Faculty of Engineering

Production Engineering Department

Theory of Metal Cutting PE 232

Lecture (1 & 2) Introduction to Machining Technology

Dr. Amira Khattab
Assistant Professor
Course Instructors
Lectures
• Prof. Helmi Youssef
• Dr. Amira Khattab
• Dr. Islam Ali
Sections
• Eng. Ahmed Mostafa
• Eng. Nada

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Course Contents
• Introduction to Machining processes
• Mechanics of Metal Cutting
• Traditional machining processes
• Tool Geometry
• Chip Formation
• Tool Material, Tool wear, Tool Life
• Machinability
• Economics of Metal cutting
• Heat Generation and Cutting Fluids
• Optimization of Machining Parameters

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Course Grading

Exam Marks

Mid Term Examination 20

Quizzes 10
Oral 30
Final Examination 90
Total 150

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References
• Helmi Youssef and Hassan Elhofy. Principles of Traditional and
Nontraditional Machining. 1st edition, 2012.

• Serope Kalpakjian and Steven R. Schmid, Manufacturing Engineering And

Technology. 6th edition, Pearson Education, 2008.

• Hassan Elhofy, Fundamental of Machining Processes: Conventional and

Non conventional processes. 2nd edition, CRC Press, 2014.

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 What is Manufacturing?

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Manufacturing Processes
• Latin manu factus, meaning “made by hand.”
• Manufacturing is concerned with making products.

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Components in Products
• Some products are a single
components (nail, bolt, fork, etc.)
• Some products are assemblies of
many components (ball point pens,
automobiles, washing machines, etc.)
• All components are manufactured.

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Discrete & Continuous PRODUCTS
• Note that items such as bolts, nuts, and paper clips are discrete products,
meaning individual items.
• By contrast, a roll of aluminum foil, a spool of wire, and metal or plastic
tubing are continuous products, which are then cut into individual pieces
of various lengths for specific purposes.

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Manufacturing
• Manufacturing adds value to the material by changing its shape or properties, or by
combining it with other materials that have been similarly altered.

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Classification of Manufacturing Processes

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What is Machining?
• Machining is the removal of the unwanted material (machining allowance)
from the workpiece so as to obtain a finished product of the desired size,
shape and surface quality.
• Machining is generally used as a final finishing operation for parts
produced by casting and forming before they are ready for assembly or
use
• Machining ranges from relatively rough cleaning of
casting to high precision micromachining components
Required narrow tolerances

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Machining in the Manufacturing Sequence

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Advantages
• Machining is characterized by its versatility and capability of achieving
the highest accuracy and surface quality in the most economic way.
The versatility of machining processes can be attributed to many factors,
some of which are
• The process does not require complex tooling.
• It can be employed to all engineering materials.
• Tool wear is kept within limits, and the tool is not costly.
• The large number of machining parameters can be suitably controlled to
overcome technical and economic difficulties.

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Limitations
• It generally necessitates a longer time to
remove material than to shape the part by
forming and casting.
• Unless carried out properly, machining can have
adverse effects on the prosperities of surface
quality of the product.
• Machining is generally energy, capital, and labor
intensive.
• Machining necessitates highly qualified
operators and specialized person.

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Variables of Machining Processes
• Any machining process has two types of interrelated variables. These are
input (independent) and output (dependent) variables.

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Manufacturing Characteristics of Alloys

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Machining Process Selection

Machining Processes

Traditional (TMPs) Nontraditional (NTMPs)

Chip removal
(Cutting) (C)
Abrasion (A) Abrasion (A) Erosion (E)

Turning
Drilling Grinding AJM CHM
Milling Lapping WJM ECM
Boring Polishing EDM
USM
Planning Honing
AFM LBM
Shaping Superfinishing
Broaching MAF PBM

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Cutting, Abrasion, and Erosion
• During machining by cutting, the tool is penetrated into the workpiece as
far as the depth of cut. The machining allowance is removed in the form of
visible chips. The shape of the produced workpiece depends on the
relative motions of the tool and workpiece.
• During machining by abrasion Metal is removed in the form of minute
and invisible chips by hard, tiny, and randomly oriented abrasive grit
(bonded or loose) of indefinite number and shape.
• During machining by erosion Metal is removed in the form of successive
surface layers as a result of dissolution, melting and vaporization of the
material being machined.

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Machining by Cutting
The main components of a typical metal-cutting process
• Tool,
• The workpiece,
• The machine tool that controls the workpiece and tool
motions required for the machining process.

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Machine Tool
• A power-driven machine that performs a machining operation

• Functions in machining:
• Holds work part
• Positions tool relative to workpiece
• Provides power at speed, feed, and depth that have been set

• The term also applies to machines that perform metal forming

operations

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Relative Motions in Cutting Processes
• Two kinds of relative motions, these are the main and feed motions, which
are defined as
• Main or primary motion: Rapid relative motion between the tool and the
workpiece. It is exerted by either the tool or the workpiece, which absorbs
most of the machine power.
• Feed motion: Slow relative motion exerted by either the tool or the
workpiece to bring a new material ahead of the tool to be cut. It may be
actuated step by step (intermittent) or continuously. It usually absorbs a
small proportion of the total machining power.
• The most common forms of these movements are circular or linear.

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Generation of Surfaces (Relative Motions in Cutting
Processes)

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Machining by Cutting

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Different Cutting Processes
• Turning
• Drilling
• Boring
• Milling
• Planning
• Shaping
• Broaching
• Gear Cutting

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Turning
• Turning is a method of machining by cutting
in which the workpiece carries out the main
rotary motion, while the tool performs the
linear motion. The process is used for the
external and internal turning of surfaces.
• The basic motions of the turning process,
1. The primary motion is the rotary motion of
the workpiece around the turning axis.
2. The auxiliary motion is the linear motion of
tool, also called the feed motion.

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Lathe

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 Lathe Components
1. Bed
Supports all major components of the lathe

2. Carriage
Slides along the ways and consists of an assembly of
the cross-slide, tool post, and apron

3. Headstock
Equipped with motors, pulleys, and V-belts that
supply power to a spindle at various rotational
speeds
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Lathe Components (Cont.’)
Chuck:

Three jaw chuck:

• If we are tightening or loosening any jaw,
all the three jaws come towards or away
the center with equal distances.
• It is used for holding round work.

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Lathe Components (Cont.’)
Chuck:

Four jaw chuck:

The jaws are driven by individual square
thread screws, and will hold irregular work
internally or externally.

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 Lathe Components (Cont.’)
4. Tailstock
Slide along the ways and be clamped at any position, supports the other end of the
workpiece

Workpiece

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Lathe Components
5. Feed Rod and Lead Screw
Powered by a set of gears through the headstock
Lathe Specifications
1. Max diameter of the workpiece that can be machined
2. Max distance between the headstock and tailstock centers
3. Length of the bed
4. Number of rotational speeds
5. Feed rates
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Copyright © 2010 Pearson Education South Asia Pte Ltd

Tool fixation

(Tool post)
 Tool Geometry
Rake angle
Increasing the Rake Angle reduces
the cutting force and the cutting
temperature resulting in increased
tool life.
However, for large rake angle, tool
edge is weakened resulting in
increased wear due to chipping of
the cutting edge. (Tool face)
Optimum : about 10 to30 degrees. Clearance
angle

It reduces the friction

between the cutting tool and
workpiece and consequently,
the heating and wear of the
tool are reduced.
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Optimum : about 6 to 12 degrees.

Examples for machined parts:
Lathe Operations

Straight Turning

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Facing

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Lathe Operations
Taper Turning

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Lathe Operations

Drilling

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Lathe Operations
Knurling

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Different Cutting Processes
• Turning
•Drilling
• Boring
• Milling
• Planning
• Shaping
• Broaching
• Gear Cutting

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Drilling
Drilling is a method of machining by cutting used for making holes by
means of twist drills. The process involves two basic motions: the primary
rotary motion and the auxiliary linear feed motion.

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Drilling Machines
Radial Drill Upright Drill

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Drilling Operations

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Different Cutting Processes
• Turning
• Drilling
• Milling
• Planning
• Shaping
• Broaching
• Boring
• Gear Cutting

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Milling Machines

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Horizontal Milling Machine

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Vertical Milling Machine

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Milling Operations

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Different Cutting Processes
• Turning
• Drilling
• Milling
• Planning
• Shaping
• Broaching
• Boring
• Gear Cutting

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Shaper and Planer

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Tool and workpiece motions for metal-cutting operations

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Machining Process Selection

Machining Processes

Traditional (TMPs) Nontraditional (NTMPs)

Chip removal
(Cutting)
Abrasion Abrasion Erosion

Turning
Drilling Grinding AJM CHM
Milling Lapping WJM ECM
Boring Polishing EDM
USM
Planning Honing
AFM LBM
Shaping Superfinishing
Broaching MAF PBM

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Production Engineering Department 27 September 2018 Slide 53
Cutting, Abrasion, and Erosion
• During machining by cutting, the tool is penetrated into the workpiece as
far as the depth of cut. The machining allowance is removed in the form of
visible chips. The shape of the produced workpiece depends on the
relative motions of the tool and workpiece.
• During machining by abrasion Metal is removed in the form of minute
and invisible chips by hard, tiny, and randomly oriented abrasive grit
(bonded or loose) of indefinite number and shape.
• During machining by erosion Metal is removed in the form of successive
surface layers as a result of dissolution, melting and vaporization of the
material being machined.

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Machining by Abrasion (Grinding)
• The abrasive grains are held together by a bonding material that forms a
shaped tool. The grinding tool can be in the form of a wheel, stick, or any
other shape.

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Machining by Abrasion (Honing)
• Honing is a smoothing process where a tool (hone)
carries out a rotary motion and a reciprocating motion
at one or two frequencies although the workpiece
does not perform any motion. The process is
performed using heads with a number of hones
mounted on them depending on the diameter of the
workpiece surface.
• Tool: Bonded abrasives honing stick

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Machining by Abrasion (Honing)

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Machining by Abrasion (Lapping)

Low pressure

Lab
Oil + Loose
abrasives
Workpiece

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Advanced Abrasion processes example (AJM)
• AJM (Abrasive jet machining): In abrasive jet machining (AJM), a focused
stream of abrasive grains of Al2O3 or SiC carried by high pressure gas or air
at high velocity is made to impinge on the work surface through a nozzle
of 0.3–0.5 mm diameter.

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Machining by Erosion
• Machining allowance is removed in the form of successive surface layers as
a result of dissolution, melting and vaporization of the material being
machined.
Laser beam Molten metal

Workpiece

LBM
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