Department of Mechanical Engineering

University of Central Punjab

Machining Operations
(Machining Centers + Other Machining
Operations)

COURSE TITLE: MANUFACTURING PROCESSES II (MEN3143)

Chapter 22 Course Instructor: Umer Hayat

 Summary of Last Lecture
2

 Milling and its types

 Machining Center
3

 Highly automated machine tool capable of performing multiple

machining operations under CNC control in one setup with minimal
human attention
 Typical operations are milling and drilling
 Three, four, or five axes

 Typical features which distinguish machining centers from conventional

machine tool are
 Multiple operations in one setup
 Automatic tool-changing
 Pallet shuttles
 Automatic workpart positioning
4

Figure 22.26 - Universal machining center (Cincinnati Milacron);

highly automated, capable of multiple machining operations under
computer control in one setup with minimal human attention
 CNC Turning Center
5

 Capable of performing various turning and related operations,

contour turning, and automatic tool indexing

 Workpart guaging (checking key dimensions after machining)

 Tool monitoring (sensors to indicate when the tools are worn)

 Automatic tool changing when tools become worn

 Automatic workpart changing at the completion of the work cycle

6

Figure 22.27 - CNC 4-axis turning center (Cincinnati Milacron);

capable of turning and related operations, contour turning, and
automatic tool indexing, all under computer control.
 CNC Mill-turn Center
7

 Highly automated machine tool that can perform turning, milling, and
drilling operations on a workpart with grinding, welding and
inspection, all in one machine tool

 Can position a cylindrical workpart at a specified angle so a rotating

cutting tool (e.g., milling cutter) can machine features into outside
surface of part
A conventional turning center cannot stop workpart at a defined angular
position and does not possess rotating tool spindles

 Can use multiple spindles

8

Figure 22.28 - Operation of a mill-turn center:

(a) example part with turned, milled, and drilled surfaces; and
(1) turn second diameter,
(2) mill flat with part in programmed angular position, (3) drill hole
with part in same programmed position, and (4) cutoff
 Shaping and Planing
9

 Shaping and planing are similar operations

 Both use a single point cutting tool moved linearly relative to the
workpart to create flat surfaces
 Difference?
 In shaping, the speed motion is accomplished by moving the cutting
tool
 In planing, speed motion is accomplished by moving the workpart
 Shaping and Planing
10

 A straight, flat surface is created in both operations

 Interrupted cutting
 Subjects tool to impact loading when entering work

 Low cutting speeds due to start-and-stop motion

 Usual tooling: single point high speed steel tools

 The machine tool for shaping is called shaper

 The machine tool for planing is called planer
 Shaper
11
 Shaper
12

 Parts: ram, column, worktable, and base

 The motion of ram consists of a

 forward stroke to achieve the cut
 return stroke (which is more quicker) during which the tool is lifted
slightly to clear the work

 On completion of each return stroke, the worktable is advanced

laterally relative to the ram motion in order to feed the part

 Both hydraulic and mechanical drive mechanisms are used but

mechanical is more common
 Planer
13
 Planer
14

 Construction and motion capability of a planer permit much lager

parts to be machined than on shaper

 Planer can be classified as either open side planer (single column

planer) or double column planer

 Double column planer provide more rigid structure for operation;

however, the two columns limit the width of the work that can be
handled on this machine
 Broaching
15

 Moves a multiple tooth cutting tool linearly relative to work in

direction of tool axis
 The cutting tool is called a broach and the machine tool is called a
broaching machine
 In certain jobs for which broach can be used, it is a highly productive
method
 Broaching
16

Advantages:
 Good surface finish
 Close tolerances
 Variety of work shapes possible

Limitations:
 Owing to complicated and often custom-shaped geometry, tooling is
expensive
 Types of Broaching
17

External Broaching
 Performed on external surface of a hole
 Creates certain cross sectional shapes

Internal Broaching
 Performed on internal surface of a hole
 A starting hole must be present in the part to insert broach at
beginning of stroke
 Sawing
18

 Cuts narrow slit in work by a tool consisting of a series of narrowly

spaced teeth
 Tool called a saw blade
 Typical functions:
 Separate a workpart into two pieces
 Cut off unwanted portions of part

 In most sawing operations, the work is held stationary and the saw
blade is moved relative to it

 According to the type of blade motion the types of sawing are:

 Hacksawing
 Bandsawing
 Circular sawing
 Hacksawing
19

 Hacksaw is a thin straight tool with cutting teeth on edge

 Linear reciprocating motion of hacksaw blade against work

 Cutting is accomplished only on the forward stroke

 Can also be done manually

 Used mostly for cutoff

operations

Power Hacksaw
 Bandsawing
20

 Involves linear continuous motion of

bandsaw blade, which is in the form
of an endless flexible loop with
teeth on one edge
 Vertical bandsaws can also be used
for contouring and slotting

Bandsaw
 Circular Sawing
21

 Rotating saw blade provides continuous motion of tool past workpart

 Circular sawing is commonly used to cut long bars, tubes, and similar
shapes to the specified length
22

Machining Operations For Special Geometries

• Screw threads
• Gears
 Screw Threads
23

 Threaded hardware components are widely used as

 fasteners in assembly e.g screws, bolts, and nuts
 for transmission of motion in machinery e.g., lead screws in
positioning systems

 Threads - grooves that form a spiral around the outside of a cylinder

(external threads) or the inside of a round hole (internal threads)

 Comparison of thread rolling and thread making using machining?

 Methods for Making Screw Threads
24

External Threads Internal Threads

 Single-Point Threading
 Threading Die  Tapping
 Thread Milling
 Thread Grinding
 Single Point Threading
25

 Simplest and most versatile method

 Uses single-point cutting tool on a lathe

 Starting diameter of the workpiece = major diameter of the screwthread

 Lathe’s lead screw is used to cut a constant spiral

 More than one passes required

 Each ensuing pass traces the same

spiral using ever greater depths of cut

until the desired form of the thread
groove is established

Suitable for low to medium

production
 Threading Die
26

 Die is rotated around the starting cylindrical stock of the proper

diameter, beginning at one end and proceeding to the other end

 Cutting teeth at the opening of the die are tapered

 so that starting depth of cut is less
 finally reaching full thread depth at the trailing side of the die

 Pitch of die = Pitch of screw

 Slit – allows size of opening to
be adjusted

 Cut threads in single pass

 Thread Milling
27

 Form milling cutter is used to shape the threads of a screw

 Shape of cutter = Shape of thread groove

 In this operation, cutter is oriented at an angle equal to the helix

angle of the thread and fed longitudinally as the workpiece is slowly
rotated

 Reasons for preferring thread milling

 Thread size is too large to be cut with die
 Produce more accurate and smoother
threads
 Thread Grinding
28

 Similar to thread milling except

 the cutter is a grinding wheel with the shape of the thread groove
 rotational speed of the grinding wheel is much greater than in milling

 Can be used to completely form threads or to finish threads which

are formed by one of previous processes

 Especially used for threads which are hardened by heat treatment

 Internal Threads - Tapping
29

 Most common process for creating internal threads

 Cylindrical tool with cutting teeth arranged in a spiral is simultaneously

rotated and fed into a pre-existing hole

 Pitch of tool threads = Pitch of threads formed

 Cutting tool is called a tap

 In the simplest version of the process, tapping is performed on a drill

press equipped with a tapping head, which allows penetration into the
hole at a rate that corresponds to the screwpitch
 At the end of the operation, the spindle

rotation is reversed so the tap can be

unscrewed from the hole