Class 1:

Importance of Tooling for conventional and

non-conventional machining processes
Pre-Requisites: Primary Manufacturing Processes

Manufacturing

Production or manufacturing can be simply defined as value addition processes by which raw
materials of low utility and value due to its inadequate material properties and poor or irregular
size, shape and finish are converted into high utility and valued products with definite dimensions,
forms and finish imparting some functional ability [1].

A typical example of manufacturing is schematically shown in Fig. 1.

Fig. 1: Value addition by manufacturing

A lump of mild steel of irregular shape, dimensions and surface, which had almost no use and
value, has been converted into a useful and valuable product like bolt by a manufacturing process
which imparted suitable features, dimensional accuracy and surface finish, required for fulfilling
some functional requirements.

Production Engineering covers two domains:

a) Production or Manufacturing Processes: This refers to science and technology of

manufacturing products effectively, efficiently, economically and environment-friendly.
 b) Production Management: This is also equally important and essential in the manufacturing
world. It mainly refers to planning, coordination and control of the entire manufacturing in
most profitable way with maximum satisfaction to the customers by best utilization of the
available resources like man, machine, materials and money.

Broad classification of Engineering Manufacturing Processes.

All manufacturing processes can be broadly classified in four major groups as follows:

1. Shaping or forming
Manufacturing a solid product of definite size and shape from a given material taken in
three possible states:
• in solid state – e.g., forging rolling, extrusion, drawing etc.
• in liquid or semi-liquid state – e.g., casting, injection moulding etc.
• in powder form – e.g., powder metallurgical process.
2. Joining process
Welding, brazing, soldering etc.
3. Removal process
Machining (Traditional or Non-traditional), Grinding etc.
4. Regenerative manufacturing
Production of solid products in layer by layer from raw materials in different form:
• liquid – e.g., stereo lithography
• powder – e.g., selective sintering
• sheet – e.g., LOM (laminated object manufacturing)
• wire – e.g., FDM. (Fused Deposition Modelling)

Purpose of Machining

Most of the engineering components such as gears, bearings, clutches, tools, screws and nuts etc.
need dimensional and form accuracy and good surface finish for serving their purposes.
Preforming like casting, forging etc. generally cannot provide the desired accuracy and finish. For
that such preformed parts, called blanks, need semi-finishing and finishing and it is done by
machining and grinding.

Principle of Machining

The basic principle of machining is typically illustrated in Fig. 2.

Fig. 2: Principle of machining (turning)

A metal rod of irregular shape, size and surface is converted into a finished rod of desired
dimension and surface by gradually removing the excess material from the preformed blank (Metal
rod) in the form of chips with the help of cutting tool(s) moved past the work surface(s). (definition
of machining)

Machining requirements

1. Machine Tool
2. Cutting Tool
3. Fixtures
4. Cutting Fluid
5. Power

The blank and the cutting tool are properly mounted (in fixtures) and moved in a powerful device
called machine tool enabling gradual removal of layer of material from the work surface resulting
in its desired dimensions and surface finish. Additionally, some environment called cutting fluid
is generally used to ease machining by cooling and lubrication.
Basic functions of Machine Tools

Machine Tools basically produce geometrical surfaces like flat, cylindrical or any contour on the
preformed blanks by machining work with the help of cutting tools.

The physical functions of a Machine Tool in machining are:

• firmly holding the blank and the tool

• transmit motions to the tool and the blank
• provide power to the tool-work pair for the machining action.
• control of the machining parameters, i.e., speed, feed and depth of cut.

Conventional and Non-Conventional Machining

• Manufacturing processes can be broadly divided into two groups and they are primary
manufacturing processes and secondary manufacturing processes. The former ones provide
basic shape and size to the material as per designer’s requirement. Casting, forming,
powder metallurgy are such processes to name a few.
• Secondary manufacturing processes provide the final shape and size with tighter control
on dimension, surface characteristics etc. Material removal processes are mainly the
secondary manufacturing processes.
• Material removal processes once again can be divided into mainly two groups and they are
“Conventional Machining Processes” and “Non-Traditional Manufacturing Processes”.
• The basic objective of all machining operations is to remove the excess material to obtain
the desired shape and size.
• Conventional machining refers to the traditional methods of material removal using
mechanical tools that are harder than the materials themselves. Examples: Turning,
grinding, drilling, and milling.
• Non-conventional machining refers to a group of modern manufacturing techniques that
do not rely solely on mechanical tools for material removal and the hardness of the cutting
tool may or may not be higher than the material.
• Non-traditional machining processes are also known as non-conventional or advanced
machining processes.
• The major characteristics of conventional machining are:
▪ Generally macroscopic chip formation by shear deformation
▪ Material removal takes place due to application of cutting forces – energy domain can
be classified as mechanical
▪ Cutting tool is harder than work piece at room temperature as well as under
machining conditions

Fig.3: Shear deformation in conventional machining leading to chip formation.

• Non Traditional Machining (NTM) Processes on the other hand are characterized as
follows:
▪ Material removal may occur with chip formation or even no chip formation may take
place. For example, in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical
dissolution at atomic level.
▪ In NTM, there may not be a physical tool present. For example, in laser jet
machining, machining is carried out by laser beam. However, in Electrochemical
Machining there is a physical tool that is very much required for machining.
▪ In NTM, the tool need not be harder than the work piece material. For example, in
EDM, copper is used as the tool material to machine hardened steels.
▪ Mostly NTM processes do not necessarily use mechanical energy to provide material
removal. They use different energy domains to provide machining. For example, in
 USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM
electrochemical dissolution constitutes material removal.

Fig. 4: Schematic representation of various metal cutting operations.

• Need of non-traditional machining processes:

1. Machining New Materials with a low machinability: Non-traditional machining
processes are often employed when conventional machining methods struggle to work
effectively on hard and brittle materials. Materials like hardened steel, ceramics,
composites, and exotic alloys can be difficult to shape using conventional methods but
can be successfully machined using non-traditional processes such as electrical
discharge machining (EDM) or laser cutting. The surface damage can be avoided that
often accompanies the stresses created by conventional machining.
 2. Complex Geometries: Non-traditional machining processes offer greater flexibility
and capability to produce intricate and complex shapes that may be challenging or
impossible to achieve with conventional methods. These processes allow for the
creation of highly precise and intricate features, such as small holes, deep cavities, fine
details, and intricate contours. E.g., drilling a noncircular hole or a microhole.
3. No Tool Wear: Traditional machining methods involve direct physical contact
between the cutting tool and the workpiece, leading to tool wear over time. Non-
traditional machining processes, such as laser cutting or waterjet machining, do not
involve physical contact between the tool and the workpiece, eliminating the issue of
tool wear. This can be advantageous when working with delicate materials or when
maintaining the tool's integrity is crucial.
4. Heat-Sensitive Materials: Certain materials, like heat-treated alloys or heat-sensitive
polymers, can be adversely affected by the heat generated during traditional machining
processes. Non-traditional methods, such as waterjet cutting or abrasive jet machining,
provide a cooler alternative that minimizes heat-affected zones and reduces the risk of
thermal damage to the workpiece.
5. Precision and Accuracy: Non-traditional machining processes often offer high
precision and accuracy, allowing for tight tolerances and fine surface finishes.
Techniques like EDM and laser cutting can achieve extremely small feature sizes and
produce intricate patterns with micron-level precision, making them suitable for
applications that demand high dimensional accuracy.

What Is Tooling Process?

Tooling is the process of designing and engineering the tools that are necessary to manufacture
parts or components. There are many different types of tooling, of which the most common are:
work holding tools, such as jigs and fixtures; cutting tools for milling and grinding machines; dies
for cold forming, sheet metal, forging and extrusion machines; and welding and inspection
fixtures.

Why Is Tooling Important?

The quality of a finished part, its properties, the speed and accuracy with which it can be produced
and the repeatability of manufacture in high volume production runs, all depend on the precision
and characteristics of the tooling. So for the best parts, tooling needs to be designed and engineered
to the highest quality.

What Should Tooling Usually Cost?

The cost of tooling will change from project to project because it depends on so many variables.
However, there is a common misconception that tooling is an expensive and sometimes cost-
prohibitive process. In fact, thanks to modern engineering techniques the tooling costs for CNC
machining and precision cold forming are relatively low in most cases.

What Factors Impact on The Cost of Tooling?

Ensuring high-quality tooling requires a wide range of factors to be considered. For example:

• the tolerances required in the finished part, as these will affect the configuration of the
tooling;
• mechanical strength and rigidity of the tool, as this is essential to ensure workpiece
accuracy, repeatability and quality;
• cutting tool strength, which has to be sufficient to withstand machining forces, especially
in high volume production; and more.

A. Quiz Test:

Select the correct answer from the given four possible answers: -

1. Machining is a
a. shaping process
b. removal process
c. regenerative process
d. joining process.
2. Feed rate is expressed in turning operation by
 a. mm/revolution
b. mm/stroke
c. mm per min
d. none of the above.
3. Rapid prototyping is a
a. joining process
b. removal process
c. regenerative manufacturing process
d. finishing process.

B. Exercises:

1. What should be the aims and objectives in manufacturing of any product?

2. Justify “Machining is a value addition process”.
3. Why even a battery operated pencil sharpener cannot be accepted as a machine tool?
4. Why is making profit must for any industry .

Answers of the given questions.

A. 1. – (b)
2. – (a)
3. – (c)
B.

Ans. 1 Aim – enhance profit rate and job opportunity

Objectives –
• reduce manufacturing time
• increase rate of production
• reduce cost of manufacturing
• raise profit and profit rate

Ans.2

Preformed Machining Product

 Poor quality Dimensional accuracy High quality
Less utility Good finish High utility
Less value High value

Ans. 3 Inspite of having all other major features of machine tools, the
sharpener is of low value.
Ans. 4 For
• Maintenance, repair & replacement
• Modernisation
• Increase salary / incentive
• Expansion

Multiple-choice questions (MCQs)

1. What is the primary goal of manufacturing processes?

a) Material extraction

b) Value addition

c) Waste reduction

d) Energy conservation

2. Which of the following is a secondary manufacturing process?

a) Casting

b) Forging

c) Machining

d) Powder metallurgy

3. What is the purpose of machining in the production of engineering components?

a) Material extraction

b) Achieving dimensional accuracy and surface finish

 c) Casting complex shapes

d) Forging strength enhancement

4. Which of the following is a basic requirement for machining?

a) Quality control

b) Computer programming

c) Cutting fluid

d) Assembly line

5. What are the basic functions of machine tools in machining?

a) Heating, melting, and shaping

b) Cooling, lubrication, and heating

c) Holding, transmitting motion, providing power, and controlling parameters

d) Welding, soldering, and brazing

6. Conventional machining processes rely on:

a) Electrical energy

b) Mechanical tools harder than the workpiece

c) Chemical reactions

d) Magnetic fields

7. What is a characteristic of non-traditional machining processes?

a) Macroscopic chip formation

b) Mechanical tool always present

c) Tool hardness higher than the workpiece

d) Material removal at atomic level

8. Why might non-traditional machining processes be preferred for certain materials?

a) Higher cost

b) Faster production speed

c) Lower machinability

d) Limited precision

9. What is the main advantage of non-traditional machining processes regarding tool wear?

a) High tool wear

b) No tool wear

c) Moderate tool wear

d) Tool wear depending on material hardness

10. What is the significance of tooling in the manufacturing process?

a) Determines the product cost

b) Affects the speed and accuracy of production

c) Controls the market demand

d) Enhances the raw material properties

Answers:

1. b) Value addition

2. c) Machining

3. b) Achieving dimensional accuracy and surface finish

4. c) Cutting fluid

5. c) Holding, transmitting motion, providing power, and controlling parameters

6. b) Mechanical tools harder than the workpiece

7. d) Material removal at atomic level

8. c) Lower machinability

9. b) No tool wear

10. b) Affects the speed and accuracy of production

Exercise questions

1. Explain the difference between primary manufacturing processes and secondary manufacturing
processes. Provide examples for each, and discuss the role of machining in secondary
manufacturing processes.

2. a) Discuss the factors that impact the cost of tooling in manufacturing. b) Explain the importance
of tooling in achieving high precision and accuracy in the production of parts or components.

3. Compare and contrast conventional machining processes with non-traditional machining

processes. Highlight situations where non-traditional machining processes are preferred over
conventional methods, providing specific examples.

References

1. Chattopadhyay, A. B. (2011). Machining and Machine Tools (With CD). John Wiley &
Sons. ISBN 8126530987, 9788126530984.