Conventional Machining

Presented by
Ahmad Juang p
 Introduction
• What is conventional machining?

• Various machining operations

Basic Process

Image courtesy - Wiki

 Turning

Fig-2 Basic scheme of Turning

• To produce rotational, axis-symmetric parts.

• Feed motion
• Feed relative to work piece.

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

 Turning Operations
• Facing
• Parting
• Grooving
• Drilling
• Screw cutting

Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel

Ref: Manufacturing Engineering and Technology

Ref:-Manufacturing
Serope Kalpakjian
Science
and Steven
- GhoshR.and
Schimid
Mallik
Effect of Turning on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials

• Physical
• Little effect

• Chemical
• Little effect

Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

• Advantages
• Increased production with medium and high turret lathes.

• Disadvantages
• Limited to rotational parts.
• High equipment cost.
• Significant tool wear.
• Low production rate.
• Large amount of scrap.

Ref: Manufacturing Science - Ghosh and Mallik

 Drilling

• Drilling Operations
• Reaming
• Tapping
• Counterboring Fig-3 Basic scheme of Drilling
• Countersinking
• Centering
• Spot facing

Ref: Manufacturing Engineering and

Image
Technology
Courtesy:-
- Serope
Ghosh and
Kalpakjian
Mallik; and
Manufacturing
Steven R. Schimid
Science
Workpiece Materials
•
Aluminum alloys
• Magnesium alloys
• Copper alloys
• Stainless steels
Effect of Drilling
• Cast iron on Work Material Properties
• Plastics
• Mechanical
• Very thin layer of highly stressed and disturbed material on new
surface.

• Physical
• Little effect

• Chemical
• Increased probability of corrosion at stressed surface
Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie
Advantages
• High production rate.

Disadvantages
• Skilled labor is required according to the hole location and
accuracy.
 Milling

Fig-4 Basic scheme of Milling

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

 Milling Operations
• Slab Milling
• Face Milling
• End Milling

Fig-5 Slab Milling Fig-6 Face Milling

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

Workpiece Materials
• Aluminum
• Brass
• Magnesium
• Nickel
• Steel
• Thermostat plastics
• Titanium
• Zinc

Ref: Troubleshooting Manufacturing Processes – Laroux K. Gillespie

Advantages
• Variety of shapes can be obtained

Disadvantages
• Skilled labor is required
• Low to medium production rate
• Limited shape complexity
• High equipment cost
• Significant tool wear
• Large amount of scrap

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
 Boring

Fig-7 Boring operation

Image Courtesy:- http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm

Boring Operations
• Single-Edge Boring
• Multi-Edge Boring
• Step Boring
• Reaming

Workpiece Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel
Ref: Manufacturing Processes Reference Guide – Robert
Ref:H.www.coromant.sandvik.com/boring
Tadd, Dell K. Allen and Leo Alting
Effect of Boring on Work Material Properties
• Mechanical
• Creates residual stresses, micro cracks
• May cause workhardening of unhardened materials
• Physical
• Little effect
• Chemical
• Little effect

Advantages
• Finish machining of cylindrical surfaces on very large workpieces.

Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alting
 Broaching

Broaching Operations
Fig-8 Broaching Tool

• Surface Broaching
• Pull down Broaching
• Push Broaching
• Pot Broaching

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond
Image Courtesy:-
F. Veilleux
wiki
 Workpiece Materials
• Aluminum
• Brass
• Bronze
• Plastic
• Malleable Iron

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux
Advantages
• External and internal flat surfaces
• Good surface finish
• High production rate
• Less skilled labor is required
• Reduced cycle times
• Increased tool life
• Reduced maintenance
• Complex and irregular shapes.

Disadvantages
• Costly tooling

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schimid
 Shaping

Fig-9 Basic scheme of Shaping

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

Fig-10 Shaper Mechanism

Image Courtesy:- http://www.roymech.co.uk/images9/shaper_mechanism_6.gif

Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on
relatively small surfaces.

Disadvantages
• Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik

 Planing

Fig-11 Basic scheme of Planing

Image Courtesy:- Ghosh and Mallik; Manufacturing Science

Advantages
• Suitable for low quantity production.
• Flat surfaces and straight profiles can be obtained on large
surfaces.

Disadvantages
• Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik

 References
• Books
• Manufacturing Science by Amitabha Ghosh and Asok Kumar Mallik, East-
West Press Pvt Ltd.
• Tool and Manufacturing Engineers Handbook, Volume 1 – Machining by
Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux, Society
of Manufacturing Engineers Publications Committee
• Troubleshooting Manufacturing Processes by Laroux K. Gillespie, Society
of Manufacturing Engineers Publications Committee
• Manufacturing Engineering and Technology by Serope Kalpakjian and
Steven R. Schimid, Pearson Education
• Manufacturing Processes Reference Guide by Robert H. Tadd, Dell K. Allen
and Leo Alting, Industrial Press
• Websites
• http://www.roymech.co.uk/images9/shaper_mechanism_6.gif
• http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm
• http://www.coromant.sandvik.com/boring
Thank you