Chapter 22:

Machining Operations and Machine

Tools II

Rizwan M. Gul
NWFP UET

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MACHINING OPERATIONS AND

MACHINE TOOLS

Turning and Related Operations

Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
Shaping and Planing
Broaching
Sawing
High Speed Machining
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Shaping and Planing

Shaping and planing are similar operations

Both use a single point cutting tool moved linearly relative to the
workpart
Difference?
In shaping, the speed motion is accomplished by moving the
cutting tool
In planing, speed motion is accomplished by moving the
workpart

Figure 22.29 (a) Shaping, and (b) planing

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Shaping and Planing

A straight, flat surface is created in both operations
Interrupted cutting
Subjects tool to impact loading when entering
work
Low cutting speeds due to startandstop motion
Usual tooling: single point high speed steel tools
The machine tool for shaping is called shaper
The machine tool for planing is called planer

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Figure 22.30 Components of a shaper

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Shaper
Parts: ram, column, worktable, and base
The motion of ram consists of a forward stroke to
achieve the cut, and a return stroke (which is more
quicker) during which the tool is lifted slightly to clear
the work
On completion of each return stroke, the worktable is
advanced laterally relative to the ram motion in order
to feed the part
Both hydraulic and mechanical drive mechanisms are
used but mechanical is more common

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Figure 22.31 Open side planer

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Planer
Construction and motion capability of a planer permit
much lager parts to be machined than on shaper
Planer can be classified as either open side planer
(single column planer) or double column planer
Double column planer provide more rigid structure for
operation; however, the two columns limit the width of
the work that can be handled on this machine
Planer are run by hydraulic mechanism

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Other Shapes Cut by Shaping and

Planing

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Broaching
Moves a multiple tooth cutting tool linearly relative to
work in direction of tool axis
The cutting tool is called a broach and the machine
tool is called a broaching machine
In certain jobs for which broach can be used, it is a
highly productive method

Figure 22.33 The broaching operation

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Broaching

Broach

Internal broach

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Advantages:
Good surface finish
Close tolerances
Variety of work shapes possible
Limitations:
Owing to complicated and often custom shaped
geometry, tooling is expensive
Types:
The two types of broaching are external (or surface
broaching) and internal broaching
External Broaching:
Performed on the outside surface of the work to
create a certain cross-sectional shape on the surface

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Internal Broaching
Performed on internal surface of a hole
A starting hole must be present in the part to insert
broach at beginning of stroke

Figure 22.34 Work shapes that can be cut by internal broaching;

crosshatching indicates the surfaces broached

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Broaching Machines
Broaching machine provide a precise linear motion of
the tool past a stationary work position
Vertical broaching machine: designed to move the
broach along a vertical path
Horizontal broaching machine: providing horizontal
tool trajectory
Most broaching machines pull the broach past the
work - pull action
However, in broaching press the broach is pushed
the through the workpart

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Sawing
Cuts narrow slit in work by a tool consisting of a
series of narrowly spaced teeth
Tool called a saw blade
Typical functions:
Separate a workpart into two pieces
Cut off unwanted portions of part
In most sawing operations, the work is held stationary
and the saw blade is moved relative to it
According to the type of blade motion the types of
sawing are:
Hacksawing
Bandsawing
Circular sawing
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Saw Blades

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 Power hacksaw linear reciprocating motion

of hacksaw blade against work
Cutting is accomplished only on the forward
stroke
Can also be done manually
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 Bandsaw (vertical) linear

continuous motion of bandsaw
blade, which is in the form of an
endless flexible loop with teeth on
one edge
Vertical bandsaws can also be
sued for contouring and slotting

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 Circular saw rotating saw blade provides continuous

motion of tool past workpart
Circular sawing is commonly used to cut long bars,
tubes, and similar shapes to the specified length
In abrasive cutoff, an abrasive disk is used to perform
cutoff operations on hard materials that would be difficult
to saw with conventional saw blade

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High Speed Machining (HSM)

Cutting at speeds significantly higher than those used in
conventional machining operations
A persistent trend throughout history of machining is
higher and higher cutting speeds
At present there is a renewed interest in HSM due to
potential for faster production rates, shorter lead
times, and reduced costs

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High Speed Machining

Comparison of conventional vs. high speed machining
Indexable tools (face mills)
Work material

Conventional speed

High speed

m/min

ft/min

m/min

ft/min

Aluminum

600+

2000+

3600+

12,000+

Cast iron, soft

360

1200

1200

4000

Cast iron, ductile

250

800

900

3000

Steel, alloy

210

700

360

1200

Source: Kennametal Inc.

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Other HSM Definitions DN Ratio

DN ratio = bearing bore diameter (mm) multiplied by
maximum spindle speed (rev/min)
For high speed machining, typical DN ratio is
between 500,000 and 1,000,000
Allows larger diameter bearings to fall within HSM
range, even though they operate at lower rotational
speeds than smaller bearings

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Other HSM Definitions HP/RPM Ratio

hp/rpm ratio = ratio of horsepower to maximum spindle
speed
Conventional machine tools usually have a higher
hp/rpm ratio than those equipped for HSM
Dividing line between conventional machining and
HSM is around 0.005 hp/rpm
Thus, HSM includes 15 hp spindles that can rotate at
30,000 rpm (0.0005 hp/rpm)

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Other HSM Definitions

Emphasize:
Higher production rates
Shorter lead times
Rather than functions of spindle speed
Important non-cutting factors:
Rapid traverse speeds
Automatic tool changes

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Requirements for High Speed Machining

Special bearings designed for high rpm
High feed rate capability (e.g., 50 m/min)
CNC motion controls with look-ahead features to
avoid undershooting or overshooting tool path
Balanced cutting tools, toolholders, and spindles to
minimize vibration
Coolant delivery systems that provide higher
pressures than conventional machining
Chip control and removal systems to cope with much
larger metal removal rates
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High Speed Machining Applications

Aircraft industry, machining of large airframe
components from large aluminum blocks
Much metal removal, mostly by milling
Multiple machining operations on aluminum to
produce automotive, computer, and medical
components
Quick tool changes and tool path control important
Die and mold industry
Fabricating complex geometries from hard
materials

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