Manufacturing Engineering Technology in SI Units, 6th Edition
Chapter 23:
Machining Processes: Turning and Hole Making
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Chapter Outline
1. Introduction
2. The Turning Process
3. Lathes and Lathe Operations
4. Boring and Boring Machines
5. Drilling, Drills, and Drilling Machines
6. Reaming and Reamers
7. Tapping and Taps
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Introduction
Machining processes has the capability of producing
parts that are round in shape
Such as miniature screws for the hinges of eyeglass
frames and turbine shafts for hydroelectric power plants
Most basic machining processes is turning where part is
rotated while it is being machined
Turning processes are carried out on a lathe or by
similar machine tools
Highly versatile and produce a wide variety of shapes
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Introduction
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Introduction
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Introduction
Turning is performed at various:
1. Rotational speeds, N, of the workpiece clamped in a
spindle
2. Depths of cut, d
3. Feeds, f, depending on the workpiece materials, cutting-
tool materials, surface finish, dimensional accuracy and
characteristics of the machine tool
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The Turning Process
Majority of turning operations use simple single-point
cutting tools, which is a right-hand cutting tool
Important process parameters have a direct influence
on machining processes and optimized productivity
Tool Geometry
Rake angle control both the direction of chip flow and
the strength of the tool tip
Side rake angle controls the direction of chip flow
Cutting-edge angle affects chip formation, tool strength
and cutting forces
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The Turning Process
Tool Geometry
Relief angle controls interference and rubbing at the
tool–workpiece interface
Nose radius affects surface finish and tool-tip strength
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The Turning Process
Tool Geometry
Material-removal Rate
The material-removal rate (MRR) is the volume of
material removed per unit time (mm3/min)
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The Turning Process
Material-removal Rate
D + Df
The average diameter of the ring is Davg = 0
2
Since there are N revolutions per minute, the removal
rate is
MMR = πDavg dfN or reduce to MMR = dfV
Since the distance traveled is l mm, the cutting time is
l
t=
fN
The cutting time does not include the time required for
tool approach and retraction
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The Turning Process
Forces in Turning
The 3 principal forces acting on a cutting tool are
important in the design of machine tools, deflection of
tools and workpieces for precision-machining operations
Cutting force acts downward on the tool tip and deflect
the tool downward and the workpiece upward
Thrust force (or feed force) acts in the longitudinal
direction
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The Turning Process
Roughing and Finishing Cuts
First practice is to have one or more roughing cuts at
high feed rates and large depths of cut
Little consideration for dimensional tolerance and
surface roughness
Followed by a finishing cut, at a lower feed and depth of
cut for good surface finish
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The Turning Process
Tool Materials, Feeds, and Cutting Speeds
The range of applicable cutting speeds and feeds for a
variety of tool materials is shown
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The Turning Process
EXAMPLE 23.1
Material-removal Rate and Cutting Force in Turning
A 150-mm-long, 12.5-mm-diameter 304 stainless steel rod
is being reduced in diameter to 12.0 mm by turning on a
lathe. The spindle rotates at N 400 rpm, and the tool is
travelling at an axial speed of 200 mm/min. Calculate the
cutting speed, material-removal rate, and cutting time.
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The Turning Process
Solution
Material-removal Rate and Cutting Force in Turning
The maximum cutting speed is
π (12.5)(400 )
V = πD0 N = = 15.7 m/min
1000
The cutting speed at the machined diameter is
π (12.0 )(400 )
V = πD0 N = = 15.1 m/min
1000
The depth of cut is d = 12.5 − 12.0 = 0.25 mm
2
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The Turning Process
Solution
Material-removal Rate and Cutting Force in Turning
200
The feed is f = = 0.5 mm/rev
400
The material-removal rate is
MMR = (π )(12.25)(0.25)(0.5)(400 ) = 1924 mm3 /min = 2 ×10 −6 m 3 /min
The actual time to cut is
150
t= = 0.75 mm
(0.5)(400)
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Lathes and Lathe Operations
Lathes are considered to be the oldest machine tools
Speeds may range from moderate to high speed
machining
Simple and versatile
But requires a skilled machinist
Lathes are inefficient for repetitive operations and for
large production runs
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Lathes and Lathe Operations:
Lathe Components
Lathe Specifications
1. Max diameter of the workpiece that can be machined
2. Max distance between the headstock and tailstock
centers
3. Length of the bed
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Lathes and Lathe Operations:
Workholding Devices and Accessories
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Lathes and Lathe Operations:
Types of Lathes
Turret Lathes
Perform multiple cutting operations, such as turning,
boring, drilling, thread cutting, and facing
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Lathes and Lathe Operations:
Types of Lathes
Computer-controlled Lathes
Movement and control of the machine tool and its
components can be achieved
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Boring and Boring Machines
The cutting tools are mounted on a boring bar to reach
the full length of the bore
Boring bars have been designed and built with
capabilities for damping vibration
Large workpieces are machined on boring mills
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Boring and Boring Machines
In horizontal boring machines, the workpiece is
mounted on a table that can move horizontally in both
the axial and radial directions
A vertical boring mill is similar to a lathe, has a vertical
axis of workpiece rotation
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Boring and Boring Machines
Design Considerations for Boring:
1. Through holes should be specified
2. Greater the length-to-bore-diameter ratio, the more
difficult it is to hold dimensions
3. Interrupted internal surfaces should be avoided
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Drilling, Drills, and Drilling Machines
Holes are used for assembly with fasteners, for design
purposes or for appearance
Hole making is the most important operations in
manufacturing
Drilling is a major and common hole-making process
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Drilling, Drills, and Drilling Machines: Drills
Drills have high length-to-diameter ratios, capable of
producing deep holes
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Drilling, Drills, and Drilling Machines: Drills
Drills are flexible and should be used with care in order
to drill holes accurately and to prevent breakage
Drills leave a burr on the bottom surface upon
breakthrough, necessitating deburring operations
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Drilling, Drills, and Drilling Machines: Drills
Twist Drill
The most common drill is the conventional standard-
point twist drill
The geometry of the drill point is such that the normal
rake angle and velocity of the cutting edge vary with the
distance from the center of the drill
Main features of this drill are:
1. Point angle
2. Lip-relief angle
3. Chiseledge angle
4. Helix angle
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Drilling, Drills, and Drilling Machines: Drills
Twist Drill
Drills are available with a chip-breaker feature ground
along the cutting edges
Other drill-point geometries have been developed to
improve drill performance and increase the penetration
rate
Other Types of Drills
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Drilling, Drills, and Drilling Machines:
Material-removal Rate in Drilling
The material-removal rate (MRR) in drilling is the
volume of material removed per unit time
⎛ πD 2 ⎞
MMR = ⎜⎜ ⎟⎟ fN
⎝ 4 ⎠
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Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
EXAMPLE 23.4
Material-removal Rate and Torque in Drilling
A hole is being drilled in a block of magnesium alloy with a
10-mm drill bit at a feed of 0.2 mm/rev and with the spindle
running at N = 800 rpm. Calculate the material-removal
rate.
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Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
Solution
Material-removal Rate and Torque in Drilling
The material-removal rate is
⎛ π (10) 2 ⎞
MMR = ⎜⎜ ⎟⎟(0.2)(800) = 12,570 mm3 / min = 210 mm3 /s
⎝ 4 ⎠
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Drilling, Drills, and Drilling Machines:
Drill Materials and Sizes
Drills are made of high-speed steels and solid carbides
or with carbide tips
Drills are coated with titanium nitride or titanium carbon
nitride for increased wear resistance
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Drilling, Drills, and Drilling Machines:
Drilling Practice
Drilling Recommendations
The speed is the surface speed of the drill at its
periphery
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Drilling, Drills, and Drilling Machines:
Drilling Practice
Drilling Recommendations
The feed in drilling is the distance the drill travels into
the workpiece per revolution
Chip removal during drilling can be difficult for deep
holes in soft and ductile workpiece materials
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Drilling, Drills, and Drilling Machines:
Drilling Practice
Drill Reconditioning
Drills are reconditioned by grinding them either
manually or with special fixtures
Hand grinding is difficult and requires considerable skill
in order to produce symmetric cutting edges
Grinding on fixtures is accurate and is done on special
computer controlled grinders
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Drilling, Drills, and Drilling Machines:
Drilling Practice
Measuring Drill Life
Drill life is measured by the number of holes drilled
before they become dull and need to be re-worked or
replaced
Drill life is defined as the number of holes drilled until
this transition begins
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Drilling, Drills, and Drilling Machines:
Drilling Machines
Drilling machines are used for drilling holes, tapping,
reaming and small-diameter boring operations
The most common machine is the drill press
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Drilling, Drills, and Drilling Machines:
Drilling Machines
The types of drilling machines range from simple bench
type drills to large radial drills
The drill head of universal drilling machines can be
swiveled to drill holes at an angle
Numerically controlled three-axis
drilling machines are automate
in the desired sequence
using turret
Drilling machines with multiple
spindles (gang drilling) are
used for high-production-rate
operations
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Reaming and Reamers
Reaming is an operation used to:
1. Make existing hole dimensionally more accurate
2. Improve surface finish
Most accurate holes in workpieces are produced by:
1. Centering
2. Drilling
3. Boring
4. Reaming
For even better accuracy and surface finish, holes may
be burnished or internally ground and honed
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Tapping and Taps
Internal threads in workpieces can be produced by
tapping
A tap is a chip-producing threading tool with multiple
cutting teeth
Tapered taps are designed to reduce the torque
required for the tapping of through holes
Bottoming taps are for tapping blind holes to their full
depth
Collapsible taps are used
in large-diameter holes
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Tapping and Taps
Tapping may be done by hand or with machines:
1. Drilling machines
2. Lathes
3. Automatic screw machines
4. Vertical CNC milling machines
One system for the automatic tapping of nuts is shown
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