This document discusses various machining processes used to produce complex shapes beyond simple round profiles. It describes milling operations like face milling and slab milling. Milling can produce parts with intricate shapes efficiently using computer numerical control (CNC) machines. Other shaping processes covered include broaching, sawing, and gear cutting. Broaching is well-suited for producing internal and external spline and gear teeth. Gears can be generated through hobbing, shaping, or fine-finished through grinding. The document explores the different machining methods, tools, and economics of producing complex geometries.

1. CHAPTER 23
Machining Process Used to Produce
Various Shapes

2. Introduction
• Addition to producing various external or internal round
profiles,cutting operations can produce many other parts with more
complex shapes
Fig:Typical parts and shapes produced with the machining process

3. Milling Operation
• Highly versatile machining operation
• Multitooth tool that produces a number of chips in one revolution
Fig:Some of the basic type milling cutters and milling operations.

4. Fig : A typical part that can be produced on a milling machine equipped with computer controls.Such
parts can be made efficiently and respectively on computer numerical control (CNC) machines,
without the need for refixturing or reclamping the part
Example of a part produces in a CNC
milling machine

5. Slab Milling
• Slab milling also called as peripheral milling
• Cutters have straight or helical teeth resulting in
orthogonal or oblique cutting action
Fig : (a) Conventional milling and climb milling (b) Slab milling operation, showing depth of
cut , d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v. (c) cutter travel
distance lc to reach full depth of cut.

6. Milling parameters

7. Face Milling
• The cutter is mounted on a spindle having an axis of rotation perpendicular
to the workpiece surface.
Fig : Face milling operation showing (a) action of an insert in face
milling; (b) climb milling; (c) conventional milling d)dimensions in
face milling. The width of cut, w, is not necessarily the same as
the cutter radius
Fig:A face milling cutter with indexable inserts.

8. Effects of Inserts Shapes
Fig:The effect of insert shape on feed marks on a face-milled surface (a) small corner radius, (b) corner
flat on insert, and (c) wiper consisting of a small radius followed by a large radius which leaves
smoother feed marks (d) feed marks due to various insert shapes

9. Face milling cutter
Fig:Terminology for a face milling cutter

10. Effect of Lead Angle
Fig : The effect of Lead angle on the undeformed chip thickness in face milling. Note that as the lead
angle increases, the chip thickness decreases, but the length of contact (i.e. chip width) increases.
The insert in (a) must be sufficiently large to accommodate the contact length increases

11. Cutter and Insert position in Face Milling
Fig : (a) Relative position of the cutter and insert as it first engages the workpiece in face milling, (b)
insert positions towards the end of cut, and (c) examples of exit angles of insert, showing
desirable (positive or negative angle) and undesirable (zero angle) positions. In all figures, the
cutter spindle is perpendicular to the page.

12. Cutters for different types of Milling
Fig : Cutters for (a) Straddle Milling, (b) form milling, (c) slotting, and (d) slitting with a milling cutter.

13. Other Milling Operations and Cutters
Fig : (a) T-slot cutting
with a milling
cutter. (b) A shell
mill.

14. Arbors
Fig : Mounting a milling cutter on an arbor for use on a horizontal milling machine.

15. Surface Features and Corner defects
Fig : Surface features and corner defects in face milling operations

16. Horizontal and Vertical Spindle Column
and Knee type Milling Machines
Fig : Schematic illustration of a vertical-spindle
column-and-knee type milling machine.
Fig : Schematic illustration of a horizontal-spindle
column-and-knee type milling machine.

17. Bed Type Milling Machine
Fig : Schematic illustration of a bed-type milling machine. Note the single vertical-spindle cutter
and two horizontal-spindle cutters.

18. Additional Milling Machines
Fig : Schematic illustration of a five-axis profile milling
machine. Note that there are three principal linear
and two angular movements of machine components.
Fig : A computer numerical control, vertical-spindle milling
machine. This machine is one of the most versatile
machine tools.

19. Examples of parts made one Planer and
by Broaching
Fig : Typical parts that can be made on a planer.
Fig : (a) Typical parts that can be made by internal
broaching. (b) Parts made by surface broaching. Heavy
lines indicate broached surfaces.

20. Broaches
Fig : (a) Cutting action of a broach, showing various features. (b) Terminology
for a branch.

21. Chipbreakers and a Broaching Machine
Fig : Chipbreaker features on (a) a flat broach and (b) a round broach. (c) Vertical broaching machine.

22. Internal Broach and Turn Broach
Fig : Terminology for a pull-type internal broach
used for enlarging long holes.
Fig : Turn broaching of a crankshaft. The crankshaft
rotates while the broaches pass tangentially
across the crankshaft’s bearing surfaces.

23. Broaching Internal Splines
Fig : Broaching in internal splines.

24. Sawing Operations
Fig : Examples of various sawing operations.

25. Types of Saw Teeth
Fig : (a) Terminology for saw teeth. (b) Types of tooth set on saw teeth, staggered to
provide clearance for the saw blade to prevent binding during sawing.

26. Saw Teeth and Burs
Fig : High-speed steel teeth welded on steel blade.
(b) Carbide inserts brazed to blade teeth.
Fig : Types of burs.

27. Spur Gear
Fig : Nomenclature for an involute spur gear.

28. Gear Generating
Fig : (a) Producing gear teeth on a blank by form cutting. (b) Schematic illustration of gear generating with a
pinion-shaped gear cutter. (c) Schematic illustration of gear generating in a gear shaper using a pinion-
shaped cutter. Note that the cutter reciprocates vertically. (d) Gear generating with rack-shaped cutter.

29. Gear Cutting with a Hob
Fig : Schematic illustration of
three views of gear cutting
with a hob.

30. Cutting Bevel Gears
Fig : (a) Cutting a straight bevel-gear blank with two cutters. (b) Cutting a spiral bevel gear
with a single cutter.

31. Gear Grinding
Fig : Finishing gears by grinding: (a) form grinding with shaped grinding wheels; (b) grinding by
generating with two wheels.

32. Economics of Gear Production
Fig : Gear Manufacturing
cost as a function of
gear quality. The
numbers along the
vertical lines
indicate tolerances.

33. THE END