01/10/2022

Benha University
Faculty of Engineering (Shoubra)
Mechanical Engineering Department (1st year)
MACHINING
In machining a cutting tool is used to remove metal. If the tool is
held by hand, it is called a hand tool; examples of hand cutting
Manufacturing Technology 1 (MEC 112) tools are:
 chisels,
 files,
 hacksaw blades.

Basic Concepts For each of the above tools the energy required to remove the
metal is provided by muscular effort, and this means that the
use of hand cutting tools is usually a slow and expensive
method of removing metal. This fact has led to the introduction of
machine tools. A machine tool may be defined as a power-
operated device designed to produce a given surface, metal
1 2 being removed in this process.

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Generating motions of machine tools

 The principle used in all machine tools is generating
the surface required by providing suitable relative
motions between the cutting tool and the workpiece.
 The cutting edge or edges on the cutting tool remove a
layer of work material; the removed material is called
chip.
 The simplest surfaces to generate are flat surfaces and
internal or external cylindrical surfaces. Such surfaces can
be generated by providing two kinds of relative motions
(primary and secondary motions) by a metal cutting
machine tool.

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 The primary motion is the main motion provided by a

machine tool or manually to cause relative motion between
the tool and workpiece so that the face of the tool
approaches the workpiece material.
 The secondary or feed motion is a motion that may be
provided to the tool or workpiece by a machine tool which,
when added to the primary motion, leads to a repeated or
continuous chip removal and the creation of a machined
surface with the desired geometric characteristics.
Usually, the primary motion absorbs most of the total
power required to perform a machining operation, while
the feed motion absorbs only a small proportion of that
power.
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Values of cut
 Cutting speed (v) : It is the relative surface speed
between the tool and the workpiece in the direction of
cut .
 For turning , drilling and milling the cutting speed is
given by:
π𝑫𝑵
𝒗 = 𝟏𝟎𝟎𝟎 (m/min)
𝑫 = Workpiece dia. in turning ( mm )
= Cutting tool dia. in drilling and milling (mm)
𝑵 = spindle rotational speed ( rpm )

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 Such formula can be deduced as follows;

 For shaping the cutting speed is given by: 𝑳
 The time consumed by cutting stroke = (𝒎𝒊𝒏)
𝟏𝟎𝟎𝟎 𝒗

𝒗 Where;
𝑳𝑵(𝟏 ) 𝑳 = Stroke length (mm)
𝒗𝒓
𝒗= (m/min) 𝒗 = Cutting speed (m/min)
𝟏𝟎𝟎𝟎
𝒌𝑳
 The time consumed by return stroke = (𝒎𝒊𝒏)
𝟏𝟎𝟎𝟎 𝒗
𝑳 = stroke length (mm) Where;
𝑻𝒉𝒆 𝒕𝒊𝒎𝒆 𝒄𝒐𝒏𝒔𝒖𝒎𝒆𝒅 𝒃𝒚 𝒓𝒆𝒕𝒖𝒓𝒏 𝒔𝒕𝒓𝒐𝒌𝒆 𝑳⁄𝒗𝒓 𝒗
𝑵 = reciprocation speed (stroke/min) 𝒌= =
𝑻𝒉𝒆 𝒕𝒊𝒎𝒆 𝒄𝒐𝒏𝒔𝒖𝒎𝒆𝒅 𝒃𝒚 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒕𝒓𝒐𝒌𝒆 𝑳⁄𝒗
=
𝒗𝒓

𝒗𝒓 = rapid return speed (m/min) 𝒗𝒓 = Rapid return speed (m/min)

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 Total time consumed for one double stroke  Feed (s) : is the feed travel per revolution of workpiece for
𝑳 𝒌𝑳
= + turning and drilling (mm/rev) or for shaping (mm/stroke). In
𝟏𝟎𝟎𝟎 𝒗 𝟏𝟎𝟎𝟎 𝒗
case of milling the feed per tooth (sz) is used.
𝑳(𝟏 𝒌)
= (𝒎𝒊𝒏)
𝟏𝟎𝟎𝟎 𝒗
 Number of double strokes per minute  The feed rate (U) is given by:
𝟏 𝑼 = 𝒔𝑵 (𝒎𝒎⁄𝒎𝒊𝒏) for turning and drilling
𝑵=
𝑳(𝟏 𝒌)⁄𝟏𝟎𝟎𝟎 𝒗 𝑼 = 𝒔𝒛 𝒛𝑵 (𝒎𝒎⁄𝒎𝒊𝒏) for milling
𝒗
𝑳𝑵(𝟏 𝒗 )
=
𝟏𝟎𝟎𝟎 𝒗
𝒗= 𝒓 𝒔 = 𝒔𝒛 . 𝐳 𝒎𝒎⁄𝒎𝒊𝒏
𝑳(𝟏 𝒌) 𝟏𝟎𝟎𝟎
𝒔𝒛 = 𝒇𝒆𝒆𝒅 𝒑𝒆𝒓 𝒕𝒐𝒐𝒕𝒉 (𝒎𝒎)
Where;
𝒛 = 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒕𝒆𝒆𝒕𝒉
𝑵 = 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒅𝒐𝒖𝒃𝒍𝒆 𝒔𝒕𝒓𝒐𝒌𝒆𝒔 𝒑𝒆𝒓 𝒎𝒊𝒏𝒖𝒕𝒆
= 𝑹𝒆𝒄𝒊𝒑𝒓𝒐𝒄𝒂𝒕𝒊𝒐𝒏 𝒔𝒑𝒆𝒆𝒅 (𝑺𝒕𝒓𝒐𝒌𝒆/𝒎𝒊𝒏)  Depth of cut (a) : is the distance moved by the tool nose relative
to the workpiece normal to the working plane.
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Cutting Tools Tool Geometry

 If a cutting tool is to shear or cut metal efficiently it is important that
the angles that make up the wedge shape of the tool be of the
correct value according to the nature of the machining operation
and the metal being machined.
Rake Angle
The rake angle of a cutting tool is the angle which facilitate the chip
formation.
Clearance Angle
The purpose of the clearance angle is
to reduce the energy required to shear
the metal, by removal or reduction of
the friction arising from the rubbing
action between the tool and the
workpiece.
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CUTTING TOOL MATERIALS

 Plain carbon tool steels
In order to penetrate the workpiece, the cutting  Alloy tool Steels
tool material should be sufficiently harder than
the workpiece material (especially harder than  High speed steels
the deformed chip). The tool must be strong  Cemented Carbides
enough to withstand the cutting forces exerted
on it. Due to the relative motion and the friction
 Ceramics ( Cemented oxides)
between the workpiece and the tool flank as  Diamonds
well as between the chip and the tool face, it is
subjected to wear on both flank and rake faces.
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End of Lecture

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