Production Engineering Lecture 6

Course Title & Instructor

• Course title: Production Engineering
• Instructor: M. Mohamed Ryead
• Lecture: 6
• Level: 1

Chip Forming Cutting

• Chip forming cutting is the separation or reduction of a material by removing chips.
• The cutting tool is harder than the workpiece.
• Machining is a specific type of chip forming cutting.

Machining

• Machining is a process where cutting achieves tolerances of at least ±0.005".
• The workpiece and cutting tool are held in precise relationship.
• Speed, feed, and rate of cutting, along with proper coolants and lubricants are crucial for economical and tool-life considerations.
• Machining is often a secondary process following forming, but it precedes finishing and joining processes.

Machining and Turning Centers

• Machining centers bring multiple cutters to the workpiece instead of moving the workpiece itself.
• This significantly reduces setup repositioning time and related potential errors.
• Modern machining centers are computer-controlled and fully automated, enabling tool changing and diverse cutting operations on multiple surfaces.
• Turning centers are computer-controlled lathes that can have dual turrets with twin turret changers.

Lathe/Turning

• A lathe is used for turning cylindrical solid and hollow shapes, threads, and similar forms.
• The workpiece is held in a chuck and rotates while the cutter, parts of the tool assembly, is controlled by an operator.
• Modern turning centers are automated with up to eight cutting tools.

Milling (Bridgeport)

• Milling is a metal cutting operation where excess material is removed by a rotating multipoint cutting tool (milling cutter).
• Milling machines use a power-operated tool where the workpiece is mounted on a moving table under a rotating serrated cutter to shape it.

Vertical Mill

• Vertical mills resemble drills, but offer more flexibility in cutting and workpiece movement.
• The head tilts and the cutting table is precisely adjustable.

Horizontal Mill

• Horizontal mills resemble vertical mills, but are intended for extended horizontal milling operations.
• These mills are still useful for tool design and repair, and smaller model shops.

Grinding

• Grinding is a surface finishing operation.
• It removes very thin layers of material, producing fine dust particles (0.25-0.5mm thick).
• Grinding is the abrasive action between the rotating abrasive wheel and the workpiece.
• Grinding machines use powerful, consistently rotating abrasive wheels against the moving workpiece.

Drilling

• Drilling is a common machining process utilizing twist drill bits to create holes in the workpiece.
• The process is mainly linear-axis centered.

Drill Bits (Types)

• Wood drill bits are suitable for soft, hardwood, veneer, and plywood.
• Metal drill bits are used for metal, and can also be used for wood.
• Concrete drill bits are designed with thicker carbide tips to withstand concrete's high resistance.

Tile and Glass Drill Bits

• Tile and glass drill bits are shaped like spears.
• Material type and size are factors for using these bits.
• Slow drilling speeds are necessary.

Sawing

• Sawing is often for cutting stock to length for other cutting operations.
• Most industrial machines can saw to extremely precise tolerances (±0.005 inch).
• Basic types include reciprocating and circular (continuous band, disc blade).

Boring

• Boring machines finish-cut internal cylindrical profiles.
• The process uses a cutter mounted on a bar.
• Originally designed for cannon barrel finishing.

Boring Machines (Details)

• Some boring bars have vibration-dampening capabilities.
• "Bore" refers to the internal diameter shaping process.

Dive into Lecture 6 of Production Engineering as we explore chip forming cutting, machining processes, and the significance of machining centers. Understand the critical parameters that influence tool life and machining efficiency. This quiz will test your knowledge of key concepts and techniques in this essential field.