Chapter 4 Metal Removal Processes
Chapter 4 Metal Removal Processes
Chapter 4 Metal Removal Processes
Outline
• Introduction to Machining
• Fundamentals of Metal Cutting
• Machining Processes: Turning, Milling, Drilling
and Shaping
• Theory of chip formation in Orthogonal cutting
• Types of chips Produced In Metal cutting
• Cutting Forces and Power
• Tool Wear and Tool Life
• Abrasive Machining Processes
• Machinability
• Selection of Cutting conditions & Machining
Economics
Introduction to Machining Processes
• Machining (metal removal process) is the process of
removing unwanted (excess) material from the workpiece
in the form of chip to get the desired final geometry.
• Machining is important commercially and technologically
for several reasons.
Variety of work materials
Variety of part shapes and geometric features
Dimensional accuracy
Good surface finishes
• Disadvantages
Wasteful of material
Time consuming
Classification of Machining Processes
Metal cutting (conventional processes)
The process in which a thin layer of excess metal (chip) is
removed by a wedge-shaped single-point or multipoint
cutting tool with defined geometry through a process of
extensive plastic deformation.
e.g. turning, milling, drilling, shaping, boring, planing, etc.
Abrasive processes:
Material removal by the action of hard, abrasive particles that
are usually in the form of a bonded wheel.
Each single particle acts like a single-point cutting tool.
e.g. Grinding
Non-traditional processes:
• Machining with mechanical, electrochemical, thermal and
chemical sources of energy.
e.g. EDM, ECM, Water Jet Machining, Ultrasonic Machining,
etc.
The Cutting Tool
• A sharp cutting tool is used to mechanically cut the
material to achieve the desired geometry.
• A cutting tool has one or more sharp cutting edges
and is made of a material that is harder than the work
material.
• The cutting edge serves to separate a chip from the
parent work material.
• A single-point tool has one cutting edge and is used
for operations such as turning.
• Multiple-cutting-edge tools have more than one
cutting edge and usually achieve their motion relative
to the workpart by rotating.
• Drilling and milling use rotating multiple-cutting-
edge tools.
Effect of cutting speed on tool flank wear (FW) for three cutting
speeds. Hypothetical values of speed and tool life are shown for a
tool life criterion of 0.50mm flank wear.
• In production, it is often a disadvantage to use the tool
until this failure occurs because of difficulties in
resharpening the tool and problems with work surface
quality.
• As an alternative, a level of tool wear can be selected
as a criterion of tool life, and the tool is replaced when
wear reaches that level.
• A convenient tool life criterion is a certain flank wear
value, such as 0.5mm.
• When each of the three wear curves intersects that line,
the life of the corresponding tool is defined as ended.
Taylor Tool Life Equation
vTn = C
where v = cutting speed, m/min (ft/min); T = tool life, min;
and n and C are parameters whose values depend on feed,
depth of cut, work material, tooling (material in particular),
and the tool life criterion used.