MACHINING
MACHINING
DR. S. BHATTACHARYA
The three principal machining processes are classified as turning, drilling and milling. Other operations falling into miscellaneous categories include shaping, planing, boring, broaching and sawing Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning. Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling.
Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but sometimes on lathes or mills. Miscellaneous operations are operations that strictly speaking may not be machining operations in that they may not be swarf producing operations but these operations are performed at a typical machine tool. Burnishing is an example of a miscellaneous operation. Burnishing produces no swarf but can be performed at a lathe, mill, or drill press.
Burnishing is the plastic deformation of a surface due to sliding contact with another object. Visually, burnishing smears the texture of a rough surface and makes it shinier. Burnishing may occur on any sliding surface if the contact stress locally exceeds the yield strength of the material.
There are two basic types of cutting tools: Single point tool; and Multiple-cutting-edge tool A single point tool has one cutting edge and is used for turning, boring and planing. During machining, the point of the tool penetrates below the original work surface of the workpart. The point is sometimes rounded to a certain radius, called the nose radius. Multiple-cutting-edge tools have more than one cutting edge and usually achieve their motion relative to the workpart by rotating. Drilling and milling uses rotating multiple-cutting-edge tools. Although the shapes of these tools are different from a single-point tool, many elements of tool geometry are similar.
Roughing operations are done at high feeds and depths feeds of 0.4-1.25 mm/rev (0.015-0.050 in/rev) and depths of 2.5-20 mm (0.100-0.750 in) are typical. Finishing operations are carried out at low feeds and depths - feeds of 0.0125-0.04 mm/rev (0.0005-0.0015 in/rev) and depths of 0.75-2.0 mm (0.030-0.075 in) are typical. Cutting speeds are lower in roughing than in finishing. A cutting fluid is often applied to the machining operation to cool and lubricate the cutting tool. Determining whether a cutting fluid should be used, and, if so, choosing the proper cutting fluid, is usually included within the scope of cutting condition. Today other forms of metal cutting are becoming increasingly popular. An example of this is water jet cutting. Water jet cutting involves pressurized water in excess of 620 MPa (90 000 psi) and is able to cut metal and have a finished product. This process is called cold cutting, and it increases efficiency as opposed to laser and plasma cutting.