Material Removal Process

1. Material Removal Processes

2. MACHINES USED FOR MACHINING
Lathe Reducing Length/Diameter
Milling Reducing Thickness/Slotting
Drilling Making Hole
Shaper Reducing Thickness/Slotting
Planner Reducing Thickness/Slotting
KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.

3. LATHE
“The Mother of Machines”
KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
It can make Cylindrical and Flat Surface

4. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
TYPES
o Engine Lathe
o Speed Lathe
o Bench Lathe
o Tool Room Lathe
o Special Purpose Lathe
o Gap Bed Lathe

5. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
BASICS

6. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Headstock

7. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Bedways

8. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Carriage/Apron

9. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Tailstock

10. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Lathe Drive Mechanism
Belts are moved from pulley to
pulley to change speeds (rpm)
Pulley System without back
gear: 4 High range speeds
Pulley System with back gear: 4
Low range speeds

11. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Carriage Feed
A. Longitudinal Feed or
“Turning” - The tool is fed along
the work.
C. Cross Feed or “Facing” – The
tool is fed across the work.

12. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Carriage Feed
Power Feed for:
Turning
Facing
Used for greater control and
accuracy.
Speed controlled by the “Quick
Change Gear Box”

13. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Carriage and Apron
The controls on the carriage and apron
control all the tool and carriage
movement.

14. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Lathe Carriage and Apron
Compound
Rest Knob
Half Nut
Lever
Carriage
Lock
Screw
Apron
Hand
Wheel
Apron
Feed
Change
Lever
Compound
Rest
Power
Feed
Clutch
Cross
Slide
Cross
Feed
Knob
Tool Post

15. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
CHUCK
Three Jaw Chuck
- For holding cylindrical
stock centered.
- For facing/center drilling
the end of your aluminum
stock

16. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
CUTTING TOOL

17. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
BASICS MACHING (TURNING)
Excess Material is removed to reduce Diameter
Cutting Tool: Turning Tool

18. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
MACHINING IN LATHE

19. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
TURNING BETWEEN CENTERS

20. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
FACING
machine end of job  Flat surface or to Reduce Length of Job
Turning Tool
Feed: in direction perpendicular to workpiece axis
Length of Tool Travel = radius of workpiece
Depth of Cut: in direction parallel to workpiece axis

21. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
FACING

22. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
KNURLING
A Forming Process: Produce rough textured surface
For Decorative and/or Functional Purpose
Knurling Tool

23. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
GROOVING
Produces a Groove on workpiece
Shape of tool  shape of groove
Carried out using Grooving Tool  A form tool
Also called Form Turning

24. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
PARTING OFF
Cutting workpiece into Two Similar to grooving
Parting Tool
Hogging – tool rides over – at slow feed
Coolant use

25. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
CHAMFERING
Beveling sharp machined edges
Similar to form turning
Chamfering tool – 45°
To
• Avoid Sharp Edges
• Make Assembly Easier
• Improve Aesthetics

26. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
TAPER TURNING
BY FORM TOOL
BY COMPOUND REST

27. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
DRILLING/REAMING/BORING

28. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
LATHE TOOLS
lathe tools are usually shaped
by the machinist using a
grinding wheel
a “boring bar” lets you get deep
inside a part for making an inner
diameter (for holes larger than
available drill bits & reamers)

29. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
DRILLING
Basic hole making processes
account for approximately
50-70% of all the metal removal
processes utilized today
o Drilling
o Reaming
o Tapping
o Boring

30. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
Drills and Reamers
standard “jobber” drill: will flex/walk, follow pilot
stub drill for less walk/greater rigidity
reamers (straight or spiral)
finish off hole (last several thousandths)
precise hole diameter
for insertion of dowel pins, bearings, etc.
plunge while spinning, extract still
countersink: for screw heads & deburring hole
center drill establishes hole position with no walk

31. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
PORTABLE DRILLING MACHINE

32. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
SENSITIVE DRILLING MACHINE
Sensitive
• Light weight-light duty
• Feed of the drill is “sensitive” to the
touch of the operator
• Used primarily for low production

33. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.

34. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
PILLAR / UPRIGHT DRILL PRESS
Upright Drill Press
• Larger than the sensitive
• Can be equipped with a gearbox and
variable speed head
• Hand and automatic feed mechanism
• Automatic coolant system
• Table can move on a rack and pinion
system

35. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
RADIAL DRILL PRESS

36. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.

37. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
GANG DRILLING MACHINE

38. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
MULTI SPINDLE DRILLING MACHINE

39. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
MILLING
Milling is one of the basic machining processes.
Milling is a very versatile process capable of
producing simple two dimensional flat shapes to
complex three dimensional interlaced surface
configurations.

40. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
MILLING PROCESS
The milling process:
– Typically uses a multi-tooth cutter
– Work is fed into the rotating cutter
– Capable of high MRR
– Well suited for mass production
applications
– Cutting tools for this process are called
milling cutters

41. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
CONVENTIONAL UP/DOWN MILLING

42. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
BASIC MILLING OPERATIONS

43. KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Department of Mechanical Engineering
I. SIVA, SL/Mech.
SOME OTHER MILLING OPERATIONS
Saddle Milling Form Milling Slotting Slitting

44. I. Siva
Senior Lecturer
Department of Mechanical Engineering
Faculty ID: 01019
Office: Fitting Carpentry Shop/Workshop Complex
eMail: siva@akce.ac.in