools
Broaching: video
Milling
• Face milling
• Peripheral milling (horizontal slab milling)
• (end milling)
Milling: Peripheral milling
Milling: end milling
Milling: gear
hobbing
 Milling: kinematics
Peripheral max. undef. Chip face milling
milling cross-section
Feed per
tooth

cutting Feed per tooth

speed

Contact arc length

Width of
cut Average chip
thickness

Depth
of
cut
workpiece

tool Average radial feed

 Milling: force fluctuation

Fc  <1 Fc =1
Down-millingmarás
ellenirányú
egyenirányú
Up-milling marás

t t
resultant
eredõ
 >1
Fc

t
Number of inserts in cut (psi;ψ)
Milling: tools
Milling:
machines
Abrasive machining
• Abrasive machining is a machining process where
material is removed from a workpiece using a
multitude of small abrasive particles.
• Common examples include grinding, honing, and
polishing.
• Abrasive processes are usually expensive, but
capable of tighter tolerances and better surface
finish than other machining processes.
Abrasives
• Aluminum oxide (Corundum)
• Silicon carbide
• Emery
• Pumice
• Sand
• Steel abrasive
Superabrasives:
• Diamond
• Cubic Boron Nitride (CBN), Borazon
 Grinding
Surface grinding Cylindrical grinding

Theoretical
underformed
chip

Centerless grinding

Upper view:

discontinuous
feed
Grinding: tools
Grinding:
machines
Superfinishing
Honing
Lapping
Polishing

Flexible tool body adhesive Bonded particles

Free particles workpiece Carrier fluid