636 Chapter 23 Machining Processes: Turning and Hole Making

The ratings given in Table 23.8 are relative, and there can be significant varia-
tions in special applications. For example, heat-treated, high-carbon, cast-steel rolls
for rolling mills can be machined on special lathes using cermet tools at material-
removal rates as high as 6000 cm3/min 1370 in3/min2. Also called high-removal-rate
machining, this process has at least two important requirements: (a) very high ma-
chine tool rigidity to avoid chatter and associated tool breakage and (b) high power
of up to 450 kW (600 hp).

Roughness (Ra)
mm 50 25 12.5 6.3 3.2 1.6 0.8 0.40 0.20 0.10 0.05 0.025 0.012
Process min. 2000 1000 500 250 125 63 32 16 8 4 2 1 0.5
Rough cutting
Flame cutting Average application
Snagging (coarse grinding) Less frequent application
Sawing
Casting
Sand casting
Permanent mold casting
Investment casting
Die casting
Forming
Hot rolling
Forging
Extruding
Cold rolling, drawing
Roller burnishing
Machining
Planing, shaping
Milling
Broaching
Reaming
Turning, boring
Drilling
Advanced machining
Chemical machining
Electrical-discharge machining
Electron-beam machining
Laser machining
Electrochemical machining
Finishing processes
Honing
Barrel finishing
Electrochemical grinding
Grinding
Electropolishing
Polishing
Lapping
Superfinishing

FIGURE 23.13 The range of surface roughnesses obtained in various processes. Note the
wide range within each group, especially in turning and boring.