Cyrys Gaile V.

Peralta
BSABE 2-3
ENGR 2320 – Materials and Processes for ABE
Laboratory Exercise 6 – Machine Shop: Machining Operation and Processes

Introduction
Machining is a manufacturing technique that involves removing undesired elements from
a workpiece and transforming it into the desired shape with the help of cutting tools. Machines
can range from very simple lathes which can make cylindrical objects all the way up to
specialized machines like surface grinders which have multiple heads that allow for contouring.
The workpiece is cut from a huge piece of stock. The huge stock could be solid bar, flat sheet,
beam, or even hollow tubes in any configuration. The procedure can also be used on an existing
part, such as a forging or a casting. The procedure can also be used on an existing part, such as a
forging or a casting.
Machining is a type of production that entails removing material with revolving cutting
tools or drills and then inspecting the product for flaws. The first step in machining is to create
the blueprint from which the machine parts are produced. This blueprint consists of size and
shape of the final products. The machine operator then uses die set to cut slots in a workpiece for
different tools to fit through. The machine tool can be thought of as a craftsman's tool that allows
a machinist to modify an object by removing material selectively. A lathe, for example, would be
required if you decided to cut out a cylinder. There are many different types of machining such
as milling, drilling, turning, and grinding.
Turning, drilling, and milling are the three main types of machining operations. Boring,
sawing, shaping, and broaching are some of the additional processes that come into the
miscellaneous category. Each machining operation necessitates the use of a certain machine tool.
The workpiece, the tool, and the chip are the three essential elements of machining. Any
cutting activity requires relative motion between the tool and the workpiece. The tool's cutting
operation removes unwanted material from the workpiece.
To remove superfluous material during the fabrication of a part, a number of machining
procedures and techniques are required. Cutting tools, abrasive wheels, and discs, among other
things, are commonly used in these procedures. Machining processes can be carried out on stock
mill shapes like bars and flats, or on parts created by previous manufacturing procedures like
casting or welding. With the advent of additive manufacturing, machining has been dubbed a
"subtractive" process, referring to the removal of material to create a final item.
II. Objectives
After performing the exercise, you are expected to:
a) Identify and be familiarize with the different processes in a workshop such as shaping,
machining, joining and surface finishing processes.
b) Identify the different tools and machines used in workshops. It includes drill press, lathe
machine, milling machine, electric arc welding and an oxyacetylene welding.
c) Discuss the principle of operations for each tool/machine used in workshops.
d) Identify

III. Activities
Research on the internet or available text book an answer the following:
1. Define and discuss the different processes and operations being done in a workshop. It
includes shaping, machining, joining and surface finishing processes

1. Machine turning
The work item is rotated while the cutter operates in a linear manner during turning. As a
result, the object takes on a cylindrical shape. For all turning activities, a lathe is the equipment
of choice. Turning, like most other machining operations, can be performed manually. The
disadvantage of manual turning is that it necessitates constant observation. This is not the case
with automatic turning. All of the movements, speeds, and tooling modifications are
programmed into a computer with Computer Numerical Control, or CNC. These instructions are
then delivered to the lathe to be finished. CNC allows for high-volume manufacturing runs to be
consistent and efficient.
2. Machine Drilling
Drilling is the process of making a circular hole in a material. Drilling is usually done
using a drill or tapping machine, although it can also be done with a milling machine. Chips are
discarded metal bits created during the machining of a workpiece. The drill bit's design allows
chips to drop away out from workpiece, keeping it clean of debris. Drifting or leading-off is
reduced by keeping the drill perpendicular to the workpiece. Before drilling, a core drill process
is frequently added for even more precision. Angular drilling is required in several drilling
operations. Angular drilling necessitates the use of specialized work-holding equipment. Other
possibilities include using many axes on a CNC machine or rotating the head on a mechanical
machine.

There are a few things you can do to avoid drifting:

 Casting/molding/forging a mark
  Center punching
 Spot drilling/center drilling
 Spot facing
Different drill bits are available for specialized drilling activities, just as they are for
turning operations. A few unique drill bits are shown here, along with their applications.
 Spotting Drills - spotting drills are used to make shallow or pilot holes. If you use a
longer drill for these small holes, the drill may stray.
 Peck Drilling - The drill should be retracted often to clean chips from the workpiece and
prevent wandering.
 Screw Machine Drills - These little drills can drill straight and accurate holes without the
need for spotting.
 Chucking Reamers - To widen previously drilled holes to extremely exact dimensions,
this tool is utilized.

3. Milling Process
Milling procedures require removing material from a workpiece with multi-point rotary
cutters.
Face milling and peripheral milling are the two basic types of milling procedures
 Peripheral milling cuts deep slots, threads, and gear teeth.
 Face milling cuts flat surfaces into the workpiece and flat-bottomed cavities. The feed
can be either horizontal or vertical.

There are two techniques to feed the workpiece into the cutting tool. In traditional
milling, the workpiece is fed against the rotation of the cutter. For manual milling machines, this
is the recommended procedure. On the other hand, climb milling feeds the material in the same
orientation as the cutter rotation. For CNC milling, this is the favored procedure.
Milling is best used as a finishing step on a workpiece that has already been machined. It
acts as a "finishing coat" and helps to define features. Add features like holes, slots, pockets, and
curves with milling as a secondary operation.

4. Shaping Process
Shaping, like planing, is a separate industrial operation that removes the work material.
Shaping differs from planing in that the operations of the workpiece and the cutting tool are
reversed. The cutting tool revolves while the workpiece tends to stay during shaping. The term
"shaping" refers to the process of altering the size and shape of an object. It will eliminate work
material in the same way as planing does. While slab from the stationary workpiece, the cutting
tool will press it against. However, unlike planing, it does not provide a carved surface.

5. Joining process
The ability to fuse or "connect" two or more components for the goal of creating a
distinct entity, such as a ready-to-sell consumer product, is what distinguishes joining
procedures. Many materials can be linked, and there are usually several options for doing so.
Sheet metal can be welded or soldered together, whereas two-by-fours can be nailed or bolted
together.
All joining processes that require the use of a distinct tool or tools to join two or more
elements, and the majority of joining processes involve the use of a distinct tool or tools. The
components are connected using a tool such as a nailgun.
Common types of joining processes used in the manufacturing industry include the following:
 Welding
 Brazing
 Soldering
 Bonding
 Nailing
 Screwing
 Bolting
 Riveting
 Clinching
 Stapling
 Press fitting

6. Grinding
Grinding is a process that removes metal from an object's surface using a revolving
abrasive wheel. It's usually a finishing procedure that gives workpieces that have already been
manufactured through other processes a smoother texture and high dimensional precision. This
process removes very little metal. Grinding can also be used to machine materials that are too
difficult to machine using other methods. External cylindrical grinding, includes roller bearing
grinding, (2) Internal cylindrical grinding, (3) Surface grinding, and (4) Form grinding are the
various types of grinding procedures.

2. List the different machines use in a workshop and discuss how it is being operated or how it
works.
1. Turning machines
 The horizontal metal-turning machine, often known as an engine lathe, is the most
significant of all machine tools. Many of its core mechanical principles are included into the
construction of other machine tools, making it the father of all other machine tools.
The engine lathe is a simple piece of equipment that can be used for a range of operations
including turning, facing, and drilling. It turns and bores with a single-point cutting tool. Turning
procedures includes twisting straighter or tapered cylinder shapes, grooves, shoulders, and screw
threads, as well as exposing flat surfaces on the ends of cylindrical pieces, and entail cutting
extra metal from the exterior diameter of a workpiece in the form of chips. Most typical hole-
machining operations, like drilling, boring, reaming, counter boring, countersinking, and
threading with a single-point tool or tap, are included in internal cylindrical operations.
Boring is the process of widening and completing a cored or drilled hole. Bored holes are
more accurate than drilled holes in terms of roundness, concentricity, and parallelism. A single-
point cutter that runs down the inside of material is used to bore a hole. Boring mills are intended
for boring and turning processes on items that are too large to be put on a lathe, and they have
circular horizontal tables which move around a vertical axis.

2. Shapers and planers

Single-point tools are used to machine flat surfaces, grooves, shoulders, T-slots, and
angular surfaces during shaping and planning operations. The largest shapers can process
components up to 36 inches long and have a 36-inch cutting stroke. The shaper's cutting tool
oscillates, cutting on the forward stroke and automatically feeding the workpiece toward the tool
on the return stroke.
Planing machines are similar to shapers, however they can handle longer workpieces.
Some planers can cut pieces as long as 50 feet. The workpiece is held in place by a revolving
table that moves it under a milling cutter. After each cutting stroke, this tool, which remains
unchanged during the cutting stroke, mechanically feeds into the workpiece.

3. Drilling machines
Drilling machines, also known as drill presses, use a twist drill to make holes in metal.
They also employ a range of other cutting tools to accomplish basic hole-machining operations
like as reaming, boring, counterboring, countersinking, and tapping internal threads with a
tapping attachment.

4. Milling machines
 The material is pushed against with a revolving metal blade called a milling cutter in a
milling machine, which cuts metal. For a wide range of milling operations, cutters of various
shapes and sizes are offered. Flat surfaces, grooves, shoulders, inclined surfaces, dovetails, and
T-slots are all cut with milling machines. For cutting curved forms and convex grooves, rounding
corners, and cutting gear teeth, various form-tooth cutters are utilized.
Milling machines are grouped into three types: standard knee-and-column machines,
including horizontal and vertical variants; bed-type or manufacturing machines; and special
milling machines.

5. Grinding machines
Grinding machines use a spinning abrasive wheel, also known as a grinding wheel or an
abrasive belt, to remove microscopic chips from metal parts. The most precise of all the basic
machining techniques is grinding. Hard or soft items are ground to precision of plus or minus
0.0001 inch using modern grinding machines (0.0025 millimeter).
Plain cylindrical, internal cylindrical, centerless, surface, off-hand, special, and abrasive-
belt grinding machines are some of the most prevalent.

6. Power saws
Power hacksaws, band saws, and circular disk saws are the three major forms of metal-
cutting power saws. Vertical band saws are used to cut shapes in metal plates, curves on the
inside and outside, and angular cuts.

7. Presses
Shearing, blanking, shaping, drawing, bending, forging, coining, upsetting, flanging,
squeezing, and hammering are some of the operations used to make metal parts. All of these
operations necessitate presses that have a moveable ram that can be pressed against an anvil or a
base. Gravity, mechanical connections, hydraulic or pneumatic systems may all be used to power
the moving ram.
Appropriate die sets are an integral element of the machine, with one portion installed on
the moveable ram and the other part placed on the solid matrix or platen. Punch presses are
machines that stamp metal pieces from sheet metal and mold them to the desired shape. On
forming presses, dies with a range of shapes are used to mold white-hot metal blanks into the
necessary shapes. Shearing, bending, flanging, and shaping sheet metal pieces of all sizes are
also done with power presses. Power presses come in a variety of sizes, from small presses that
can be put on a workbench to machines that weigh over a million pounds (450,000 kilograms).
3. Identify the different safety and health standards when operating the different machines in a
workshop.

 Always keep your hands, hair, and feet away of any moving machinery. Keep an
eye on everything that moves, especially cutting instruments and chucks. After making
adjustments, remove chuck keys, wrenches, and other tools from the machines.
 Materials for workshops should be kept in sufficient quantity at the work area. Massive
storage at the workplace is inefficient and contributes to traffic congestion.
 For incompatible materials, segregation in storage is required. Flammable substances, in
particular, must be kept in a properly constructed, designated, and situated flammable
store.
 Heavy, big, or awkward goods should be stored in such a way that moving them does not
require bending or reaching. They should not be kept over the shoulder or below the
knee.
 To avoid confusion or unintended interaction with incompatible compounds, all
substances must be carefully labeled. Remove or hide the old label after cleaning the
container and relabel it when reusing it. Food containers, in particular, should not be used
to store solvents or chemicals.
 Materials should be kept in the proper containers. Broken glass and sharps must be kept
in a steel or strong plastic bin that is clearly labeled (never cardboard). Instead of flimsy
cardboard boxes or cartons, rigid containers must be employed. Shelving must be secure
and never overloaded. Ensure that freestanding shelves and cupboards are secured to
walls.
 Materials must be stored in such a manner to avoid spillage, leakage, breakage or falls.
 Stored objects should be examined on a regular basis to ensure that they are properly
stored and that obsolete goods are removed. Items that are deteriorating, no longer useful,
or not necessary should be identified through effective stock rotation.

1. Dress for the Occasion

In your workspace, avoid wearing baggy, loose, or otherwise ill-fitting apparel.
Wearing jewelry or other loose-hanging objects is not a good idea.
2. Vision Protection
Wear safety glasses when working because when cutting, sanding, etc., wood
chips and particles can fly up into your face and eyes at any time.
3. Keep Your Workshop Clean
Keeping the workplace clean and neat, as well as eliminating another potential
safety danger. It is necessary to clean out all electrical contractors on your devices on a
regular basis, not only to avoid a fire hazard, but also to ensure that they do not
malfunction. The main cause of machines not starting is fine sawdust blocking contactors
and switches.
4. No Drugs, Alcohol Or Other Impairments
It dampens your ability to operate machinery properly.
 5. Keep Tools And Equipment Sharp
Maintaining a clean and orderly workplace, as well as removing another potential
safety hazard. Not only to minimize a fire threat, but also to ensure that your equipment
do not malfunction, it is vital to clean out all electrical contractors on a regular basis. Fine
sawdust obstructing contactors and switches is the most common cause of machines not
starting.
6. Avoid Unnecessary Distractions
Machine requires utmost and full attention when working on them.
7. Use Safety Tools To Assist You
Use tools to keep the workpiece solid while keep your arms away from of the
cutter blade.
8. Inspect Timber For Nails, Knots Or Any Imperfections
Examine the wood you're dealing with. It may contain flaws that cause it to kick
back, become stuck, or bind on the blade, among other things. It is critical to inspect your
workpiece before cutting or machining.
9. Electrical Extension Cords
Cord should not be strung over the floor and knotted. Reduce the risk of tripping
in your shop, as well as the potential for expensive power tools to be damaged if the wire
becomes tangled in your foot.
10. Read The Book
Knowing how each equipment works and what it can do will keep you safe.

References
Machining, Machining Operations & Types of Machining Tools. (n.d.). Engineering
Articles. Retrieved from https://www.engineeringarticles.org/machining-operation-and-types-of-
machining-tools/
Machining, Elements of machining. (2016, January 13). Scholarexpress. Retrieved from
https://scholarexpress.com/machining-elements-of-machining/
Different Types of Machining Operations and the Machining Process. (n.d.). Thomas
Net. Retrieved from https://www.thomasnet.com/articles/custom-manufacturing-fabricating/
machining-processes/
Team, T. C. (2020, October 23). Machining Processes: Turning, Milling, and Drilling -.
Trimantec. Retrieved from https://trimantec.com/blogs/t/machining-processes-overview
Monroe Engineering. (2020, August 18). Planing vs Shaping in Manufacturing: What's
the Difference? Retrieved from https://monroeengineering.com/blog/planing-vs-shaping-in-
manufacturing-whats-the-difference/
 Monroe Engineering. (2020, January 28). Joining vs Forming Manufacturing Processes:
What's the Difference? Retrieved from https://monroeengineering.com/blog/joining-vs-forming-
manufacturing-processes-whats-the-difference/
Surface finishing processes. (2007). SpringerLink. Retrieved from
https://link.springer.com/chapter/10.1007/978-3-8248-9415-4_18
Machine tool - Basic machine tools. (n.d.). Encyclopedia Britannica. Retrieved from
https://www.britannica.com/technology/machine-tool/Basic-machine-tools
Zach, M. (n.d.). General Safety Rules | Machine Safety at Carleton | Carleton College.
Carleton. Retrieved from https://apps.carleton.edu/machinesafety/rules/
General workshop safety, Hazard management, Health And Safety Compliance. (n.d.).
University of Otago. Retrieved from
https://www.otago.ac.nz/health-safety/hazards/otago064790.html